Making Things Dojo Textbook Company

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Sequencer (Elementary Version)

Edition for Creating Circuits

Mitsubishi Motors Corporation

1
(Revision history)
Prepared on Apr. 1, 2008
Prepared by S. Ozaki
(Mizushima)
Dojo Name
Maintenance Dojo
Rev. No. Rev. Date Reason for Revision/Revised Contents Revised by Dojo Name Rev. Page
Rev. 1 Month/day/year
Rev. 2 Month/day/year
Rev. 3 Month/ day/Year

Rev.4 Month/day/year
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Rev. 6 Month/day/year
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Rev. 14 Month/day/year

2
 Making Things Dojo Training Schedule
Training Name Sequencer Circuit Total of Training Time 18.0 H
1. Training Contents of Training Required Time
item
1) Overview of Sequencer 1.0 H
2) Major Contact Symbols to be used in Sequencer 1.0 H
3) Creation of Simplified Circuits (Self-holding, Timer) 1.0 H
4) Overview of Time-chart 1.0 H
5) How to Convert Respective Numbers (Binary Numbers, Decimal Numbers, Hexadecimal Numbers, BCD) 2.0 H
6) Practice of Data Command (MOV, <, >, =, BIN 、 BCD) 4.0 H
7) Create various kinds of circuits and write into sequencer to check the function. 5.0 H
8) Conduct the job of judging the completion of training. 3.0 H
2. Training 1) Maintenance Dojo (Electrical) Textbook and Training Materials
method
2) GPP (GX Developer to have set up) This textbook
- Sequencer Circuit (Edition for Creating Circuits)
1) Place
2) Training

materials 3) Using GPP, create circuits and write to check the results.
3) Method

3. Method
for judging
the 1) Using GPP. it is possible to create contact circuits, and write into sequencer and monitor.
completion 2) Using GPP and typical data command, it is possible to create circuits and monitor.
of training
(What and 3) It is possible to convert binary numbers or hexadecimal numbers into other numbers.
how to be
achieved)
4. Job of Judging Job and Job Name Required Time
judging the
completion 1) Using GX Developer, it is possible to create circuits for judging the completion and check the function. 3.0 H
of training 2) Convert binary numbers, binary-coded decimal numbers, and hexadecimal numbers.
3
 Safety Precautions
1. Be sure to check whether or not to have been charged
when you touch any terminals.
2. If you operate any items, check that the item are
completely safe.
3. To prevent receiving an electric shock, be sure to conduct
the power-on/off operation of NFB in the front with a hand
opposite to your heart.
4. To prevent burn injury, be sure to wear safety gloves when

power-on operation.
5. If you should find an operator who receives an electric
shock, firstly keep the operator away from the source of an
electric shock and then cut off NFB, never hastily touching
the operator with bare hands.
6. Make emergency contact to rescue the operator’s life
when necessary. 4
 What is Sequencer?
Control circuits have been formed with intense-electric circuits
(relay, etc.) so far, but general-purpose computer have developed,
as a result, the cost of general-purpose computer has become
inexpensive, and then the general-purpose computer has started to
be used for controlling the production machines or equipments as
sequencer.
Currently, the control-exclusive computer which provides special
motions for the production machines or equipments has been
widely used instead of the general-purpose computer, because it
can be fabricated inexpensively.
Advantages to using sequencer are as follows:
<1> Programs providing complex motions can be easily created
<2> Programs can be changed within the required shorter period.
<3> Cost-effectiveness is excellent because it is possible to
correspond to various kinds of controls by changing programs.

5
 Overview of Sequencer
Schematic diagram
Power
supply part CPC part Input part Input part Output part Output part

X0 X10 Y20 Y30

X1 X11 Y21 Y31
X2 X12 Y22 Y32

XF X1F Y2F Y3F

Button Sample program

X10
To illuminate a lamp when you Y30
push a button, write a program
(shown at right) into CPU.
6
Input and Output Numbers of Sequencer
Schematic diagram
Power
Input part Input part
Input (X
supply part CPC part Output part Output part
number) or
X0 X10 Y20 Y30 output (Y
number) is
X1 X11 Y21 Y31
decided
X2 X12 Y22 Y32 depending
on kinds of
cards
inserted into
XF X1F Y2F Y3F slots.

Input and output From X30 or Y30

numbers are
From X20 or Y20
assigned in order
from the slot next X10 or Y10
to CPU. From X0 or Y0
7
Hard Wiring Connection of Practical Training Machine
Power
supply part CPC part Input part Output part
PB
X10 Y30 Lamp

PB X11 Y31
X12 Y32

Q61P Q00CPU QX10 QY10

Power
AC
100V supply
X1F Y3F
COM COM

Conduct hard wiring connection as shown in diagram above.

The practical training adopts this system from now onward.

8
Practical Training of Sequencer Circuit
Using GPP, create various kinds of circuits and write into
sequencer.
<1> Typical symbols
<2> Contact point “a”, “b” and output
<3> Self-holding circuit
<4> Timer circuit
<5> Overview of time-chart
<6> Practice exercise (1), (2)
<7> Data command and respective numbers
<8> Conversion among respective numbers, etc.
Let’s do practical training while operating actually.
9
 Major Symbols Used in Sequencer
Typical symbols
Symbol
Signal Name Format Function Remarks
in circuit

X00 Load the external ON/OFF

In case of MELCO
Input signal X 00 condition of limit switch, etc.
make MELSEC
into sequencer.
Output the results calculated
Output signal Y 00 from sequencer as external Ditto
Y00 output.
Use this relay to use the
M00 results calculated from
Internal relay M 00 Ditto
sequencer for internal
calculation.
Even if the external input
L00 condition varies, the condition
Latch relay L 00 Ditto
must be kept until the reset is
input.
K20 The value entered
Measure the time, and then
on the top of timer
Timer T 00 calculate according to the
T00 is a set value of
results.
timer.

10
 Creation of Simplified Circuits
Create circuits using GPP, and then check using sequencer.
(Referring to the edition for operating GPP, operate GPP,
create circuits and write.)
X10

Y30
X11

Y31

X10 is referred to as contact point “a”, if the input

corresponding to X10 becomes ON, the contact point of X10
becomes ON, and then Y30 becomes ON. If released, Y30
becomes OFF.
X11 is referred to as contact point “b”, if the input
corresponding to X11 becomes ON, the contact point of Y31
becomes OFF. If X11 becomes OFF, Y31 becomes ON.
11
Creation of Self-holding Circuits

Using GPP, create circuits shown in diagram below and write into sequencer to
check the function.

X10 X11
Y30

M00
M00

<1> When the input corresponding to X10 becomes ON, Y30 and
M00 become ON.
<2> Even if X10 is released, Y30 and M00 continue ON because the

contact point is ON.  Self-holding circuit

<3> During this condition, if the input corresponding to X11 is ON,
12
 Circuits Using the Timer
Using GPP, create circuits shown in diagram below and write into sequencer to
check the timer function.

X10 T00 K20

T00
M00
M00
<1> If X10 is pressed, M00 becomes ON, and even if X10 is released, it
continues ON.
<2> When the timer of T00 becomes time-out (2 seconds has passed), the
contact point of the timer becomes ON and cut off the self-holding
circuit.
<3> Values entered into timer indicate 2 seconds for K20 because of the
low-speed timer.
(As for the high-speed timer, prefix “H” like H T0 K10, etc.
The set value K100 of the low-speed timer is 10 seconds,
The set value K100 of the high-speed timer is 1 second. ）
<4> Change the set values of the timer13frequently to check the function of
 Pulse Circuit using the Timer
Using GPP, create circuits shown in diagram below and write into sequencer to
check the timer function.

L1000 K5
T00
L1000 K5
T01
T01
SET
L1000

T00
RST
L1000

Check that L1000 becomes ON/OFF at intervals of 0.5 sec. in this

circuit.

14
 Practice (1) of creating circuits

X10 X11 T0
M1 Y30

M1 T1
Y31

M1 K10 T2
T0 Y32

K20 T3
T1 Y33

K30
T2

K40
T3
Using GPP, create circuits and write into sequencer to check using the
monitor that Y30 thru Y33 become ON every time one second has
15
 Overview of Circuit Time-chart

X10
X11

M1
T0
T1
T2
T3

To understand the function of circuits, draw the time-chart

to be checked.

16
 Practice (1) of Changing Circuits
Change the design conditions of the created circuits frequently
to practice creating circuits.
Then, study the change of circuits so as to function under the
following conditions.
1. In the circuits for practice (1) of creating sequencer circuits,
Change all of the set values for T0 thru T3 to K10, and then,

to modify the circuits so as to do the same function as the

previous circuits.
2. Using GPP, create the studied circuits and write into
sequencer to check the function using the monitor.

17
 Practice (2) of Changing Circuits

Study the circuits which meet the following conditions to

create circuits.
1. The termination is when all of the lamps of Y30 thru Y33
have illuminated in the current circuits, but study the
circuits so that the lamps will illuminate and go off
repeatedly until X11 becomes ON.
2. Write the studied circuits into sequencer, and check the
function using the monitor.

18
 Overview of Circuit Time-chart
X10

X11

M1

T0

T1

T2

T3
T4

Study and check the function of circuits using the time-chart.

19
 Data Command

- Data command is used frequently in sequencer.

So, learn the meaning of the following respective numbers and
practice the numeration.

- Binary number (Binary)

- Hexadecimal number (Hex Decimal)
- Binary-coded decimal number (Binary Code Decimal)
- Decimal number (Decimal)

20
 Relationship among respective
numbers
Binary-coded <1> There is no problem because
Decimal Hexadecimal
Binary number （ BIN) decimal number
number number decimal number is regularly
（ BCD ）
used by everyone.
０ 00 0000 0000 0000 0000 <2> Hexadecimal number is used
1 01 0000 0001 0000 0001 for input and output numbers
2 02 0000 0010 0000 0010
of sequencer, etc.
As for the number of 1 thru 9,
3 03 0000 0011 0000 0011
4 04 0000 0100 0000 0100 the numeration is the same
5 05 0000 0101 0000 0101 as
that of decimal number, but
6 06 0000 0110 0000 0110
as
7 07 0000 0111 0000 0111 for the number of 10 and
8 08 0000 1000 0000 1000 over,
the numeration is A, B, C, D,
9 09 0000 1001 0000 1001
E, F
10 0A 0000 1010 0001 0000 <3> Binary number is used for
11 0B 0000 1011 0001 0001 processing inside sequencer.
12 0C 0000 1100 0001 0010 <4> Binary-coded decimal number
13 0D 0000 1101 0001 0011 is used for output of
14 0E 0000 1110 0001 0100 indicators,
15 0F 0000 1111 0001 0101 etc.
16 10 0001 0000 0001 0110 Let’s check these in the following
～ ～ ～ ～
pages.
32 20 0010 0000 0011 0010
21
 Decimal Number and Binary Number
B15 B14 B13 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1 B0

２１５ ２１４ ２１３ ２１２ ２１１ ２１０ ２９ ２８ ２７ ２６ ２５ ２４ ２３ ２２ ２１ ２０

３２７６８ １６３８４ ８１９２ ４０９６ ２０４８ １０２４ ５１２ ２５６ １２８ ６４ ３２ １６ ８ ４ ２ １

０ １ ０ ０ １ １ １ １ ０ ０ ０ １ ０ ０ ０ １

Hexadecimal Number and Binary Number

B15 B14 B13 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1 B0

１６３ １６２ １６１ １６０

４ F １ １

０ １ ０ ０ １ １ １ １ ０ ０ ０ １ ０ ０ ０ １

4 X 163 + 15(F) X 162 + 1 X 161 + 1 X 160 = 20241

∴4F11 (hexadecimal number) = 20241 (decimal number)
In MELSEC sequencer (of MELCO make),
Decimal number is indicated by prefixing “K” like K10, K100, etc., or
Hexadecimal number is indicated by prefixing “H” like H10, H100, etc.
22
 BCD （ Binary Code Decimal)

B15 B0
B14 B13 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
bit bit

８０００ ４０００ ２０００ １０００ ８００ ４００ ２００ １００ ８０ ４０ ２０ １０ ８ ４ ２ １

4 9 3 1

0 1 0 0 1 0 0 1 0 0 1 1 0 0 0 1

In Binary-coded decimal number (BCD), the digit in the

numeric frame of the third column shown above is 0 thru 9,
and if the digit is over 9, it is carried onto the upper digit.

23
 Decimal to Binary Conversion
Convert the decimal-number indicated numerical values to binary number.

B15 B14 B13 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1 B0

３２７６８ １６３８４ ８１９２ ４０９６ ２０４８ １０２４ ５１２ ２５６ １２８ ６４ ３２ １６ ８ ４ ２ １

０ ０ ０ ０ ０ ０ ０ １ ０ ０ １ ０ １ １ ０ ０

e.g.: Convert 300 to binary number.

<1> 300-256 = 44
** While the bit of max value which is less than 300 or equal is set to 1, subtract that value from 300.
<2> 44 – 32 = 12
**While the bit of max value which is less than the remaining value of 44 or equal is set to 1, subtract that value from 44.
<3> 12 – 8 = 4
** While the bit of max value which is less than the remaining value of 12 or equal is set to 1, subtract that value from 12.
<4> 4 – 4 = 0
** While the bit of max value which is approximate to the remaining value of 4 or equal is set to 1, subtract that value from 4.
<5> End (There is no remainder)

Answer: 0000000100101100
24
 Binary to Decimal Conversion
Convert the binary-number indicated numerical value
(0100100100010001) to decimal number.

B15 B14 B13 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1 B0

２１５ ２１４ ２１３ ２１２ ２１１ ２１０ ２９ ２８ ２７ ２６ ２５ ２４ ２３ ２２ ２１ ２０

３２７６８ １６３８４ ８１９２ ４０９６ ２０４８ １０２４ ５１２ ２５６ １２８ ６４ ３２ １６ ８ ４ ２ １

0 1 0 0 1 0 0 1 0 0 0 1 0 0 0 1

In case of binary number shown above, the value in decimal

number is 16384 + 2048 + 256 + 16 + 1 = 18705.

25
Practice of Hexadecimal to Binary Conversion
Let’s practice conversion in the following exercises.

Bit 15 Bit 0
Hexadecimal Binary

7 0 B 8

Bit 15 Bit 0
Hexadecimal Binary

A 1 E 4

Bit 15 Bit 0
Hexadecimal Binary

2 C 5 D

Hexadecimal Bit 15
Binary Bit 0

9 6 8 F

Convert hexadecimal number (in the frames at left) to

binary number (in the frames
26
at right) to be entered.
Practice of decimal to binary and hexadecimal conversion
Let’s practice conversion in the following exercises.
Decimal Bit 15 Bit 0
Binary Hexadecimal
13

Decimal
Bit 15 Bit 0
Binary Hexadecimal
100

Decimal Bit 15
Binary Bit 0
Hexadecimal
200

Decimal Bit 15 Bit 0

Binary Hexadecimal
301

Convert decimal number (at left) to binary and hexadecimal

numbers. 27
Practice of Binary to BCD Code Conversion

Bit 15 Binary Bit 0 Bit 15 BCD Code Bit 0

0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 1

Bit 15 Binary Bit 0 Bit 15 BCD Code Bit 0

0 0 0 0 0 0 0 0 0 0 0 0 1 1 0 1

Bit 15 Binary Bit 0 Bit 15 BCD Code Bit 0

0 0 0 0 0 0 0 1 0 0 0 0 0 1 1 1

Bit 15 Binary Bit 0 Bit 15 BCD Code Bit 0

0 0 0 0 0 0 0 1 0 1 0 0 0 1 0 0

Convert binary number (in the frames at left) to binary-coded

decimal number (in the frames at28 right) to be entered.
 Data Command
Sequencer allows for control according to data (numerical
values), not only ON/OFF control of contact point like the relay
circuit.
Basic data control command is as follows:
- Numerical value move command: MOV Command  (read
as “Move”)
- Numerical value compare command: < , > , = , < > , > = , < =
Let’s consider the function in the following example circuit.
X0
MOV D0 D10
The current value of D0 is 10, D10 is 0.

When X0 becomes ON, the value in the box of D0 moves

to D10, and then the content in the box of D10 becomes
10 from 0. 29
 Data Compare Command <1>
Circuits of comparing various kinds of data
X11

> D0 D10 Y30

If D0 > D10, Y30 becomes ON.

X11
< D0 D10 Y31

If D0 < D10, Y31 becomes ON.

X11

= D0 D10 Y32

If D0 = D10, Y32 becomes ON.

Using GPP, create circuits, write into sequencer, and change the write data with
device test mode to check the function.
30
 Data Compare Command <2>
Circuits of converting various kinds of data
X11
<> D0 D10 Y30

If D0 < > D10, Y30 becomes ON.

X11
<= D0 D10 Y31

If D0 < = D10, Y31 becomes ON.

X11
>= D0 D10 Y32

If D0 > = D10, Y32 becomes ON.

Using GPP, create circuits, write into sequencer, and change the write data with
device test mode to check the function.
31
 Data Compare Command
Using GPP, convert the constant in the program (write
during RUN) to check ON/OFF at Y30.
X10
MOV H10 D0

MOV K11 D10

> D0 D10 Y30

When X10 becomes ON, the constant moves into D0

and D10 respectively to compare both values, and then
the output Y30 becomes ON or OFF.
32
 Data Compare Circuit

1 sec. pulse
+ K1 D0

= K7 D0 Y30
Y30
MOV K1 D0

What kind of function will this circuit offer?

Write it into sequencer and check the function.

33
 BIN and BCD Command
Using GPP, create circuits and write into sequencer to
check the function by monitoring.
L0
MOV K100 D0

BIN D0 D10

BCD D0 D20

Force L0 to be ON, and check the values of D10 and D20

by monitoring. And then, consider the reason for difference
of the indicated values.
34
 BCD and BIN Command <1>
X10
MOV K100 D0

BIN D0 D10

BCD D0 D20

1 1 1 = Displayed 100
D0 0 0 0 0 0 0 0 0 0 0 0 0 0
on the monitor.
D10 is BIN command, therefore the bit pattern shown below is indicated in BCD.

D10 0 0 0 0 0 0 0 0 0 1 1 0 0 1 0 0 = Displayed 100

on the monitor.
AS for D20, D0 is 100, therefore the BCD conversion value is indicated in bit.

D20 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 = Displayed 100

on the monitor.
35
Practice of Sequencer CPU Replacement
1. Set CPU’s RUN to STOP
2. Read out program and parameter, and save them to F/D.
3. Read out all device to save to F/D.
4. Collate F/D and CPU.
5. Replace with a new CPU.
6. Set CPU to STOP, and turn on.
7. Write the preliminarily read-out program and parameter into CPU.
8. Write all device into CPU.
9. Collate among GPP, CPU’s program, parameter, and all device.
10. Reset CPU.
11. Conduct RUN.

Note; If it is impossible to do the operation of 2, 3 above due to failures, etc.,

write the program and parameter (which have been saved for back-up)
into CPU. And judging the conditions, if necessary, write all device.

36
 Answer to Exercise <1>

X10 X11 T0
M1 Y26
M1 T1
Y27
M1 K10 T2
T0 Y28

T3
T0 K10
T1 Y29

T1 K10
T2

T2 K10
T3

Learn how to change the set value of the timer and how to
insert the contact point. 37
Answer to Practice of decimal to binary and hexadecimal conversion

Let’s practice conversion in the following exercises.

Decimal Bit 15 Bit 0
Binary Hexadecimal
13 0 0 0 0 0 0 0 0 0 0 0 0 1 1 0 1 0 0 0 0

Decimal
Bit 15 Bit 0
Binary Hexadecimal
100 0 0 0 0 0 0 0 0 0 1 1 0 0 1 0 0 0 0 6 4

Decimal Bit 15
Binary Bit 0
Hexadecimal
200 0 0 0 0 0 0 0 0 1 1 0 0 1 0 0 0 0 0 C 8

Decimal Bit 15 Bit 0

Binary Hexadecimal
301 0 0 0 0 0 0 0 1 0 0 1 0 1 1 0 1 0 1 2 D

Convert decimal number (at left) to binary and hexadecimal

numbers. 40
Answer to Practice of Binary to BCD Code Conversion

Bit 15 Binary Bit 0 Bit 15 BCD Code Bit 0

0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 1

Bit 15 Binary Bit 0 Bit 15 BCD Code Bit 0

0 0 0 0 0 0 0 0 0 0 0 0 1 1 0 1 0 0 0 0 0 0 0 0 0 0 0 1 0 0 1 1

Bit 15 Binary Bit 0 Bit 15 BCD Code Bit 0

0 0 0 0 0 0 0 1 0 0 0 0 0 1 1 1 0 0 0 0 0 0 1 0 0 1 1 0 0 0 1 1

Bit 15 Binary Bit 0 Bit 15 BCD Code Bit 0

0 0 0 0 0 0 0 1 0 1 0 0 0 1 0 0 0 0 0 0 0 0 1 1 0 0 1 0 0 1 0 0

Convert binary number (in the frames at left) to binary-coded

decimal number (in the frames at41
right) to be entered.