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series

Programmable Controller
Maintenance Guide

FEH329
Revision

* The manual No. is printed at the bottom right of the cover of this manual.

Printed on * Manual No. Revision contents

Apr. 2015 FEH329 First edition


Contents

Revision
Contents
Section 1 Section 1 Warranty Information
1-1 Period .............................................................................................................................................. 1-1
1-2 Coverage ......................................................................................................................................... 1-1
1-3 Malfunction Diagnosis ................................................................................................................... 1-1
1-4 Usage .............................................................................................................................................. 1-1
1-5 Period for Repair and Provision of Spare Parts After the Production is Discontinued
(Maintenance Period) .................................................................................................................... 1-1
1-6 Delivered Term ............................................................................................................................... 1-1
1-7 Service ............................................................................................................................................ 1-1

Section 2 User’s Manuals Regarding PLC Maintenance


Section 3 Maintenance
3-1 Maintenance Overview .................................................................................................................. 3-1
3-2 Maintenance Plan .......................................................................................................................... 3-1
3-3 Preventive Maintenance ............................................................................................................... 3-2
3-4 Corrective Maintenance ................................................................................................................ 3-4

Section 4 Failure Classification and Service Life


4-1 Failure Classification ..................................................................................................................... 4-1
4-2 Service Life of MICREX-SX Series ................................................................................................ 4-1
4-3 Environmental Specifications and Service Life of PLC ............................................................. 4-1
4-4 Life-limited Parts Contained in PLC ............................................................................................. 4-2
4-5 Relation between Use Conditions and Product Life ................................................................... 4-3
4-6 List of Modules Containing Life-limited Parts and Expendable Parts ...................................... 4-5

Section 5 Spare Parts


5-1 Storing Spare Parts ....................................................................................................................... 5-1
5-2 Notes on Spare Parts ..................................................................................................................... 5-1

Section 6 Warnings, Prohibitions, and Notes


6-1 Warnings ......................................................................................................................................... 6-1
6-2 Prohibitions .................................................................................................................................... 6-1
6-3 Notes ................................................................................................................................................ 6-2
Section 1 Warranty Information
1-1 Period
The period of the warranty is effective until the earliest of either 1 year from the date of purchase or, 18 months from the date of
manufacture printed on the plate.
The warranty for the parts repaired by Fuji Electric service department is effective for 6 months from the date of repair.

1-2 Coverage
(1) If malfunction occurs in the period of warranty due to Fuji Electric’s responsibility the malfunctioning parts are exchanged or
repaired for free at the point of purchase or delivery. However, the warranty does not apply to the following cases.
1) The malfunction occurs due to inappropriate conditions, environment, handling, or frequency of use to affect the lifetime
of the product that is not instructed in a catalogue, instruction manual or user's manual.
2) The malfunction is caused by the factors that do not originate in the purchased or delivered product.
3) The malfunction is caused by other devices or software design that does not originate in Fuji Electric products.
4) For programmable Fuji Electric products, the malfunction occurs due to programming that is not performed by Fuji
Electric.
5) The malfunction occurs due to an alteration or repair that is not performed by Fuji Electric.
6) The malfunction occurs because the expendable parts listed in an instruction manual or catalogue were not stored nor
replaced in an appropriate manner.
7) The malfunction occurs due to factors that were not foreseeable by the practical application of science and technology at
the time of purchase or delivery.
8) The malfunction occurs due to a natural disaster (e.g. earthquake, lightning, storm and flood damages), a fire, or an
overwhelming disaster (e.g. abnormal voltage) that Fuji Electric is not responsible for.
(2) The warranty is only applicable to the single purchased delivered product.
(3) The warranty covers only the area stated in 1-2 (1). Any damage induced by the malfunction of the purchased or delivered
product, including the damage or loss to a device or machine and passive damages, is not covered by the warranty.

1-3 Malfunction Diagnosis


Malfunction is to be diagnosed temporarily by the purchaser. This diagnosis can be conducted by Fuji Electric or its service
providers with due charge upon the request from the purchaser. The charge is to be paid by the purchaser at the rate stipulated
in the rate schedule of Fuji Electric.

1-4 Usage
Be sure to use the product described in this usr’s manual under the conditions in which any fatal accidents will not occur even
in the case of product failure or malfunction. In addition, safety measures such as redundant design, malfunction preventing
design, fail-sale design, foolproof design must be taken externally and systematically.
Be sure not to use the product under the conditions or circumstances that are not instructed in an instruction manual or user’s
manual. For the usage below, contact Fuji Electric beforehand.

power plant including nuclear power, radiation facilities, railroad, space/flight equipments, lifeline facilities including
gas/water/electricity/communication, medical equipments, motor vehicles, combustion/fuel equipments, entertainment
devices, data center, systems involving billing or settlement, other usage that largely affect human lives, bodies, society,
major property or rights.

1-5 Period for Repair and Provision of Spare Parts after the Production is
Discontinued (Maintenance Period)
The discontinued models (products) can be repaired for 7 years from the date of discontinuation. Also, most spare parts used
for repair are provided for 7 years from the date of discontinuation. However, some electric parts may not be obtained due to
their short life cycle. In this case, repair or provision of the parts may be difficult in the above period. Please contact Fuji Electric
or its service providers for further information.

1-6 Delivered Term


Standard products that do not entail application setting or adjustment are regarded as received by the purchaser upon delivery.
Fuji Electric is not responsible for local adjustments and test runs.

1-7 Service
The price of the delivered or purchased products does not include the service fee for the technician. Please contact Fuji Electric
or its service providers.

1-1
Section 2 User’s Manuals Regarding PLC Maintenance

Besides this book, user's manuals listed in the following table also describe product maintenance.
Title Manual No.
Hardware, MICREX-SX Series FEH201
Troubleshooting For Expert (D300win) V3, MICREX-SX Series FEH197
Troubleshooting For SX-Programmer Standard, MICREX-SX Series FEH194

The above manuals are available for free on Fuji Electric Co.,Ltd.site below:
http://www.fujielectric.com

2-1
Section 3 Maintenance
3-1 Maintenance Overview
Programmable logic controllers (abbreviated as “PLC” hereafter), which are widely used in various industries and public
fields, are an important foundation of automatic control systems. A PLC is designed and produced for ten years of durability.
However, components contain relatively short-lived parts (expendable parts) such as electromagnetic relays, electrolytic
capacitors or batteries. Furthermore, higher-density mounting for downsizing has been progressing. Reliability of electronic
parts are subject to installation environments.
To properly exert and maintain PLC system functions, periodic maintenance of the product, which is described in this manual,
is essential.
Broadly, there are two types of maintenance: “preventive maintenance” and “corrective maintenance.” Preventive maintenance
is divided into “daily inspection" and "periodic inspection.”

Daily Inspection
Maintenance Preventive Maintenance
Periodic Inspection

Corrective Maintenance Troubleshooting

3-2 Maintenance Plan


A maintenance plan means planning maintenance work such as periodic inspections of equipment and replacement of parts
considering environmental resistance and durability of the PLC when a system is installed. A maintenance plan is also to
determine a replacement time considering the life cycle of equipment. The following figure shows an example of a maintenance
plan.
Delivery 1 year 3 years 5 years 5 years = Design life
of product

System
Daily inspection
replacement

Periodic inspection

Parts replacement

Replacement
Battery
Replacement
CPU module
Replacement
Relay module

Repair service
Production stop
Repair without charge

Repair with charge


7 years

Note 1: The replacement time of a battery differs depending on the type of a CPU module or the use environment.
Note 2: The replacement time of a power supply module and a relay module differs depending on the use conditions and
environment.
* The details are described in a later section.

3-1
Section 3 Maintenance
3-3 Preventive Maintenance
Preventive maintenance is intended to maintain stable trouble-free operation by removing a cause of a failure before it occurs.
Check for parts that may cause a failure or a sign of a failure periodically or before operation and conduct periodic maintenance
such as replacement of life-limited parts before they reach the end of their lives.
(1) Daily inspection
Conduct the daily inspection to check if the product operates properly before the equipment is started.
(2) Periodic maintenance
A PLC contains a large number of life-limited electronic parts. The periodic inspection is to prevent a failure by replacing such
parts before they reach the end of their lives. The periodic inspection shall be conducted once every six months to a year.
Under severe use conditions, the inspection interval should be shortened.
(3) Notes on inspection
Be sure to check all the inspection items using a check sheet. The inspection results managed as a history will be useful for
the next inspection or in case of trouble.
(4) Inspection items
The following table lists the inspection items.
Also refer to “1-2 Inspection and Maintenance” of the troubleshooting manual (FEH194, FEH197).
Note 1: The daily inspection shall be conducted before the equipment is started. However, for a system that is powered on all
the time such as a continuously operating system, mainly conduct the visual inspection items.

Inspection Daily Periodic


Inspection item Inspection contents Criteria Trouble processing
method ins. ins.

CPU module Investigate the cause according to Visual


Check ERR/ALM LED. Lamps must be OFF.  
the trouble shooting manual. inspection
Replace the battery with a new one
Visual
Check BAT LED. Lamp must be OFF. according to instructions described
inspection
 
in the hardware manual.
The term of validity Visual
Check battery replacement time.
indicated on the battery
The same as above
inspection

Power Check PWR LED. Lamp must be OFF. Investigate the cause according to Visual  
supply LED
Check ALM LED. Lamp must be OFF. the trouble shooting manual. inspection  
module
Check that the voltage is within 100V AC: 85 to 132V
Check the status of the power source.
Voltage the normal range when measured 200V AC: 170 to 264V
Adjust the power supply voltage.
Tester  
at a terminal block. 24V DC: 19.2 to 30V

Check for frequent momentary


Voltage Voltage fluctuations must
fluctuation
power failures or abrupt
be within the above range.
Check the status of the power source. Oscilloscope 
voltage rises or drops.
I/O Investigate the cause according to the Visual
module
LED Check ERR LED. Lamp must be OFF.
trouble shooting manual. inspection
 

Power Check externally supplied power Voltage must be within the Check the status of the power source.
supply supply voltage for I/O. specified range Adjust power supply voltage.
Tester  
Function Investigate the cause according to Visual
module
LED Check ERR and ALM LEDs. Lamps must be OFF.
the trouble shooting manual. inspection
 
Ambient Check that the temperature is
environment Place a heater, radiating fan, heat
within the specified range. Max/Min
Temperature 0 to +55℃ exchanger, or the like in the panel to  
(temperature in the panel when thermometer
adjust the temperature.
installed inside the panel)

Visual
Check for condensation, extreme Remove dew condensation.
Humidity
discoloration, or corrosion.
20 to 95%RM
(Blow and dry.)
inspection,  
hygrometer

Suppress the vibration from the


Vibration must be within Inspection
Vibration Check for vibration. vibration source. Or provide vibration
the specified range. by touching
countermeasures with the PLC.
Check for dirt or other foreign No dirt or other foreign Visual
Dust
matter. matter.
Remove dirt or other foreign matter.
inspection
 

Replace the module.


* Consider the possibility of a contact
Visual
Oil Check for oil mist on the module. No oil mist. failure in the internal circuit or
inspection

deterioration of the mold resin.
Improve the installation environment.

3-2
Section 3 Maintenance
3-3 Preventive Maintenance

Ambient Send the module to Fuji Electric to


environment check the internal circuit damage.
No discoloration or Visual
Gas Check for corrosive gases.
damage of the product
Depending on the result, replace the
inspection

module.
Improve the installation environment.

Installation status Visual


Check that all modules are Secure the coupler locks. inspection,
mounted securely.
No looseness
Retighten the screws. Inspection
 
by touching

Visual
Check for loose screws on
the external wiring terminals.
No looseness Retighten the screws. inspection,  
Screwdriver

Check that crimp terminals Crimp terminals must be


Reconnect the crimp terminals in Visual
do not contact with each connected in parallel with
parallel with each other. inspection
 
other. each other.

Visual
Check that cable connectors
are inserted securely.
No looseness Insert the cable connectors securely. inspection,  
Screwdriver
Check for damage of external Visual
wiring cables.
No abnormal appearance Exchange the wiring.
inspection
 
Program Verify that the program in CPU Use backup program in case of
matches the source program. The program in CPU must trouble. Program
Check that the source program is match the source program. * Back up the source program in verification

stored under proper conditions. advance.

Life-limited parts Do not exceed the estimated Replace the module.


Check the operation hours.
service life. Overhaul by Fuji Electric.
Check list 
Maintenance parts The designated number of
Check that the designated number Inspection
(spare parts) spare parts must be Replenish the spare parts. 
of spare parts are available. record
available.

The spare parts must be


stored according to the
Check that the spare parts are general specifications of Inspection
stored under proper conditions. the hardware manual and
Improve the storage environment.
record

at an ambient temperature
of 40℃ or less.

Power on the spare power supply


Check that the spare power The spare power supply module. When the spare power
Inspection
supply module is powered on module must be powered supply module has not been
record

once a year. on once a year. powered for more than a year,
contact Fuji Electric for overhaul.

Spare batteries stored for a year or


Check how long the batteries The term of validity Inspection
have been stored. indicated on the battery
two should be replaced with the new
record

ones even within the term of validity.

The modules must operate


Check the operation of other Operation
modules.
properly according to the Contact Fuji Electric for repair.
test

specifications.
System status The value must be within
Check the grounding resistance.
the specified range.
Determine the cause to improve. Tester 

The value must be greater


Check the insulation resistance.
than the specification.
Determine the cause to improve. Megger 

There is no dangerous part


Check the safety. that can lead to an accident Improve the dangerous part. ― 
causing an injury or death.

3-3
Section 3 Maintenance
3-4 Corrective Maintenance
Corrective maintenance is a maintenance task to solve a trouble after it occurs.
For more information about troubleshooting of MICREX-SX, refer to “Troubleshooting Manual (FEH194, FEH197).”
This manual roughly describes the corrective maintenance.
The following table summarizes troubles.

Type Description Error status


Hardware fault e.g. The abnormal state continues.
- CPU does not start up or perform arithmetic operation. (Replace the related hardware to restore
- Output remains ON or OFF state. the system.)
PLC system malfunction Malfunction occurs due to, for example, the following reasons: The abnormal state occurs temporarily and
- High-frequency noise, lighting surge, external radio wave, does not continue.
static electricity (Remove the cause to restore the system.)
- Power supply voltage drop, momentary power failure,
open/close surge
Failure by accident A failure occurs due to, for example, the following reasons: Whether the abnormal state continue or not
- Short circuit of power supply or load, break in signal cable depends on the type of the trouble.
- Misoperation of PLC, or peripheral devices (Repair the failure to restore the system.)
Program error Generally, a control program is created on the assumption The abnormal state occurs temporarily and
that the control target operates normally. However, for example, does not continue.
if signal input is not generated at a normal timing or on a normal
condition, it looks as if control was stopped because PLC has no
program to solve it. Or it is mistakenly determined that a hardware
fault occurred because the system had operated normally.

(1) Trouble handling procedure

Trouble occurred

Trouble detection

Troubleshooting

Restoration

Operation check

Trouble history record

Completion

3-4
Section 3 Maintenance
3-4 Corrective Maintenance
(2) Detecting trouble
When trouble occurs in a PLC system, you need to specify the cause to handle the trouble.

1) Specifying the cause


When trouble is detected, check the following points first.
a) Has the trouble been caused by misoperation of the user?
b) Has the trouble occurred in the machine manufacturer (controlled target)?
c) Has the trouble occurred in the controller?

2) Points for handling trouble


The following four points are important to handle trouble (corrective maintenance).
a) Specify a real cause
It is important to grasp a trouble phenomenon and an occurrence state as correct and detailed as possible.
There is a high possibility that the trouble cannot be solved if the trouble phenomenon cannet be reproduced.
b) Minimize a stop time of the system
Remove the cause by a) and minimize a stop time of the system. To minimize the stop time by trouble, it is important to
develop a preventive maintenance plan such as storing spare parts or a maintenance contract with an equipment in
advance.
c) Carefully perform restoration work and then start operation (power on)
Restoration work requires extreme caution. Mistakes in restoration work may cause secondary trouble such as a machine
fault or program loss.
d) Taking a measure to prevent a recurrence
To prevent the same trouble from reoccurring, it is important to investigate the real cause of the trouble and take preventive
measures.

3) Advance preparation
To handle trouble smoothly, you need to do the following preparations in advance.
a) Understand your machine and equipment well.
a) - 1 Order the latest manual or other technical documents.
a) - 2 Prepare a maintenance manual for each device.
a) - 3 Conduct a safety education.
b) Also, understand the peripheral and related devices well.
c) Be familiar with handling the peripheral devices.
d) Understand a cause of trouble and preventive measures well.
e) Establish a trouble handling system and develop a preventive maintenance plan such as maintenance contract with an
equipment maker.
f) Prepare spare parts.

(3) Notes on restoration work


1) Notes when replacing hardware
a) Do not touch the conductive parts of the modules or memory elements. Otherwise, static electricity accumulated on your
body may discharge to damage the semiconductor parts.
* If you need to touch the conductive parts, wear antistatic work clothes and shoes, and discharge static electricity (for
example, by touching a grounded metallic object) before starting replacement work.
b) Do not touch the conductive parts such as pins or connectors. Otherwise, the grease of your hand may cause a contact
failure.
c) Backup of program and parameter
Back up the data in advance before replacing the module. Otherwise, the data may be lost by misoperation.

3-5
Section 4 Failure Classification and Service Life
4-1 Failure Classification
As shown in the figure below, failures of a PLC including hardware (parts) are generally divided into the following three stages:
“initial failure,” “chance failure,” and “wear-out failure.”

End of service life


Failure occurrence rate

Initial failure period

Chance failure period Wear-out


failure period

Number of years in use

Handling initial failure: Screening (before shipment)

Handling chance failure:


1) Selecting highly reliable parts (product design)
2) Periodic inspection  Preventive maintenance,
parts replacement

Handling wear-out failure:


Preventive maintenance, parts replacement

1) The initial failure period is a period when failures occur due to a cause that cannot be removed through a screening or
aging test during the process of production or inspection in the maker. The maker is responsible for the troubles that occur
during this period. The period when initial failures of electronic parts occur is one year or approximately 5000 hours as real
operation time.
2) The chance failure period is a period when unexpected and sudden failures occur during the service life of the product
before it deteriorates or wears away. It is difficult to take technical measures.
A hardware (parts) fault due to lightning surge is an example.
The failure occurrence rate during this period depends on the selection of the parts and the set design margin by the
maker, and the use environment of the PLC. For the use environment, the failure rate is generally high when the difference
in the ambient temperature between the operation time and the stop time is high. This is because the temperature change
due to heat generation in the PLC is large and the temperature sttress on the electronic parts causes a failure.
Generally, the chance failure period is referred to as a service life.
3) From the late chance failure period to the ware-out failure period, the number of failures sharply increases because the
parts deteriorate or wear away. At this time, a service life can be elongated by replacing deteriorated or worn-out parts as
preventive measures.
Normally, the service life of the PLC is estimated to be 10 years excluding wear parts such as relay contacts and life-limited
parts such as aluminum electrolytic capacitors.

4-2 Service Life (Product Life) of MICREX-SX Series


MICREX-SX Series is designed for 10 years of service life under normal use conditions (ordinary temperature: 40°C, humidity:
60%RH) excluding expendable parts.

4-3 Environmental Specifications of PLC and Product Life


The environmental conditions such as an ambient temperature are known to greatly affect the product life of a PLC.
The environmental conditions of a PLC include temperature, humidity, vibration, corrosive gases, overcurrent, and electrical
noise. The specified range of the environmental conditions described in the PLC catalogue shall not be exceeded. However,
the product life of a PLC is specified based on normal use conditions (ordinary temperature: 40°C, humidity: 60%RH). Use
under severe conditions (near the specification limit) largely affects the reliability (product life).
A PLC contains life-limited parts such as aluminum electrolytic capacitors, and expendable parts such as batteries and
electromagnetic relays. You need to conduct systematic maintenance work and periodically replace such parts.

4-1
Section 4 Failure Classification and Service Life
4-4 Life-limited Parts Contained in PLC
(1) Aluminum electrolytic capacitor
Aluminum electrolytic capacitors are used in power supply modules and most other modules to regulate the internal power
supply. A liquid called electrolyte is sealed in an aluminum electrolytic capacitor. An electrolyte liquid deteriorates and vaporizes
over time to lower the performance of parts. Generally, the described parts life of an aluminum electrolytic capacitor is subject
to 10% decrease in the capacitance.
The parts life has a close relation to a temperature owing to the property of an electrolyte liquid. It is known that a 10°C rise in
use environment temperature reduces the lifetime by half, and conversely a 10°C fall in use environment temperature doubles
the lifetime. (Arrhenius’s equation)
e.g.)
If an aluminum electrolytic capacitor whose parts life is 2000 hours at 105 ) is used under the temperature of 40 , the
expected lifetime is 20 years.
2000 hours 2 (105 - 40 ) /10 24 hours 365 days = Approx. 20 years
A rubber packing, which is used for sealing an electrolyte liquid in an aluminum electrolytic capacitor, deteriorates in about 10
years and may not be able to keep sealing. In the worst case, the electrolyte liquid may leak to cause damage to ambient
electronic circuits.

(2) Battery (expendable parts)


A CPU module of the PLC contains a lithium primary battery (unrechargeable battery) to hold data.
When powered off, the CPU module holds internal data and activates a calendar circuit using a battery. Therefore, you need to
replace the battery periodically.
The data backup time by a battery depends on the CPU module type. Refer to “5-2 Battery Replacement” of the hardware
manual (FEH201) for information on the replacement time.
A lithium primary battery with little self-discharge can be stored more than five years when stored separately. However, a bettery
used for the PLC has a factor of mechanical deterioration because a connecter is weled to it. The service life of a battery single
body shall be five years.

(3) Electromagnetic relay (expendable parts)


Electromagnetic relays, which have a switch to electrically turn on and off a current, deteriorate every time a current is switched
on and off. The lifetime of an electromagnetic relay is expressed by a possible number of on/off times and varies depending on
the current size, current type (AC or DC), and load type (resistive load or inductive load).
For more information on the lifetime of an electromagnetic relay used in the input/output modules of the PLC, refer to “3-5-2
Life curve of relays” of the hardware manual (FEH201). If the electromagnetic relay is used exceeding the lifetime, a
dangerous state occurs. For example, a current cannot be switched on and off by deterioration of the electromagnetic relay
contact, or a current cannot be switched off by contact melting (contact transfer) .

(4) Optical communication element


Optical communication elements include parts called “photocoupler” used for electrical insulation, and infrared LEDs and PIN
photo diodes used for communication using optical fiber cables.
A large number of these parts are used in input/output modules and communication modules for signal insulation.
Their performance deteriorates over time due to an applied current and use temperature environment. Finally it becomes
impossible to perform data communication.
A PLC is designed for 10 years of product life by providing safety coefficient and designing circuits in anticipation of performance
deterioration. However, especially for the temperature environment, when the general use conditions (ordinary temperature:
40°C, humidity: 60%RH) are exceeded, performance deterioration accelarates.

(5) Retain memory (EEPROM, FLASH, MRAM, FeRAM)


A memory (nonvolatile memory) can hold data without a power supply. Generally the number of rewriting times is limited. If the
limit is exceeded, data cannot be stored properly. If data cannot be stored properly, arithmetic processing of the PLC may stop
by an error and a memory error is detected by the PLC self diagnostic function.
Note:Depending on the purpose or the use frequency of the memory, a memory error cannot be detected.
A retain memory installed in CPU modules and communication modules has built-in software designed to prevent a failure
within a product life of 10 years.
For external memory cards (e.g. a memory card dedicated to Fuji PLC, FLASH memory card, and SD memory card), the number
of writing times varies depending on how to create a PLC application program. Be careful of the limit of the number of rewriting
times.
Also, stored data are generally guaranteed for 10 years by the parts maker because data holding time is limited due to electrical
charges that are accumulated in the memory. If exceeding 10 years, the stored data may start to be lost.

4-2
Section 4 Failure Classification and Service Life
4-5 Relation between Use Conditions and Service Life
PLC modules contain life-limited parts and expendable parts. The product lives of some modules relate to use conditions and
environment.

(1) Power supply module


Power supply modules are designed for 10 years of service life under normal use conditions (ordinary temperature: 40°C,
humidity: 60%RH). However, a power supply module should be replaced for the periodical inspection of the preventive
maintenance or overhauled by Fuji Electric in five years for the following reason.
Aluminum electrolytic capacitors mainly determine the servile life of a power supply module.
A power supply module contains a large number of aluminum electrolytic capacitors and a power supply circuit has large heat
generation. Therefore, a power supply module is most affected by Arrhenius’s equation (a 10°C temperature rise doubles
reaction rates.)
Power supply modules are designed for 10 years of service life under normal use conditions. However, the normal use
conditions can be exceeded due to heat generation from the adjacent modules or the installation environment in the control
panel. For this reason, it is recommended to replace the power supply module or replace the aluminum electrolytic capacitors
(overhaul of the power supply module by Fuji Electric) in five years, which is half of the service life of 10 years.
If the use environment temperature is higher than the normal use conditions, estimate the expected product life based on
Arrhenius’s equation (a 10°C temperature rise doubles reaction rates.)
Even if deterioration of aluminum electrolytic capacitors is neglected, the power supply module does not lose its functions
immediately. However, the stability of the power supply is affected by, for example, increase in ripple current. Consequently, the
whole PLC system may be affected and malfunction of the PLC system may occurs.
In addition, an electrolyte liquid may leak from aluminum electrolytic capacitors that are used over a long period. The electrolyte
liquid may cause serious damage to the ambient circuits, which may lead to smoke or fire.

(2) CPU module


The major life-limited parts (expendable parts) contained in CPU modules is a battery (lithium primary battery).
The current consumption differs depending on the CPU module type, and so does the data holding time by a battery.
For more information on the backup time by a battery for individual CPU modules and battery replacement procedure, refer to
“5-2 Battery Replacement” of the hardware manual (FEH201).
For the backup time by a battery, note the following:
1) The battery is used only when the CPU module is powered off.
The the backup time by a battery are the accumulated time when the CPU module is powered off.
2) The the backup time by a battery described in the hardware manual is based on the use environment temperature of 25°C.
The higher the use environment temperature is, the higher the current consumption is. Consequently, the backup time by
a battery is shortened. Consider that a 10°C rise in use environment temperature shortens the backup time by half.
Here, use environment temperature means an environment when data is backed up by a battery and the CPU module is
powered off.
3) “BAT” LED to indicate a battery drop of the CPU module lights on only when the CPU module is powered on. Therefore,
when the “BAT” LED lights on, the battery may have already been depleted.
Considering the above notes and the backup time described in the hardware manual, determine the battery replacement with
time to spare. If “BAT” LED lights on, replace the battery with a new one immediately according to the procedure described in
the hardware manual.
The battery may have already been depleted when “BAT” LED lights on. Therefore, do not power the CPU module off until the
battery replacement is completed, or back up the data before the CPU module is powered off.
If the CPU module is powered off with the battery depleted, the internal data and the calendar are lost.
* The CPU module has a condenser to hold the data during battery replacement. Even if the CPU module is powered off, the
data can be held for about five minutes.

(3) Relay output module


Relay output modules contain electromagnetic relays that are expendable parts. The product life of a relay output module is
equal to that of an electromagnetic relay.
For more information on the lifetime of an electromagnetic relay used in PLC, refer to “3-5-2 Life curve of relays” of the
hardware manual (FEH201). If the electromagnetic relay is used exceeding the lifetime, a dangerous state occurs. For
example, a current cannot be switched on and off by deterioration of the electromagnetic relay contact, or a current cannot be
switched off by contact melting (contact transfer) .
Referring to the hardware manual, determine the parts replacement time with time to spare and replace them before a failure
occurs.

4-3
Section 4 Failure Classification and Service Life
4-5 Relation between Use Conditions and Product Life
(4) I/O modules other than relay output module (digital/analog)
I/O modules other than relay output modules contain “photocouplers of optical communication elements”, which are life-
limited parts, to apply electrical insulation.
An I/O module is designed for 10 years of service life under normal use conditions (ordinary temperature: 40°C, humidity:
60%RH) maintaining safety factor in consideration of deterioration of the optical communication element.
However, an I/O module generally has large heat generation. If a large number of I/O modules adjoin each other, heat may be
accumulated within the product, which cause deterioration of the photocoupler performance.
Deterioration of the photocouplers causes malfunction of the I/O circuits.

(5) Communication module


Communication modules contain “high-speed response photocouplers”, which are life-limited parts, to apply electrical
insulation. Optical communication modules using optical fiber cables contain “infrared LEDs” and “PIN photo diodes,” that are
life-limited parts.
These optical communication elements deteriorate due to a rise in the use environment temperature. As the deterioration
progresses, communication cannot be performed properly. It is possible to check occurrence of a communication by
“Transmission RAS” of the PLC.
Generally, communication errors start to occur in the process of deterioration. Errors increases gradually and communication
becomes completely impossible finally. Check the “Transmission RAS” periodically to find out a sign of deterioration of the
parts.
Error information caused by other factors such as communication cable break is also displayed in “Transmission RAS.”
Therefore, you need to properly determine whether the error is caused by deterioration of the optical communication element
or not.

4-4
Section 4 Failure Classification and Service Life
4-6 List of Modules Containing Life-limited Parts and Expendable Parts
The following table lists the products of MICREX-SX Series, which contain electronic parts. Which parts are contained in which
module is described. Only products carried in a catalog as of October, 2014 are shown in the following table. For information
on new products released after October, 2014, e-mail Fuji Electric at micrex-sx@fujielectric.com.
* All the products shown in the following table contain small-capacity aluminum electrolytic capacitors to stabilize operation
of the circuits even if a check mark is not put in the columns of the aluminum electrolyitc capacitor. Aluminum electrolytic
capacitors used for that purpose are designed to withstand during 10 years of the product life. Therefore, they are excluded
from the periodical inspection target.

Life-limited parts, expendable parts

Aluminum
Electro- Optical
electrolytic Retain
magnetic Battery communication
capacitor memory
Product name Type relay element
(Note 1)
Daily
Periodic inspection Periodic inspection
inspection

Risk (high) Risk (low)

E-SX bus CPU module From NP1PU*-…  


E-SX bus Integrated type module NP1L-RU1 
E-SX bus Input unit NU2X3206-W 
E-SX bus Output unit (transistor) NU2Y32T09P6 
E-SX bus Analog input unit NU2AXH2-MR  
E-SX bus Analog output unit NU2AYH2V-MR  
E-SX bus High-speed counter unit NU2F-HC2 
E-SX bus Auxiliary power supply unit NU2V-PA1

NP1PH-…  
NP1PS-…  
CPU module
NP1PM-…  
NP1PU-…  
Power supply module NP1S-…   
Base board NP1B*-…

Digital input module NP1X… 


Digital output module (transistor) NP1Y…T/U… 
Digital output module (SSR) NP1Y…S 
Digital output module (relay) NP1Y…R-… 
Digital input/output module NP1W… 
Analog input module NP1AX…  
Analog output module NP1AY…  
Analog input/output module NP1AW…  

4-5
Section 4 Failure Classification and Service Life
4-6 List of Modules Containing Life-limited Parts and Expendable Parts
(Continued from preceding page)

Life-limited parts, expendable parts

Aluminum
Electro- Optical
electrolytic Retain
magnetic Battery communication
capacitor memory
Product name Type relay element
(Note 1)
Daily
Periodic inspection Periodic inspection
inspection

Risk (high) Risk (low)

WEB module NP1L-WE1 


ETHERNET module NP1L-ET1 
FL-net module NP1L-FL3 
LonWorks if module NP1L-LW1 
P/PE link master module NP1L-PL1/PE1 
LE-net module NP1L-LE1  
LE-net loop module NP1L-LL2 
General-purpose communication module NP1L-RS*  
OPCN-1 module NP1L-JP1/RJ1/JS1  
DeviceNet module NP1L-DN1/RD1/DS1  
T-link module NP1L-TL1/RT1/TS1  
PROFIBUS-DP module NP1L-PD1/PS1/RP1  
AS-i master module NP1L-AS2  
S-LINK master module NP1L-SL1 
Remote master module NP1L-RM1  
SX bus optical link module NP1L-OL* 
SX bus optical converter unit NP2L-OE1 
SX bus electric repeater unit NP2L-RP1

SX bus Duplication Unit NP2L-BH1

P/PE-link optical converter FNC360A-C20   


T-link optical converter FNC160A-C20   
High-speed counter module NP1F-HC* 
Pulse train output positioning control module NP1F-HP2  
Pulse train multiple positioning control module NP1F-MP2  
Analog multiple positioning control module NP1F-MA2  
Memory card interface module NP1F-MM1 
Dummy module NP1F-DMY

Multi-use communication module NP1F-MU1  


Flow meter F/AD conversion module NP1F-PI4  
Online adapter FOA-… 

4-6
Section 4 Failure Classification and Service Life
4-6 List of Modules Containing Life-limited Parts and Expendable Parts
(Continued from preceding page)

Life-limited parts, expendable parts


Aluminum
Electro- Optical
electrolytic Retain
magnetic Battery communication
capacitor memory
Product name Type relay element
(Note 1)
Daily
Periodic inspection Periodic inspection
inspection

Risk (high) Risk (low)

NR1*X-1606DT 
I/O terminal input
NR2DX-3206DT 
NR1*Y-08R07DT 
I/O terminal output (relay) NR1LW-11R80DT 
NR2DY-16R06DT 
NR1*Y-16T05DT 
I/O terminal output (transistor)
NR2DY-32T05DT 
NR1*W-16T65DT 
I/O terminal input/output
NR2DW-32T65DT 
I/O terminal pulse train output NR1SF-HP4DT  
NR2JAX-…   
I/O terminal analog
NR2JAY-…   
NP3PS-SX1PCS…  
Board build in personal computer NP3L-LL2PCS 
NP3L-FL3PCS 
Power supply unit for FLT-ASFKA NP8S-LC*  

4-7
Section 5 Spare Parts

It is recommended to prepare spare parts to promptly restore a system in case of trouble. For preventive maintenance and
corrective maintenance, you should store a dedicated cable and one or more spare parts for each module.
Preparation of the spare parts is also useful for periodically replacing the products before they reach the end of their service
lives to cause a failure. Product replacement is conducted in a maintenance activity such as pediodic inspection to maintain
reliability of the PLC system. The older the equipment gets, the more often failures occurs. Maintenance of the equipment
becomes difficult because, for example, spare parts may not be available due to production stop. Therefore it is important to
dvelop a maintenance plan considering product replacement when installation of a PLC system is planned.

5-1 Storing Spare Parts


Spare parts shall be stored in a packaged state at shipment from Fuji Electric under the following conditions.
Temperature: Storage at a temperature of 40°C or less is recommended.
* Although the storage temperature described in the specifications is -25 to 70°C, the spare parts should be
stored at a temperature of 40°C or less to keep their performance.
Relative humidity: 5 to 95%RH, no condensation
Atmosphere: No dust, salt, corrosive gases, and organic solvent
Power-on check: Power on the spare modules once a year to check the operation.
If a module is stored for a long period without being powered on, performance of the aluminum electrolytic
capacitor in the module deteriorates. The module may no longer be able to exert its functions when in use.

5-2 Notes on Spare Parts


(1) Battery (lithium primary battery)
Battery voltage drops because of slight self-discharging. Spare batteries should be replaced with the new ones in one or two
years even within the term of validity.

(2) Power supply module


For spare power supply modules, power on once a year.
If a power supply module is stored for a long period without being powered on, performance of the aluminum electrolytic
capacitor in it deteriorates (e.g. capacitance reduction or increase in leak current). The performance and quality of the module
declines.
In addition, be sure to store power supply modules at an ambient temperature of 40°C or less.
If a power supply module is stored at an ambient temperature exceeding 40°C, the lifetime of the aluminum electrolytic capacitor
in the module deteriorates.

(3) CPU module


For CPU modules, software is updated to correct defects and expand functions. If a CPU modules is stored for a long period,
the software may be better to be updated to the latest version. Contact Fiji Electric about this. In some cases, software may not
be able to be updated to the latest version due to a version of the hardware.
A battery (lithium primary battery) for memory backup is supplied with a CPU module in a packaging box. When a spare CPU
module stored for a long period is used, the validity term of the battery may nearly expire. Check the term of validity and replace
the batteries with the new one if necessary.
Even when not replacing the battery with the new one, check the term of validity as an inspection item of the preventive
maintenance.

5-1
Section 6 Warnings, Prohibitions, and Notes

6-1 Warnings
 Never touch any part of charged circuits as terminals and exposed metal portion while the power is turned ON. It may result
in an electric shock to the operator.
 Turn OFF the power before mounting, dismounting, wiring, maintaining or checking, otherwise, electric shock, erratic
operation or troubles might occur.
 Place the emergency stop circuit, interlock circuit or the like for safety outside the PLC. A failure of the PLC might break or
cause problems to the machine.
 Connect the ground terminal to the ground, otherwise, an erratic operation might occur.
 The modules covered in this book have not been designed or manufactured for use in equipment or systems which, in the
event of failure, can lead to loss of human life.
 If you intend to use the modules covered in this book for special applications, such as for nuclear energy control, aerospace,
medical, or transportation, consult your Fuji Electric agent.
 Be sure to provide protective measures when using the module covered in this book in equipment which, in the event of
failure, may lead to loss of human life or other grave results.

6-2 Prohibitions
 Do not connect in reverse polarity, charge (except rechargeable ones), disassemble, heat, throw in fire or short-circuit the
batteries, otherwise, they might burst or take fire.
 Do not use batteries having any deformation, spilled fluids, or other abnormality. The use of such batteries might cause
explosion or firing.
 Do not open the FG terminal with the LG-FG short circuited. (It must be grounded, otherwise it might cause electric shock.)
 Do not use one found damaged or deformed when unpacked, otherwise, fire, failure or erratic operation might be caused.
 Do not shock the product by dropping or tipping it over, otherwise, it might be damaged or troubled.
 Do not attempt to change system configurations (such as installing or removing I/O modules) while the power is ON,
otherwise, failure or erratic operation might occur. (*Except when using a hot plug base board)
 Do not attemp to repair the module by yourself contact your Fuji Electric agent. When replacing the batteries, correctly and
securely connect the battery connectors, otherwise, fire, accidents or failure might occure.
 Do not remodel or disassemble the product, otherwise, failure might occur.
 Do not use this equipment in a residential environment. If using, electromagnetic interference might be caused to other
equipment.

6-1
Section 6 Warnings, Prohibitions, and Notes

6-3 Notes
 Follow the directions of the operating instructions when mounting the product. If mounting is improper, the product might
drop or develop problems or erratic operations.
 Use the rated voltage and current mentioned in the operating instructions and manual. Use beyond the rated values might
cause fire, erratic operation or failure.
 Operate (keep) in the environment specified in the operating instructions and manual. High temperature, high humidity,
condensation, dust, corrosive gases, oil, organic solvents, excessive vibration or shock might cause electric shock, fire,
erratic operation or failure.
 Select a wire size to suit the applied voltage and carrying current. Tighten the wire terminals to the specified torque.
Inappropriate wiring or tightening might cause fire, malfunction, failure, or might cause the product to drop from its mounting.
 Contaminants, wiring chips, iron powder or other foreign matter must not enter the device when installing it, otherwise,
erratic operation or failure might occur.
 Periodically make sure the terminal screws and mounting screws are securely tightened.
Operation at a loosened status might cause fire or erratic operation.
 Put the furnished connector covers on unused connectors, otherwise, failure or erratic operation might occur.
 Engage the loader connector in a correct orientation, otherwise, an erratic operation might occur.
 Before touching the PLC, discharge any static electricity that may have been collected on your body. To discharge it, touch a
grounded metallic object. Static electricity might cause erratic operation or failure of the module.
 Be sure to install the electrical wiring correctly and securely, observing the operating instructions and manual. Wrong or
loose wiring might cause fire, accidents, or failure.
 Clean this product after power-off using a towel that is moistened with lukewarm water and then wrung tightly. Do not use
thinner or other organic solvents, as the module surface might become deformed or discolored.
 Follow the regulations of industrial wastes when the device is to be discarded.
 External power supply (such as 24 V DC power supply) which is connected to DC I/O should be strongly isolated from AC
power supply. (Use of EN60950 conforming power supply is recommended.) Otherwise, accident or failure might be caused.
 Back up the program and the stored data of the CPU module in an external storage device such as a personal computer
when the operation of the PLC system is halted.
If the battery of the CPU module is depleted during operation stop, the stored date is lost.

6-2
Fuji Electric Co., Ltd.
Gate City Ohsaki, East Tower,
11-2, Osaki 1-chome, Shinagawa-ku, Tokyo 141-0032, Japan

E-mail: micrex-sx@fujielectric.co.jp
URL: http://www.fujielectric.com/

Materials covered in this document are subject to revision due to the modification of the product.