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Programmable Controller
Maintenance Guide
FEH329
Revision
* The manual No. is printed at the bottom right of the cover of this manual.
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
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.
1-4 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.
1-7 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
System
Daily inspection
replacement
Periodic inspection
Parts replacement
Replacement
Battery
Replacement
CPU module
Replacement
Relay module
Repair service
Production stop
Repair without charge
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.
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
3-2
Section 3 Maintenance
3-3 Preventive Maintenance
Visual
Check for loose screws on
the external wiring terminals.
No looseness Retighten the screws. inspection,
Screwdriver
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.
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.
Trouble occurred
Trouble detection
Troubleshooting
Restoration
Operation check
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.
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.
3-5
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.”
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.
4-1
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.
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.
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.
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.
Aluminum
Electro- Optical
electrolytic Retain
magnetic Battery communication
capacitor memory
Product name Type relay element
(Note 1)
Daily
Periodic inspection Periodic inspection
inspection
NP1PH-…
NP1PS-…
CPU module
NP1PM-…
NP1PU-…
Power supply module NP1S-…
Base board NP1B*-…
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)
Aluminum
Electro- Optical
electrolytic Retain
magnetic Battery communication
capacitor memory
Product name Type relay element
(Note 1)
Daily
Periodic inspection Periodic inspection
inspection
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)
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
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.