User’s Manual LG Programmable Logic Controller MASTER-K 120S series LG Industrial Systems - When using LGIS equipment, thoroughly read this datasheet and associated manuals introduced in this datasheet. Also pay careful attention to safety and handle the module properly.
SAFETY INSTRUCTIONS To Prevent injury and property damage, follow these instructions. Incorrect operation due to ignoring instructions will cause harm or damage, the seriousness of which is indicated by the following symbols. WARNING This symbol indicates the possibility of death or serious injury CAUTION This symbol indicates the possibility of injury or damage to property. ■ The meaning of each symbol in this manual and on your equipment is as follows This is the safety alert symbol.
SAFETY INSTRUCTIONS Design Precautions Warning Install a safety circuit external to the PLC that keeps the entire system safe even when there are problems with the external power supply or the PLC module. Otherwise, serious trouble could result from erroneous output or erroneous operation. - Outside the PLC, construct mechanical damage preventing interlock circuits such as emergency stop, protective circuits, positioning upper and lower limits switches and interlocking forward/reverse operation.
SAFETY INSTRUCTIONS Design Precautions Caution Do not bunch the control wires or communication cables with the main circuit or power wires, or install them close to each other. They should be installed 100mm (3.94inch) or more from each other. Not doing so could result in noise that would cause erroneous operation. Installation Precautions Caution Use the PLC in an environment that meets the general specification contained in this manual or datasheet.
SAFETY INSTRUCTIONS Wiring Precautions Warning Completely turn off the external power supply when installing or placing wiring. Not doing so could cause electric shock or damage to the product. Make sure that all terminal covers are correctly attached. Not attaching the terminal cover could result in electric shock. Caution Be sure that wiring is done correctly be checking the product’s rated voltage and the terminal layout. Incorrect wiring could result in fire, damage, or erroneous operation.
SAFETY INSTRUCTIONS Startup and Maintenance Precautions Warning Do not touch the terminals while power is on. Doing so could cause electric shock or erroneous operation. Switch all phases of the external power supply off when cleaning the module or retightening the terminal or module mounting screws. Not doing so could result in electric shock or erroneous operation. Do not charge, disassemble, heat, place in fire, short circuit, or solder the battery.
Revision History Date Code 2002.7. 10310000380 First edition is published 2003.5. 10310000380 A revised edition is published 2003.9 10310000380 Revision history – Main unit and expansion modules are added – Built-in function are upgraded A revised edition is published. - Main units are added - Built-in functions are upgraded.
◎ Chapter 1. Contents ◎ General 1.1 Guide to Use This Manual ················· 1 - 1 1.2 Features ······················· 1 - 2 1.3 Terminology ······················ 1 - 3 Chapter 2. System Configuration 2.1 Overall Configuration ··················· 2 - 1 2.1.1 Basic System································································································ 2 - 1 2.1.2 Cnet I/F System····························································································· 2 - 2 2.
4.4 Communication I/F Module ················· 4 - 13 4.4.1 Cnet I/F Module····························································································4 - 13 4.4.2 Fnet I/F Module ····························································································4 - 13 4.4.3 Pnet I/F Module ····························································································4 - 14 4.4.
5.9.2 Usage ········································································································5 - 30 5.10 External Memory Module ················· 5 - 32 5.10.1 Structure ···································································································5 - 32 5.10.2 Usage·······································································································5 - 32 5.11 RTC Module ······················ 5 - 34 5.11.
Chapter 8. Communication Function 8.1 Dedicated Protocol Communication ·············· 8 - 1 8.1.1 Introduction ·································································································· 8 - 1 8.1.2 System configuration method ··········································································· 8 - 2 8.1.3 Frame Structure ···························································································· 8 - 5 8.1.
Chapter 10. Maintenance 10.1 Maintenance and Inspection ················ 10 - 1 10.2 Daily Inspection ···················· 10 - 1 10.3 Periodic Inspection ··················· 10 - 2 Chapter 11. Troubleshooting 11.1 Basic Procedure of Troubleshooting ············· 11 - 1 11.2 Troubleshooting ············································································ 11 - 1 11.2.1 Troubleshooting flowchart used when the power LED turns off ·····························11 - 2 11.2.
Chapter 1 General Chapter 1. General 1.1 Guide to Use This Manual This manual includes specifications, functions and handling instructions for the MASTER-K120S series PLC. This manual is divided up into chapters as follows: No. Title Chapter 1 General Chapter 2 System configuration Describes available units and system configurations in the MASTER-K120S series. Chapter 3 General Specification Describes general specifications of units used in the MASTER-K120S series.
Chapter 1 General 1.2. Features 1) MASTER-K120S series is extremely compact, to fit a wide range of applications and have following features. (1) High speed processing High speed processing of 0.1~0.9µs/step with an general purpose processor included . (2) Various built-in functions The main unit can perform many functions without using separate modules. Therefore, It is possible to construct various systems just using the main unit.
Chapter 1 General 1.3 Terminology The following table gives definition of terms used in this manual. Terms Module Unit Definition Remarks Example) A standard element that has a specified function which configures the CPU module system. Devices such as I/O board, which inserted onto the mother board Power Supply module or base unit. I/O module A single module or group of modules that perform an independent Operation as a part of PLC system.
Chapter 1 General Terms Definition Current flows from the switch to the PLC input terminal if a input signal turns on. Sink Input Current flows from the PLC input terminal to the switch after a input signal turns on. Source Input Current flows from the load to the output terminal and the PLC output turn on. Sink Output Output Contact Current flows from the output terminal to the load and the PLC output turn on.
Chapter 2 System Configuration Chapter 2. System Configuration The MASTER-K120S series has suitable to configuration of the basic, computer link and network systems. This chapter describes the configuration and features of each system. 2.1 Overall Configuration 2.1.
Chapter 2 System Configuration 2.1.2 Cnet I/F system Cnet I/F System is used for communication between the main unit and external devices using RS-232C/RS-422 Interface. The MK120S has a built-in RS-232C port, RS-485 port and has also G7L-CUEB for RS-232C, G7L-CUEC for RS-422. It is possible to construct communication systems on demand.
Chapter 2 System Configuration (3) RS-232C Communication over a long distance via modem by Cnet I/F modules MASTER-K120S G7L-CUEB G7L-CUEB MASTER-K120S Modem Modem MASTER-K120S Modem G7L-CUEB Modem 2) 1:n Communications system This method can connect between one computer and multiple main units for up to 32 stations Can be connected Max.
Chapter 2 System Configuration 2.2 Product Functional Model The following describes functional model of the MASTER-K120Sseries. 2.2.1 Product Functional Block Product function block for the K120S series is as follows. Main Unit Power supply Expansion Modules Input signal Power supply Input signal Input Input DC24V Power supply • Comm.
Chapter 2 System Configuration 2.2.2 K120S Series System Equipment Product 1) Main Unit – Standard type Items I/O Point & Power Supply Models 12 DC inputs(24VDC) K7M-DR20U K7M-DR30U 8 relay outputs • Max. expansion : 3 modules 18 DC inputs(24VDC) • High-speed counter : 12 relay outputs K7M-DR60U - 2 Phase : 50 kHz 1channel, 10 kHz 1channel.
Chapter 2 System Configuration 3) Expansion Modules Section Expansion module Items Models Description G7E-DR10A • 6 DC inputs / 4 relay outputs G7E-DR20A • 12 DC inputs / 8 relay outputs G7E-DC08A • 8 DC inputs G7E-TR10A • 10 Transistor outputs G7E-RY08A • 8 relay outputs G7E-DR08A • 4 DC Input, 4 Relay output G7F-ADHA • A/D : 2 channel , D/A : 1 channel G7F-ADHB • A/D : 2 channel , D/A : 2 channel G7F-AD2A • A/D : 4 channel G7F-DA2I • D/A : 4 channel(current output) G7F-DA2V • D/
Chapter 3 General Specifications Chapter 3. General Specifications 3.1 General Specifications The following table shows the general specifications of the MASTER-K120S series. No.
Chapter 4 Names of Parts Chapter 4. Names of Parts 4.1 Main Unit ⑤ ④ ⑧ BUILT_IN CNET ⑦ ② RUN PAU/REM STOP OFF ON ROM MODE ① ⑥ ③ ③ ⑨ - + RS-485 No.
Chapter 4 Names of Parts No Name Description ② I/O LED Indicates operating status of I/O ③ Built-in RS-485 connector (Except K7M-DR10/14UE) 2-pin connector for built-in RS-485 communications. Designates main unit’s operation mode y RUN : Run program operation ④ Key switch for mode creation .
Chapter 4 Names of Parts 2) K7M-DRT60U 3) K7M-DT60U 4.1.
Chapter 4 Names of Parts 2) K7M-DRT40U 3) K7M-DT40U 4.1.
Chapter 4 Names of Parts 2) K7M-DRT30U 3) K7M-DT30U 4.1.
Chapter 4 Names of Parts 2) K7M-DRT20U 3) K7M-DT20U 4.1.
Chapter 4 Names of Parts 4.1.6 20-points main unit (Economic) 1) K7M-DR20UE 4.1.7 14-points main unit (Economic) 1) K7M-DR14UE 4.1.
Chapter 4 Names of Parts 4.2 Expansion I/O Module 4.2.1 20points I/O Module 1) G7E-DR20A ④ ③ ① ⑦ ⑧ ② ⑤ ⑥ 4.2.2 ⑤ ⑥ No. Names ① Input LED ② Output LED ③ Input contact ④ Input common terminal ⑤ Output contact ⑥ Output common terminal ⑦ Expansion cable ⑧ Expansion Cable Connecting Terminal No.
Chapter 4 Names of Parts 4.2.3 8points I/O Module 1) G7E-DC08A ② ③ ① ⑤ ④ ② No. Names ① Input LED ② Input contact ③ Input common terminal ④ Expansion cable ⑤ Expansion Cable Connecting Terminal No.
Chapter 4 Names of Parts 4.3 Special Module 4.3.1 A/D·D/A Combination Module 1) G7F-ADHA ⑤ No. ② ⑥ ⑦ ① ④ ③ Names ① RUN LED ② Analog Output Terminal ③ Analog Input (Voltage/current) selecting jumper pin ④ Analog Input Terminal ⑤ External Power Supply Terminal (DC24V) ⑥ Expansion Cable ⑦ Expansion Cable Connecting Terminal 2) G7F-ADHB ③ ⑤ ⑥ ① ④ ② 4 -10 No.
Chapter 4 Names of Parts 4.3.2 D/A Conversion Module 1) G7F-DA2I No. ③ ④ ① ⑤ Names ① RUN LED ② Analog Output Terminal ③ Expansion Cable ④ Expansion Cable Connecting Terminal ⑤ External Power Supply Terminal (DC24V) ② 2) G7F-DA2V ⑤ No. ④ ③ ① Names ① RUN LED ② Analog Output Terminal ③ Expansion Cable ④ Expansion Cable Connecting Terminal ⑤ External Power Supply Terminal (DC24V) No. Names ② 4.3.
Chapter 4 Names of Parts 4.3.4 Analog timer Module ② No. ③ Names ① RUN LED ② Analog Timer Volume Control Resistor ③ Expansion Cable ④ Expansion Cable Connecting Terminal ④ ① 4.3.5 RTD Input Module ⑤ ② No.
Chapter 4 Names of Parts 4.4 Communication I/F Module 4.4.1 Cnet I/F Module 1) G7L-CUEB No. Names ① RS-232C connector ② Communication status LED ③ Expansion cable ④ Expansion cable connecting terminal ⑤ TM/TC selecting dip switch No. Names ① RS-422/485 connector ② Power supply/Communication status LED ③ Expansion cable ④ Expansion cable connecting terminal No. Names ① Station No.
Chapter 4 Names of Parts 4.4.3 Pnet I/F Module 1) G7L-PBEA No. Names ① Station No. selecting switch ② Pnet cable connector ③ Expansion cable ④ Expansion cable connecting terminal ⑤ Communication status LED No. Names ① Station No. selecting switch(NA) ② DeviceNet cable connector ③ Expansion cable ④ Expansion cable connecting terminal ⑤ Baud rate selecting switch ⑥ Power supply/Communication status LED 4.4.4 DeviceNet I/F Module 1) G7L-DBEA 4.
Chapter 5 Power Supply / CPU Chapter 5. Power Supply / CPU 5.1 Power Supply Specifications 5.1.1. Standard Type Items Input Output(1) Output(2) K7M – DR/DRT/DT20U K7M – DR/DRT/DT30U Rated voltage 85 ~ 264 VAC Rated frequency 50 / 60 Hz (47 ~ 63 Hz) Rated current 0.5A(110VAC)/0.25A(220VAC) Inrush current Up to 30A Efficiency 65% min.(rated input/maximum load) Input fuse 2A/AC250V (Time Lag Type) Permitted Momentary power failure 10 ms Output voltage DC 5V Output current 1.
Chapter 5 Power Supply / CPU 5.2 CPU Specifications The following table shows the general specifications of the MASTER-K120S series 5.2.1.
Chapter 5 Power Supply / CPU (continued) Specifications Items Remarks K7M-DR/DRT/DT20U K7M-DR/DRT/DT30U K7M-DR/DRT/DT40U K7M-DR/DRT/DT60U Controlled by commands, Relay and PRC auto tuning, PID control function PWM output, manual output, adjustable operation scan time, Anti-windup, SV-Ramp, Delta MV, Position and Velocity algorithm Dedicated protocol support Cnet I/F Function MODBUS protocol support RS-232C - 1port User defined protocol support RS-485 - 1 port No protocol support Capacity 1 phas
Chapter 5 Power Supply / CPU 5.2.2. Economic Type Specifications Items Remarks K7M-DR10UE Program control method K7M-DR14UE K7M-DR20UE Cyclic execution of stored program, Time-driven interrupt, Process-driven interrupt I/O control method Indirect mode(Refresh method), Direct by program command Program language Instruction list, Ladder diagram Numbers of instructions Basic : 30, Application : 269 Processing speed 0.
Chapter 5 Power Supply / CPU (continued) Specifications Items Remarks K7M-DR10UE K7M-DR14UE K7M-DR20UE K7M-DR30UE Dedicated protocol support Cnet I/F Function MODBUS protocol support RS-232C - 1port User defined protocol support RS-485 - 1 port RS-485 is available on K7M-DR10/14UE only No protocol support Capacity 1 phase : 10 kHz-2 channel 2 phase : 5 kHz-1 channel 4 different counter modes as following; Built-in Function Counter High-speed function counter -. 1 phase operation mode. -.
Chapter 5 Power Supply / CPU 5.3 Operation Processing 5.3.1 Operation Processing Method 1) Cyclic operation A PLC program is sequentially executed from the first step to the last step, which is called scan. This sequential processing is called cyclic operation. Cyclic operation of the PLC continues as long as conditions do not change for interrupt processing during program execution.
Chapter 5 Power Supply / CPU 2) Interrupt operation method If a situation occurs which is requested to be urgently processed during execution of a PLC program, this opera tion method processes immediately the operation, which corresponds to interrupt program. The signal, which infor ms the CPU of those urgent conditions is called interrupt signal. The MASTER-K120S CPU has three kind of int errupt operation methods, which are internal, external and high speed counter interrupt signal methods. 5.3.
Chapter 5 Power Supply / CPU 5.3.3 Scan Time The processing time from a 0 step to the 0 step of next scan is called scan time. 1) Expression for scan time Scan time is the sum of the processing time of scan program that the user has written, of the task program processing time and the PLC internal processing time.
Chapter 5 Power Supply / CPU 5.3.5 Timer Processing The MASTER-K series use up count timer. There are 5 timer instructions such as on-delay (TON), off-delay (TOFF), integral (TMR), monostable (TMON), and re-triggerable (TRTG) timer. The measuring range of 100msec timer is 0.1 ~ 6553.5 seconds, 10msec timer is 0.01 ~ 655.35 seconds, and that of 1msec timer is 0.001 ~ 65.53 seconds. Please refer to the ‘MASTER-K programming manual’ for details.
Chapter 5 Power Supply / CPU 3) Integral timer In general, its operation is same as on-delay timer. Only the difference is the current value will not be clear when the input condition of TMR instruction is turned off. It keeps the elapsed value and restart to increase when the input condition is turned on again. When the current value reaches preset value, the timer output relay is turned on. The current value can be cleared by the RST instruction only.
Chapter 5 Power Supply / CPU 5) Retriggerable timer The operation of retriggerable timer is same as that of monostable timer. Only difference is that the retriggerable timer is not ignore the input condition of TRTG instruction while the timer is operating (decreasing). The current value of retriggerable timer will be set as preset value whenever the input condition of TRTG instruction is turned on.
Chapter 5 Power Supply / CPU 5.3.6 Counter Processing The counter counts the rising edges of pulses driving its input signal and counts once only when the input signal is switched from off to on. MASTER-K series have 4 counter instructions such as CTU, CTD, CTUD, and CTR. The followings shows brief information for counter operation. Refer to the ‘MASTER-K Instruction Manual’ for details. 1) Up counter (CTU) -. The counter output relay is turned on when the current value reaches the preset value. -.
Chapter 5 Power Supply / CPU 4) Ring counter -. The current value is increased with the rising edge of the counter input signal, and the counter output relay is turned on when the current value reaches the preset value. Then the current value and counter output relay is cleared as 0 when the next counter input signal is applied. 5) Maximum counting speed (1) The maximum counting speed of counter is determined by the length of scan time.
Chapter 5 Power Supply / CPU 5.4 Program 5.4.1 Classifications of Program All functional elements need to execute a certain control process are called as a ‘program’. In MASTER-K120 series, a program is stored in the EEPROM mounted on a CPU module or flash memory of a external memory module. The following table shows the classification of the program.
Chapter 5 Power Supply / CPU 1) Scan program -. The scan program is executed regularly in every scan from 0 step to last step. -. When interrupts has occurred, CPU pauses scan program and executes corresponding interrupt program first. -. When this interrupt program finished, scan program is to resume. 2) Interrupt program -. When an interrupt occurs, the CPU module will stop the current operation and execute the corresponding interrupt routine first.
Chapter 5 Power Supply / CPU 2) parameter setting 3) Time driven interrupt TDI occurs periodically with the constant interval assigned in parameter setting. The interrupt routine of TDI starts with the TDINT instruction and ends with the IRET instruction. When multiple interrupt factors occur simultaneously, interrupt routines are executed according to the priority given to the each interrupt.
Chapter 5 Power Supply / CPU REMARK Total available interrupt points is 8(In standard type). -. Time driven interrupt + process driven interrupt + high speed counter driven interrupt ≤ 8 points Interrupt signal is ignored when self-interrupt occurs more than 2 times during interrupt processing is executing. ignored Interrupt executing time Interrupt signal (ex : rising edge) 5.4.
Chapter 5 Power Supply / CPU (4) External device malfunction The PLC user program detects malfunctions of external devices. If a fatal error is detected the system ent ers into the STOP state, and if an ordinary error is detected the system continues its operation. REMARK 1) In occurrence of a error, the state is to be stored in the representative system error flag F006. 2) For details of flags, refer to Chapter 11. Troubleshooting.
Chapter 5 Power Supply / CPU 5.5 Operation Modes The CPU operates in one of the four modes - RUN, STOP, PAUSE and DEBUG mode. The following describes ope ration processing in each operation mode. 5.5.1 RUN Mode In this mode, programs are normally operated. The first scan start in the RUN mode Initialize data area according to the preset restart mode. Check the program and determine it can be executed or not.
Chapter 5 Power Supply / CPU 5.5.2 STOP mode In this mode, programs are not operated. 1) Processing when the operation mode is changed. The output image area is cleared and output refresh is executed. 2) Operation processing contents (1) I/O refresh is executed. (2) Normal or abnormal operation and mounting conditions of the loaded module are checked. (3) Communications service or other internal operations are processed. 5.5.3 PAUSE mode In this mode, the program operation is temporarily stopped.
Chapter 5 Power Supply / CPU 3) Debug operation conditions following four operation conditions can be specified. Operation conditions executed by one command. Description When executed, Stop operation after executing one instruction executed by break-point settings.
Chapter 5 Power Supply / CPU 3) Mode change Remote operation Remote operation mode change is available only when the operation mode is set to the remote STOP mode (i.e., the mode setting switch position is in the STOP→ PAU/REM’). Mode setting switch position PAU / REM Mode change by the KGLWIN Mode change using FAM or Cnet I/F, etc.
Chapter 5 Power Supply / CPU 5.6 Functions 5.6.1 Self-diagnosis 1) Functions (1) The self-diagnosis function permits the CPU module to detect its own errors. (2) Self-diagnosis is carried out when an error occurs during PLC power supply is turned on or operating process. If an error is detected, the system stops operation to prevent faulty PLC operation. 2) WDT (Watch dog timer) function The watch dog timer is an internal timer of a PLC to detect the error of hardware and a sequence program.
Chapter 5 Power Supply / CPU 5.6.2 I/O Force On/Off function It is possible to input/output a designated data regardless of the program operation results. When used with OUTOFF instruction simultaneously, OUTOFF is prior to I/O Force On/Off. 1) Forced I/O setting method. -. I/O Force on/off setting is applied to input area and output area. -. I/O Force on/off should be set for each input and output, the setting operates from the time that Force I/O setting enable’ is set. -.
Chapter 5 Power Supply / CPU Set ‘forced I/O data’ by bit Set ‘forced I/O data enable’ by bit -. When forced I/O set enables, forced I/O function is executing.
Chapter 5 Power Supply / CPU 2) Special data register for forced I/O The contents of forced I/O setting is registered to special data register as below. It is possible to use ‘forced I/O function’ to program.
Chapter 5 Power Supply / CPU 5.6.3 Direct I/O Operation function This function is useful when reads an input relay’s state directly during execution of a program and uses in the operation, or write the operation result directly to an output relay. Direct input/output is executed by the ‘IORF’ instruction. If this instruction is used, the input/output image area will be directly updated and applied to the continuing operations. REMARK -.
Chapter 5 Power Supply / CPU 5.7 Memory Configuration The CPU module includes two types of memory that are available by the user. One is program memory, which is used to store the user programs written to implement a system by the user. The other is data memory, which sto res data during operation.
Chapter 5 Power Supply / CPU 5.8 I/O Address Allocation I/O No. allocation means to give an address to each module in order to read data from input modules and output data to output modules. Max. 3 expansion module is available in standard type. Mounting module Max. module can be mounted remark Expansion I/O module 3 2 modules in economic type A/D, D/A conversion module 3 Analog timer module 3 Communication module 1 Not available on economic type 1) I/O No. allocation method -.
Chapter 5 Power Supply / CPU 5.9 Built-in Cnet Selection Switch 5.9.1 Structure You can see dip switches as shown when you open I/O terminal block cover. BUILT_IN CNET Terminal block cover OFF ON ROM MODE 5.9.2 Usage Dip switch position Description upper switch is for Cnet. OFF ON Turn upper switch on to use built-in RS-232C communication ROM MODE Upper switch is for Cnet. OFF ON Turn upper off switch to use external communication modules. ROM MODE * The lower switch is for O/S download setting.
Chapter 5 Power Supply / CPU Dip switch for Built-in Cnet is placed in deep place to prevent a mistaken operation caused by terminal block cover, etc. Use a small driver to operate it.
Chapter 5 Power Supply / CPU 5.10 External Memory Module MK120S series supplies external memory module for the user to save programs safely or download a program on the system and use it in case of a program is damaged. 5.10.1 Structure Installation connector 5.10.2 Usage 1) Saving the user’s program on the external memory module. (1) Turn the power of the base unit off. (2) Install the memory module. -. When only main unit is used : Connect to the expansion connector of the basic unit. -.
Chapter 5 Power Supply / CPU (6) Select Online – Flash memory – Write to external memory in menu, and the following message box will displayed. (7) Turn the power of the main unit off. (8) Remove the external memory module. Through the above steps a user can save a program into the external memory module. 2) Run the PLC with a program of external memory module (1) Turn the power of the main unit off.
Chapter 5 Power Supply / CPU 5.11 RTC Module MK120S series supplies RTC(Real Time Clock) module for the time-scheduling control. To use RTC function with K120S series, the RTC operation module should be attached to the expansion slot of main unit or expansion module. Clock operation by the RTC function is continued with a super capacitor when the CPU is powered off. 5.11.1 Structure Installation connector 5.11.2 Usage 1) Read RTC data (1) Read RTC data from KGLWIN -.
Chapter 5 Power Supply / CPU (2) Read RTC data from special register Description Special register Area (Word) Upper byte Lower byte Data (BCD format) F053 Lower 2 digits of year Month H0207 F054 Day Hour H2313 F055 Minute Second H5020 F056 Higher 2 digits of year Date H2002 Example : 2002. 07. 23. 13:50:20, Tuesday 2) Write RTC data There is two ways to write new RTC data to the CPU. The first one is using a graphic loader (KGLWIN).
Chapter 6 Input and Output Specification Chapter 6 Input and Output Specification 6.1 Input / Output Specifications Digital input that offers to MASTER-K120S series are made to use both of electric current sink and electric current source. To keep use coil load as an output module, maximum opening and shutting frequency is 1 second on and 1 second off. The following diagram shows maximum life relay for relay output. ×( Frequency 100 10,000) 50 30 20 10 AC 125V r/load DC 30V r/load AC 250V r/load 0.
Chapter 6 Input and Output Specification 6.2 Digital Input Specification 6.2.1 Main unit 1) Specification Main unit Model K7M-DR10UE Specification K7M-DR14UE K7MDR/DRT/DT30U K7M-DR30UE K7MDR/DRT/DT40U K7M-DRT40U K7MDR/DRT/DT60U K7M-DRT60U 12 points 18 points 24 points 36 points Number of input points 6 points Insulation method Photo coupler Rated input voltage DC 24V Rated input current 7 mA (Standard Type P0~P3:9mA, Economic Type P0,P1:9mA) Operating voltage range DC20.4 ~ 28.
Chapter 6 Input and Output Specification 3) Input wiring Main unit’s wiring method is as follows. DC input specifications offered by MASTER-K120S is to be used for both electric current sink and electric current source.
Chapter 6 Input and Output Specification 4) Example of external devices. To connect with external device of DC output type into DC input module, wire depending on the type of the external device as shown.
Chapter 6 Input and Output Specification 6.2.2 Expansion Module 1) Specifications Expansion Module Model Specification Number of input points G7E-DR10A G7E-DC08A G7E-DR20A 6 points 8 points 12 points Insulation method Photo coupler Rated input voltage DC 24V Rated input current 7 mA Operating voltage range DC 20.4 ~ 28.8V (ripple: less than 5%) Max. Simultaneous input points 100% simultaneously On On voltage / On current DC19V or higher/ 5.
Chapter 6 Input and Output Specification 6.3 Digital Output Specification 6.3.1 Main unit (Relay Output) 1) Specification (1) Standard type Model Specifications Main Unit K7M-DR20U (K7M-DRT20U) K7M-DR30U (K7M-DRT30U) Output point 8 points(4 points) Insulation method Relay insulation Rated load voltage/current DC24V / 2A (r/load), AC220V / 2A (COS Ψ = 1)/1 point , 5A / 1COM Min. load Voltage/current DC5V / 1mA Max. load voltage/current AC250V, DC110V Current leakage when off 0.
Chapter 6 Input and Output Specification (2) Economic type Model Specifications Main Unit K7M-DR10UE K7M-DR14UE Output point 4 points Insulation method Relay insulation Rated load voltage/current DC24V / 2A (r/load), AC220V / 2A (COS Ψ = 1)/1 point , 5A / 1COM Min. load Voltage/current DC5V / 1mA Max. load voltage/current AC250V, DC110V Current leakage when off 0.1mA (AC220V, 60Hz) Max.
Chapter 6 Input and Output Specification 3) Output wiring (1) Main unit U L L L L L DC5V DC24V 6-8 L L L L L L L L AC110/220V L L L L L L DC24V L L L L DC24V L
Chapter 6 Input and Output Specification 6.3.2 Main unit (TR Output : DRT/DT type only) 1) Specification Model Specifications Main Unit K7M-DRT/DT20U K7M-DRT/DT30U 4 points / 8 point Insulation method Photo coupler insulation Rated load voltage DC12/24V Operation load Voltage DC10.2 ~ 26.4V Max. load current 0.5A/1 point (DRT Type P40~P43: 0.1A/1point, DT Type P40~P41 0.1A/1point) Current leakage when off Less than 0.1mA Voltage drop when on Less than DC0.
Chapter 6 Input and Output Specification 2) Output wiring AC100-240V FG P40 P41 P42 COM0 COM1 COM2 L L P P43 COM3 L L DC12V/24V 6-10
Chapter 6 Input and Output Specification 6.3.3 Expansion Module 1) Specifications Expansion Module Model Specifications G7E-DR10A G7E-DR08A G7E-RY08A G7E-DR20A Output point 4 points 8 points Insulation method Relay insulation Rated load Voltage/current DC24V / 2A (Resistive load), AC220V / 2A (COS Ψ = 1) / 1 point 5A / 1COM Min. load Voltage/current DC5V / 1mA Max. load voltage/current AC250V, DC110V Current leakage when off 0.1mA (AC220V, 60Hz) Max.
Chapter 6 Input and Output Specification Expansion Module Model Specifications G7E-TR10A Output point 10 points Insulation method Photo coupler insulation Rated load Voltage/current DC12V/24V Operating load voltage range DC10.2 ~ 26.4V Max. load current 0.5A/1 point, 4A/1COM Current leakage when off 0.1mA or lower Max. inrush current 4A/10ms or lower Max. Voltage drop when on DC 1.
Chapter 7 Usage of Various Functions Chapter 7. Usage of Various Functions 7.1 Built-in Functions 7.1.1 High-speed counter function This chapter describes the specification, handling, and programming of built-in high speed counter of MASTER-K120S.
Chapter 7 Usage of Various Functions 3) Names of wiring terminals Input pulse Preset input ① ② ③④ ⑤ ⑥ ⑦ ⑧ ⑨ BUILT_IN CNET OFF ON ROM MODE P00 P02 P04 P06 P08 P01 P03 P05 P07 No. Terminal P10 COM0 P23 COM1 P0F P11 P22 24G 24V Names Usage No.
Chapter 7 Usage of Various Functions 4) External interface circuit I/O Termi nal No. Internal circuit 3.3 kΩ Input 1Phase 2Phase Ch0 Input pulse Ch1 Input pulse Ch0 A Phase Input Ch0 B Phase Input P02 Ch2 Input pulse Ch2 A Phase Input P03 Ch3 Input pulse Ch2 B Phase Input P00 P01 3.3 kΩ 3.3 kΩ 3.3 kΩ COM 0 3.3 kΩ Input Ch0 Preset input P06 Ch2 Preset input Ch2 Preset input P07 Ch3 Preset input - P05 3.3 kΩ 3.3 kΩ COM 0 Operati on Input warranted voltage On 20.4~28.
Chapter 7 Usage of Various Functions 6) Wiring example (1) Voltage output pulse generator 24V Pulse Generator Pulse Generator CHSC A B COM 24VG (2) Open collector output pulse generator 24V CHSC COM PulsePulse Generator Generator A B 24VG 7-4
Chapter 7 Usage of Various Functions 7) Instruction(HSCST) HSCAST High speed counter Available device Instruction M P K L F T C No.
Chapter 7 Usage of Various Functions 8) Parameter Setting (1) Format setting (a) Linear counter • If HSC is designate as Linear counter, it can counts from -2,147,483,648 to 2,147,483,647. • The carry flag F18*(* is channel number) turns on when the current value of high speed counter is overflow during up counting and HSC stop counting. • The borrow flag F19*(* is channel number) turns on when the current value of high speed counter is underflow during down counting and HSC stop counting.
Chapter 7 Usage of Various Functions (2) Mode setting (a) 1-phase operation mode - Current value increases by 1 at the rising edge of input pulse. A-phase input pulse Current value 1 2 3 4 5 (b) 1-phase pulse + direction mode - Current value increases by 1 at the rising edge of A-Phase pulse when B-phase is ‘low’ state. - Current value decreases by 1 at the rising edge of A-Phase pulse when A-phase is ‘High’ state.
Chapter 7 Usage of Various Functions (d) 2-phase multiplication mode (MUL4) - Up or Down is set automatically by the phase difference between A and B phase. • Up counter - At the rising edge of A-Phase pulse when B-phase is ‘low’. - At the falling edge of A-Phase pulse when B-phase is ‘high’. - At the rising edge of B-Phase pulse when A-phase is ‘high’. - At the falling edge of B-Phase pulse when A-phase is ‘low’. • Up counter - At the rising edge of A-Phase pulse when B-phase is ‘high’.
Chapter 7 Usage of Various Functions (4) Latch Counter setting If this function is enabled, Current value of high speed counter is always retained. Current value - When power supply is off. - When is ‘Stop’ or ‘Pause’ - When input condition of ‘HSCST’ is off 0 Time Latches CV Latches CV (5) Comparison Output setting (a) Comparison set - When current value of HSC is equal to SV1, corresponding output point turns on. - P40 ~ P47 are available for comparison output point.
Chapter 7 Usage of Various Functions (b) Zone Comparison Set - When current value of HSC isn’t less than SV1 and more than SV2. corresponding output point turns on. - P40 ~ P47 are available for comparison output point. - If SV2 is less than SV1, SV2 setting error(h’12) occurs and zone comparison set is disabled. Input pulse Output point Current value 999 1000 2000 (c) Comparison Task - If Comparison Task is selected in parameter window, corresponding interrupts is enabled.
Chapter 7 Usage of Various Functions (6) RPM setting - Can calculates RPM of input pulse - RPM is stored in designated device.
Chapter 7 Usage of Various Functions 9) Programming example (1) Parameter setting • Channel : Ch0 • Counter format : Ring counter ( 0 ~ 100,000) • Counter mode : 2-phase multiplication mode - P0 : A-phase pulse input, P1 : B-phase pulse input • Preset - Preset type : internal preset (M100) - Preset value : 0 • Last counter setting - None • Comparison output - Output mode : Zone comparison set - SV1 : 10,000 SV2 : 20,000 - Output point : P43 • RPM setting - Refresh cycle : 100(*10ms) - Pulses per rotate :
Chapter 7 Usage of Various Functions (2) Programming • When M0 turns on, HSC starts its operation • If current value is not less than 50,000, F170 turns on. • Current value is saved in D0(double word). Remark The contact point which is designated as HSC input can’t be used for pulse catch or external interrupt. Duplicated designation may cause faults.
Chapter 7 Usage of Various Functions 7.1.2. Pulse Catch Function In the main unit, 4(economic type) or 8(standard type) points of pulse catch input contact points are internalized. Through using this contact point, short pulse signal short can be taken which can not be executed by general digital input. 1) Usage When narrow width of pulse signal is input, a trouble occurs which can not be detected by general digital input, so the operation does not perform as user's intention.
Chapter 7 Usage of Various Functions Remark 1) Pulse catch input contact points operate as general digital input if they are not designated as pulse catch input. 2) Do not designate HSC input points as pulse catch input.
Chapter 7 Usage of Various Functions 7.1.3 Input Filter Function External input of MASTER-K120S selects input on/off delay time from the range of 0-1000ms of KGLWIN. Credibility secured system may be established by adjustment of input correction no. through using environment. 1) Usage Input signal status affects to the credibility of system in where noise occurs frequently or pulse width of input signal affects as a crucial factor.
Chapter 7 Usage of Various Functions 7.1.4 External Interrupt Function MASTER-K120S Series can perform max 4(economic) or 8(standard) points of external contact interrupt by using input of main unit without special interrupt module. 1) Usage This function is useful to execute a high speed execution regardless of scan time. 2) Minimum processing time.
Chapter 7 Usage of Various Functions 5) Usage (1) Click twice the parameter on the project window of KGLWIN. (2) Designate contact point, no. of priority and movement condition of the task program which is moved by interrupt inputting. Time driven Interrupt execution periodic set interrupt input contact No. interrupt input executing condition ◎ Rising ◎ Falling ◎ Rising/Falling (3) For the details , refer to KGLWIN manual.
Chapter 7 Usage of Various Functions 7.1.5 PID control function(Standard type only) 1) Introduction This chapter will provide information about the built-in PID (Proportional Integral Derivative) function of MASTER-K120S main unit. The MASTER-K120S series does not have separated PID module like MASTER-K300S and MASTERK1000S series, and the PID function is integrated into the main unit. The PID control means a control action in order to keep the object at a set value (SV).
Chapter 7 Usage of Various Functions 2) Specification (1) Control operation (a) Proportional operation (P operation) ① P action means a control action that obtain a manipulate value which is proportional to the deviation (E : the difference between SV and PV) ② The deviation (E) is obtained by difference between SV and PV and the formula of deviation is as following; MV = Kp × [SV − PV ] where, Kp : the proportional constant (gain), SV: set value, PV: present value ③ When E happens, MV by P operation is li
Chapter 7 Usage of Various Functions (b) Integral operation (I operation) ① With integral operation, the manipulate value (MV) is increased or decreased continuously in accordance time in order to eliminate the deviation between the SV and PV. When the deviation is very small, the proportional operation can not produce a proper manipulate value and an offset remains between PV and SV. The integral operation can eliminate the offset value even the deviation is very small.
Chapter 7 Usage of Various Functions Fig. 2.5 The system response when a long integration time given Fig. 7.4 The system response when a long integration time given Fig. 2.6 The system response when a short integration time given Fig. 7.
Chapter 7 Usage of Various Functions ⑤ The D action when a constant deviation occurred is shown as Fig. 7.6 Fig. 7.6 Derivative action with a constant deviation ⑥ The expression of D action is as following; MV = Kp × Td dE dt ⑦ Derivative action is used only in PID action in which P and I actions combine with D action.
Chapter 7 Usage of Various Functions (e) Integral windup All devices to be controlled, actuator, has limitation of operation. The motor has speed limit, the valve can not flow over the maximum value. When the control system has wide PV range, the PV can be over the maximum output value of actuator. At this time, the actuator keeps the maximum output regardless the change of PV while the PV is over the maximum output value of actuator. It can shorten the lifetime of actuator.
Chapter 7 Usage of Various Functions (2) Realization of PID control on the PLC In this chapter, it will described that how to get the digitized formula of the P, I, and D terms.
Chapter 7 Usage of Various Functions (4) parameter setting and explanation (a) PID8 instruction parameter setting and explanation. ① Scan time Scan time is the period of reading data (sampling), and also 10 times scaled up. The range of sampling time is 0.1 ~ 10 seconds, and actual input range is 0 ~ 100. Generally, Scan time of Digital PID control should be less than 1/10 of time constant of system response for better performance.
Chapter 7 Usage of Various Functions ⑥ Proportional gain The MASTER-K120S can handle only integer, not the floating point type. Therefore, to enhance the accuracy of PID operation, the PID8 instruction is designed to input the P_GAIN data as the 100 times scaled up. For example, if the designated P_GAIN is 98, actual input data of P_GAIN should be 9800. If the designated P_GAIN is 10.99, input 1099 to the P_GAIN. ⑦ Derivative time and integral time I_TIME and D_TIME are 10 times scaled up.
Chapter 7 Usage of Various Functions ⑩ SV Ramp If a large amount of SV changes during PID operation, The deviation(E) changes rapidly. Then manipulation value(MV) is changed rapidly also. This can cause damage on load or actuator. To prevent this situation, SV can be changed step by step by parameter setting. Setting range is 1~4000(Default value is 1). Setting value represents the number of time which taken from starting set value to last set value.
Chapter 7 Usage of Various Functions (b) PID8AT instruction parameter setting and explanation. ① Scan time S_TIME is the period of reading data (sampling), and 10 times scaled up for more precious operation. The range of sampling time is 0.1 ~ 10 seconds, and actual input range is 0 ~ 100. ② Control target(SV) SV (set value : the designated value) and PV (process value : present value) of MASTER-K120S PID operation have the range 0 ~ 4000.
Chapter 7 Usage of Various Functions ⓐ Relay response method. • PID parameters are obtained by On/Off operation during 1 cycle of PV variation. • PID parameters are obtained by amplitude and period of oscillation • The On/Off operation will be occur at the SV value. MV Period SV Amplitude ⓑ Process reaction curve method(PRC method). • PID parameters are obtained by step response of process.
Chapter 7 Usage of Various Functions 5) instruction (1) PID8 PID8 PID Control Available device Instruction M P K L F T C No. of S n ○ S1 ○ Error Error flag turns on when designating area is over (F110) and the instruction isn’t executed. n #D integer Steps Error (F110) 5 ○ Zero (F111) ○ Designation Flag set ■ PID8 D Flag n Registration No. at parameter(0~7) S1 Execution status registration area S1 a) Usage • when the condition of execution is on, PID operation executes.
Chapter 7 Usage of Various Functions (2) PID8AT PID8AT PID Auto Tuning Available device Instruction M P K L F T C No. of S D n ○ S1 ○ integer steps 5 ○ Zero (F111) Carry (F112) ○ Designation Flag set Error Error flag turns on when designating area is over (F110) and the instruction isn’t executed. ■ PID8AT #D Flag Error (F110) n n Registration No.
Chapter 7 Usage of Various Functions 6) Program Example (1) System configuration G7F- G7F-DA2I MASTER-K120S RD2A RS-232C (PV : temperature) KGL-WIN V3.
Chapter 7 Usage of Various Functions a) PID operation explanation (without A/T function) • Measure current temperature (-200~600°C) by RTD module then digital conversion value(0 ~ 4000) is stored to D4780 • PID8 instruction will calculate manipulate value (MV : 0 ~ 4000) based on PID parameter settings (P_GAIN, I_TIME, D_TIME, etc.) and PV from RTD module. Then, the calculated MV is output to the channel 0 of D/A module.
Chapter 7 Usage of Various Functions e) Program Explanation • When the input condition M0 turns on, PID operation executes at no.0 parameter. • PID execution status registrate D0000 and the output value of control result registrate D0001 • If SV Ramp is designated, current SV is registrate D0005 • D/A module converts the MV to analog signal and output to the actuator (power converter). • When the input condition M0 turns off, output 0 to the D/A conversion module.
Chapter 7 Usage of Various Functions c) operation parameters • Scan time : S_TIME=5 (sampling time = 0.5 seconds) • Auto / Manual operation setting : Auto • Output limit : Max.
Chapter 7 Usage of Various Functions f) Program Explanation • When the input condition M2 turns on, PID auto tuning operation executes at no.0 parameter. • When auto tuning finished, PID operation executes with calculated P,I,D parameter. • PID execution status registrate D0000 and the output value of control result registrate D0001 • If SV Ramp is designated, current SV is registrate D0005 • D/A module converts the MV to analog signal and output to the actuator (power converter).
Chapter 7 Usage of Various Functions 6) Error code list (1) PID8AT Description Error Code Corrective action H0100 Scan time setting range error Set scan time to available setting range H0200 PV setting range error Set PV setting to available setting range H0300 SV setting range error Set SV to available setting range SV If PRC identification method is selected, check current PV is less than SV.
Chapter 7 Usage of Various Functions 7. 2 Special module The special module and allocated data registers are as followings.
Chapter 7 Usage of Various Functions 7.2.1 A/D·D/A Combination module 1) Performance specification The performance specification of the analog mixture module are following. Item Voltage Input range Digital output Analog Input Analog output Common Current Specifications G7F-ADHA G7F-ADHB DC 0∼10V (input resistance more than 1 ㏁) DC 0∼20 ㎃ (input resistance 250Ω) DC 4∼20 ㎃ (input resistance 250Ω) Classified by parameter 12Bit( 0~4000) 1.Setting by jumper pin for V/I selection 1.
Chapter 7 Usage of Various Functions 2) Names of parts and functions Explain about names of parts and functions (1) G7F-ADHA No ① Contents. RUN LED Indicate the operating status the G7F-ADHA Analog input terminal Voltage Input ② ⑤ Current input CH0 (INPUT) V0 I0 COM0 CH0 (INPUT) V0 I0 COM0 When current input is used, short the V and I terminal. ④ Jumper pin of analog input Input Select Voltage Input Current Input CHO CH1 ③ ⑥ ⑦ Right is CH.1selecting left is CH.
Chapter 7 Usage of Various Functions (2) G7F-ADHB No ① Contents. RUN LED Indicate the operating status the G7F-ADHB Analog input terminal Voltage Input ④ V0 ② Current input C I0 COM0 CH0 (INPUT) V0 I0 COM0 ① When current input is used, short the V and I terminal.
Chapter 7 Usage of Various Functions 3) Parameter setting (1) Scaling function This function convert automatically range when the inout/output range is not matched. In case that input/output is current , this function is useful that external equapment’ range is not matched each other. (MASTER-K120S series converts range automatically as following : 0 ~ 20mA ⇔ 4 ~ 20mA) 4000 4000 800 0 0 0㎃ 20 ㎃ 20 ㎃ 4㎃ -1000 Resolution : 20 ㎃/3200 = 6.
Chapter 7 Usage of Various Functions 4) Wiring (1) Caution for wiring • Make sure that external input signal of the mixture module of AC and analog I/O is not affected by induction noise or occurs from the AC through using another cable. • Wire is adopted with consideration about peripheral temperature and electric current allowance. Thicker than Max. size of wire AWG22 (0.3 ㎟) is better. • If wire is put near to high temp.
Chapter 7 Usage of Various Functions 5) I/O converstion characteristics (1) Analog input characteristics a) Voltage input 2004 0 0V 2002 2001 2000 5.000V 2000 2003 5V 5.0025V Digital output value Digital output value 4000 10V Analog input voltage Input Voltage A/D conversion characteristics (voltage input) In voltage input, digital amount 0 is output by 0V input and 4,000 is output by 10V input. Therefore input 2.5mV equals to digital amount 1, but value less than 2.5mV can’t be converted.
Chapter 7 Usage of Various Functions (2) Analog output characteristics a) Voltage output Analog output voltage Analog output voltage 10V 5V 5.0025 2.5 ㎷ 5V 2000 2001 2002 200 200 200 0V 0V 0 2000 Digital input 4000 Digital input value D/A conversion characteristic (voltage output) Input of digital amount 0 outputs analog amount 0V, 4000 does 10V.Digital input 1 equals to 2.5mV of analog amount. Current output Analog output current 20 ㎃ Analog output current b) 10 ㎃ 0㎃ 0V 0 2000 5㎂ 10.
Chapter 7 Usage of Various Functions 6) Program example (1) Distinction program of A/D conversion value a) Program explanation - When digital value of channel 0 is less than 2000, P090 is on. - when digital value of channel 0 is more than 3000, P091 is on. - When digital value of channel 0 is more or same than 2000 or lesser than 3000, P092 is on.
Chapter 7 Usage of Various Functions (2) Program which controls speed of inverter by analog output voltage of 5 steps a) Program explanation -.When P80 becomes On, 2000 (5V) is output. -. When P81 becomes On, 2400 (6V) is output. -.When P82 becomes On, 2800 (7V) is output. -.When P83 becomes On, 3200 (8V) is output. -.When P84 becomes On, 3600 (9V) is output.
Chapter 7 Usage of Various Functions 7.2.2 A/D Conversion module 1) Performance specifications The performance specifications of the analog input module are following. Item Specifications Voltage Current Analog input Voltage/Current Selection Digital output resolution DC 4∼20 ㎃ ( input resistance 250Ω ) DC 0∼20 ㎃ ( input resistance 250Ω )) -.
Chapter 7 Usage of Various Functions 2) Names of parts and functions The Names of parts and functions of the analog input module are following. No ① Contents RUN LED Indicate the operating status the G7F-AD2A Analog input terminal ④ ① Voltage input Current input CH0 V0 COM0 I0 · CH0 V0 COM0 I0 · ② 24V 24G Input ▶ When current input is used, short the V and I terminal.
Chapter 7 Usage of Various Functions 3) Parameter setting (1) Scaling function The scaling function is the same that of A/D, D/A combination module. 4) Wiring (1) Caution for wiring • Make sure that external input signal of the mixture module of AC and analog I/O is not affected by induction noise or occurs from the AC through using another cable. • Wire is adopted with consideration about peripheral temperature and electric current allowance. Thicker than Max. size of wire AWG22 (0.3 ㎟) is better.
Chapter 7 Usage of Various Functions 5) Analog/Digital conversion characteristics (1) Analog input characteristics a) Voltage input Digital Output Value 2000 2004 2003 2002 2001 0 0V 5V 5.0025V 2000 5.000V Digital Output Value 4000 10V Voltage Input Analog Input Voltage A/D Conversion Characteristics (Voltage Input) In voltage input, digital amount 0 is output by 0V input and 4,000 is output by 10V input. Therefore input 2.5mV equals to digital amount 1, but value less than 2.
Chapter 7 Usage of Various Functions 6) Program example (1) Distinction program of A/D conversion value(Analog input range: DC4∼20 ㎃, 0~10VDC) (a) Program explanation • When digital value of channel 0 is the same or more than 2000 and the same or less than 3000, P090 is on. • When digital value of channel 1 is the same or more than 2000 and the same or less than 3000, P091 is on. • When digital value of channel 2 is the same or more than 2000 and the same or less than 3000, P092 is on.
Chapter 7 Usage of Various Functions (c) Program 7-54
Chapter 7 Usage of Various Functions 7.2.3 D/A Conversion module 1) Performance specifications The performance specifications of the analog output module are following. Specifications Item G7F-DA2I G7F-DA2V DC 0∼20 ㎃( Load resistance 510Ω) Output Range DC 4∼20 ㎃( Load resistance 510Ω) DC 0 ~ 10V(Lod resistance 2 ㏀∼1 ㏁) Classified by parameter Digital Output Number of output Max.
Chapter 7 Usage of Various Functions 2) Names of parts and functions The Names of parts and functions of the analog input module are following.
Chapter 7 Usage of Various Functions 3) Parameter setting 1) Specify the kind of special module 2) Set Output type of each channel 7-57
Chapter 7 Usage of Various Functions 5) Scaling function The scaling function is the same that of A/D, D/A combination module. 6) Wiring (1) Caution for wiring • Make sure that external input signal of the mixture module of AC and analog I/O is not affected by induction noise or occurs from the AC through using another cable. • Wire is adopted with consideration about peripheral temperature and electric current allowance. Thicker than Max. size of wire AWG22 (0.3 ㎟) is better.
Chapter 7 Usage of Various Functions 7) Digital/Analog conversion characteristics (1) G7F-DA2I a) 0~20mA output 20 ㎃ Output current Output current 10 ㎃ 5㎂ 10.005 ㎃ 10.000 2000 2001 2002 2003 2004 2005 0㎃ 0V 0 2000 Digital input 4000 Digital input D/A conversion characteristics(Current output) Digital amount 0 outputs analog amount 0mA, 4000 does 20mA.Digital input 1 equals to 5 ㎂ of analog amount. b) 4~20mA output 20mA Output voltage Output voltage 12mA 6.25 ㎂ 12.006 12.
Chapter 7 Usage of Various Functions 8) Program example (1) Program which controls speed of inverter by analog output voltage of 5 steps(0 ~ 20mA output) a) Program explanation • When P80 becomes On, 2000 (10mA) is output. • When P81 becomes On, 2400 (12mA) is output. • When P82 becomes On, 2800 (14mA) is output. • When P83 becomes On, 3200 (16mA) is output. • When P84 becomes On, 3600 (18mA) is output.
Chapter 7 Usage of Various Functions 7.2.4 Analog timer 1) Performance specification The performance specification of the analog timer module are following. Item Specification Number of channels 4 Output value range 8 Bit (Digital output range: 0 ∼ 200) Setting type Setting by variable resistance Accuracy of timer ±2.0% (Accuracy about max.
Chapter 7 Usage of Various Functions 3) Program example (1) Program explanation Program which controls on-delay time of output contact point within 0 to 20 sec. By analog timer module.
Chapter 7 Usage of Various Functions 7.2.5 RTD input module(Standard type only) 1) Performance specification The performance specification of the RTD input module are following. Item Connectable RTD Temperature input range Digital output Specification Pt 100 (JIS C1640-1989, DIN 43760-1980) JPt100 (KS C1603-1991, JIS C1604-1981) Pt 100 : -200 ~ 600℃ (18.48 to 313.59Ω) JPt100 : -200 ~ 600℃ (17.14 to 317.
Chapter 7 Usage of Various Functions 3) Parameter setting 4) Digital conversion value register Ch.
Chapter 7 Usage of Various Functions 6) Temperature conversion characteristics The RTD input module, as shown below, linearlizes the non-linear characteristic resistance input of the RTD 7) Digital conversion value The RTD input module, as shown below, outputs digital converted value of detected temperature value.(Range 0 ~ 4000) Digital conversion value 4000 Detected temp. value -2000 0 6000 Digital Conversion value = (Detected Temp.
Chapter 7 Usage of Various Functions 8) Burn-out detection function The RTD input module has the function of burn-out detection on the Pt100, JPt100 or cable. • As shown below, if disconnection occurs in the RTD or cable then a voltage outside the measurable range voltage is inputted by the internal burn-out detection circuit and burn-out detection error code is generated. • The RTD input module can detect disconnection for each channel. But, burn-out detection is possible only in the channels enabled.
Chapter 7 Usage of Various Functions 9) Wiring (1) Caution for wiring • Make sure that external input signal of the mixture module of AC and analog I/O is not affected by induction noise or occurs from the AC through using another cable. • Wire is adopted with consideration about peripheral temperature and electric current allowance. Thicker than Max. size of wire AWG22 (0.3 ㎟) is better. • If wire is put near to high temp.
Chapter 7 Usage of Various Functions 10) Program example (1) A program for output of detected temperature value as a BCD value a) Program explanation The present A/D conversion value of the detected temperature value which is detected from the temperature-measuring resistor Pt 100 is displayed on the BCD digital display by use of channel 0 of the temperature-measuring resistor input module.
Chapter 7 Usage of Various Functions 7.3 Positioning Function(DRT/DT type only) The DRT/DT type of MASTER-K120S series support 2 axes of positioning function. The purpose of positioning function is to transfer the moving objects by setting speed from the current position and stop them on the setting position correctly. And it also control the position of high precision by positioning pulse string signal as it is connected to various servo running devices or stepping motor control running devices.
Chapter 7 Usage of Various Functions 2) Output Specification(P40, P41) Signal Name Rated load voltage Load voltage range Max. load current DC 10.2∼26.4V 100 ㎃ DC 12/24V Positioning Forward direction Max. voltage drop during On ≤DC 0.3V Reverse direction CW/Pulse CCW/Directio n 3) Names of wiring terminal AC220V FG P40 COM0 P41 COM1 P42 P44 P COM2 Stepping motor COM3 P43 ⑤ ①⑤ ② ⑤ ③④ ⑥ Motor driver Direction pulse COM Pulse output No. Terminal No.
Chapter 7 Usage of Various Functions 4) Internal circuit and wiring example P - Power supply(DC 12/24V) P40 – pulse output(Ch0) R COM0 – Output common 0 P41 – pulse output(Ch1) R Internal COM1 – Output common 1 circuit P42 – Direction pulse(Ch0) R P43 – Direction pulse(Ch1) R COM2 – Output common 2 Motor driver For Ch0 (24V) P R P40 pulse output(Ch0) R COM0 Output common 0 P41 pulse output(Ch1) R R COM1 Internal Output common 1 circuit P42 Direction pulse(Ch0) P43 Direction pulse(Ch1)
Chapter 7 Usage of Various Functions 7.3.2 Positioning function 1) Positioning function Positioning Control includes position control, speed control. (1) Position control Positioning control from start address (present stopped position) to goal address (transfer amount) for the assigned axis A) Control by Absolute method (Absolute coordinate) ⓐ Positioning control from start address to goal address (the address assigned by positioning data).
Chapter 7 Usage of Various Functions (2) Speed Control (Uniform Speed Operation) • This controls the speed by the setting speed until deceleration stop command(POSCTR) is entered after execution by POSVEL command.. • The speed can be changed by the speed override instruction(POSSOR) • Speed control contains 2 types of start method : Forward direction start and Reverse direction start.
Chapter 7 Usage of Various Functions 2) Operation pattern • Operation pattern describes various configuration for how to operate the positioning data using several operation step no and how to determine the speed of position data.
Chapter 7 Usage of Various Functions 3) Operation Mode (1) End Operation A) With one time start command(rising edge of POSIST command), the positioning to the goal position is executed and the positioning shall be completed at the same time as the dwell time proceeds. B) This operation mode can be used as last positioning data of pattern operation. C) Operation direction shall be determined by position address.
Chapter 7 Usage of Various Functions (2) Keep Operation A) With one time Start command(POSIST), the positioning to the goal position of operation step is executed and the positioning shall be completed at the same time as dwell time proceeds and without additional start command, the positioning of operation step for (current operation step no. +1) shall be done. B) Keep operation mode is available to execute several operation step in order. C) Operation direction shall be determined by position address.
Chapter 7 Usage of Various Functions (3) Continuous Operation A) With one time Start command, the positioning for operation step set by continuous operation mode is executed to the goal position without stop and the positioning shall be completed at the same time as dwell time proceeds. B) If you want to operate with the position and speed of next step before the operation step that is active currently reaches the goal position, the operation by Next Move continuous operation command is available.
Chapter 7 Usage of Various Functions 4) Operation Method (1) Repeat Operation A) With one time start command, the positioning to the goal position is executed and the positioning shall be completed at the same time as the dwell time proceeds. B) The operation type of Repeat operation mode is same as that of Single operation but the different thing is to determine next operation by operation step no. assigned by repeat step no. change command after positioning completion of Repeat operation mode.
Chapter 7 Usage of Various Functions 5) Positioning start (1) Direct start(POSDST) • This is used to operate directly by setting the axis, goal position address, operation speed without parameter setting. • Refer to the ‘7.3.4 Instruction’ for details. (2) Indirect start(POSIST) • This is used to operate by setting the operation step no. by parameter. • Refer to the ‘7.3.4 Instruction’ for details.
Chapter 7 Usage of Various Functions 7) Return to Origin(POSORG : Rising edge ↑) • Return to Origin (homing) is carried out to confirm the origin of the machine when applying the power. • In case of Return to Origin, it is required to set Return to Origin parameter for each axis. • If the origin position is determined by origin return, the origin detection signal is not recognized during positioning operation.
Chapter 7 Usage of Various Functions (3) Origin Detection after Deceleration when Approximate origin turns on This is the method using the approximate origin and origin signal and the action by origin return command is as follows. (A) It accelerates to the setting origin return direction and acts by origin return high speed. (B) In this case, if approximate origin as external input is entered, it decelerates and acts by origin return low speed.
Chapter 7 Usage of Various Functions 8) JOG Operation (POSJOG : Level input) (1) JOG operation • Carries out the positioning control by Jog command(POSJOG). • Carries out the monitoring when the positioning acts by JOG command and the position address is changed. • This is used when acting without origin determination.
Chapter 7 Usage of Various Functions 10) External Input Stroke High/Low Limit • External input stroke limit includes External input high limit signal and External input low limit signal. • This is used to stop the positioning function promptly before reaching Stroke limit/Stroke End of the Driver by installing the stroke limit inside Stroke limit/Stroke end of the Driver. • If it deviates the high limit, Error H53 will occur and if it deviates the low limit, Error H54 will occur.
Chapter 7 Usage of Various Functions • Timing diagram 1) Unused the M Code Output Continues End Positioning Indirect start Completed Flag Current step M-th step N-th step 2) Use the M Code Continues End Positioning Indirect start Completed Flag Current step M-th step N-th step M1911 M1912 Reset in the program Reset in the program 12) Error and Output Prohibition • Error includes Light failure error and Heavy failure error.
Chapter 7 Usage of Various Functions 7.3.3 Positioning parameter and operation data 1) Positioning parameter • Positioning parameter setting • Parameter should be assigned for each axis Basic parameter (1) Basic parameter (A) Acceleration/Deceleration time • This is applied at the starting/ending point of positioning operation, return to origin high speed, and JOG high speed operation • The setting range is 0 ∼ 10,000 (unit: 1ms) for each axis. • When set to zero, operates constant speed.
Chapter 7 Usage of Various Functions (B) Backlash Compensation Amount • The tolerance that the machine does not work by the wear when the rotation direction changes in case that a gear, screw etc is combined to run at the motor axle, is called as ‘Backlash”. Therefore, when you change the rotation direction, it is required to add the backlash compensation amount to the positioning amount for output. • The setting range is 0 ∼ 1,000(unit: Pulse) at each axis.
Chapter 7 Usage of Various Functions (2) Origin return parameter (A) Origin return method • For the details, please refer to ‘7) Return to Origin’ in chapter 7.3.2 (B) DOG, origin signal Ch 0 Ch 1 DOG P0005 P0007 Origin P0004 P0006 (C) Origin return speed • The speed when returning to the origin by origin return command : high speed and low speed • When setting the origin return speed, it should be “speed limit ≥ origin return high speed ≥ origin return low speed ≥ bias speed”.
Chapter 7 Usage of Various Functions (3) JOG speed (A) JOG High Speed • JOG high speed operation has operation pattern as acceleration, constant speed, deceleration section. Therefore, acceleration section and deceleration section is controlled by JOG acceleration/deceleration time. • JOG high speed setting range : 5 ∼ 100,000(unit: 1pps) (notices when setting the high speed : Bias speed ≤ Jog high speed ≤ Speed limit) (B) JOG Low Speed • JOG low speed operation has only constant speed operation pattern.
Chapter 7 Usage of Various Functions (2) Coordinate • The coordinate of position data includes Absolute and Incremental (A) Absolute Coordinate (Control by Absolute method) ① This carries out the positioning control from the current position to the goal position (the goal position assigned by positioning data). ② Positioning control is carried out based on the assigned position of origin return or POSPRS command (origin address).
Chapter 7 Usage of Various Functions (6) Speed • Operation speed can be assigned for each operation step No. • Setting range of operation speed : 5 ~ 100,000( Setting unit: 1pps ) • The change of speed value is available when assigned by D area (7) Dwell Time • This is the waiting time before carrying out the next positioning operation after completing one positioning operation. • Setting range is 0 ∼ 10,000 (setting unit : 1 ㎳).
Chapter 7 Usage of Various Functions 7.3.4 Instructions 1) Positioning Indirect start(POSIST) POSIST Positioning Indirect Start Available device Instruction M P K L F T C No. of S D #D S integer steps Error (F110) 5 ○ ○ n ○ ○ ○ ○ ○ ○ ○ ○ ○ Flag Zero (F111) Carry (F112) ○ Designation Flag set Error Error flag turns on when designating area is over (F110) and the instruction isn’t executed S Channel which is designated at parameter(0~1) n Starting step No.
Chapter 7 Usage of Various Functions 2) JOG Operation(POSJOG) POSIST Positioning Indirect Start Available device Instruction M P K L F T C No. of S D #D S steps 7 ○ Zero (F111) Carry (F112) ○ n1 ○ ○ ○ ○ ○ ○ ○ n2 ○ ○ ○ ○ ○ ○ ○ Designation Flag set Error Error flag turns on when designating area is over (F110) and the instruction isn’t executed ■ POSJOG integer Flag Error (F110) S n1 S Ch.
Chapter 7 Usage of Various Functions 3) Positioning Control Instruction(POSCTR) POSCTR Positioning control instruction Available device Instruction M P K L F T C No. of S D #D S ○ ○ ○ ○ ○ ○ ○ ○ ○ S ○ 5 ○ Zero (F111) ○ Channel designation(0~1) Control instruction designation Error flag turns on when designating area is over n1 0: Deceleration stop. 1:Emergency stop.
Chapter 7 Usage of Various Functions 4) Current position preset (POSPRS) POSPRS Current position preset Available device Instruction M P K L F T C No.
Chapter 7 Usage of Various Functions 5) PWM output (PWM) PWM PWM(Pulse Width Modulation) output Available device Instruction M P K L F T No. of C S D #D S integer steps Error (F110) 7 ○ ○ SV1 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ SV2 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ Designation Flag set S Error Error flag turns on when designating area is over (F110) and the instruction isn’t executed ■ PWM Flag S SV1 Ch.
Chapter 7 Usage of Various Functions 6) Speed control operation (POSVEL) POSVEL Speed control operation Available device Instruction M P K L F T C No. of S D #D S steps Error (F110) 7/9 ○ Zero (F111) Carry (F112) ○ n1 ○ ○ ○ ○ ○ ○ ○ SV ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ Designation Flag set Error Error flag turns on when designating area is over (F110) and the instruction isn’t executed ■ POSVEL integer Flag S n1 S Ch.
Chapter 7 Usage of Various Functions 7) Speed override (POSSOR) POSSOR Speed override instruction Available device Instruction M P K L F T C No. of S D #D S SV (F110) ■ POSSOR steps Error (F110) 5/7 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ Zero (F111) ○ Designation Flag set Error integer Flag Error flag turns on when designating area is over and the instruction isn’t executed S S Ch.
Chapter 7 Usage of Various Functions 8) Positioning direct start(POSDST) POSDST Positioning direct start Available device Instruction M P K L F T C No.
Chapter 7 Usage of Various Functions 9) Return to origin(POSORG) POSORG Return to origin Available device Instruction M P K L F T C No. of S D #D S steps 7 ○ Zero (F111) ○ n1 ○ SV ○ 플래그 Set 영역설정 Error Error flag turns on when designating area is over (F110) and the instruction isn’t executed ■ POSORG integer Flag Error (F110) S n1 S Ch.
Chapter 7 Usage of Various Functions 7.3.
Chapter 7 Usage of Various Functions Device Function Description F0310 Position control Position control operation of Ch1 F0311 Speed control Speed control operation of Ch1 F0312 Return to origin Return to origin operation of Ch1 F0313 JOG low speed JOG low speed operation of Ch1 F0314 JOG high speed JOG high speed operation of Ch1 F0315 PWM operation PWM output operation of Ch1 F0320~ F032F Current Step No. Current step No.
Chapter 7 Usage of Various Functions 2) Error code Error code Condition Corrective action Operation H10 Acceleration time of basic parameter is out of range Stop Set Acceleration time within 0~10,000 range H11 Deceleration time of basic parameter is out of range Stop Set Deceleration time within 0~10,000 range H12 Speed limit of basic parameter is out of range Stop Set speed limit within 5~ 100,000 range.
Chapter 7 Usage of Various Functions Error code Condition H44 POSSOR command can’t be executed during decelerating Operating H45 POSORG command can’t be executed during operation Operating H46 POSORG command can’t be executed when output is prohibited Corrective action Operation Stop - Check if positioning is in the decelerating section when POSSOR signal occur. Check if positioning operation is executing when POSORG signal occur. Check if output is prohibited when POSORG signal occur.
Chapter 7 Usage of Various Functions 7.3.
Chapter 7 Usage of Various Functions 3) Wiring with servo motor driver(MR-J2/J2S-□A) HC-MF HA-FF Series motor NF MR-J2S- A MC TE11 L1 Power 3Phase 200VAC U U V V W L2 L3 L11 L21 CTE2 D W E PE EMG PE P K7M-DRT**U B1 B2 24VDC OPP of Servo ON signal Cutoff by alarm signal CN1A Max: 2m SM electronic brake detector CN2 Signal Pulse Common Direction Common Input +24V Ch0 Ch1 P40 P41 *3 COM0 COM1 P42 P43 PP 3 SG 10 NP 2 COM2 COM2 P P OPC 11 COM 9 14 *1 *3 Origin P04
Chapter 7 Usage of Various Functions 4) Wiring with Servo motor driver(FDA-5000 AC Servo Driver) K7M-DRT**U *4 Max 2m FDA-5000 Signal name Ch0 Ch1 Pulse P40 P41 Common COM0 COM1 Direction P42 Common COM2 COM2 Input +24V Origin *2 *3 1.5K,1/2W P43 P P P04 P06 24G P24V 1.
Chapter 8 Communication Functions Chapter 8. Communication Functions 8.1 Dedicated Protocol Communication 8.1.1 Introduction MASTER-K120S’s built-in Cnet communication uses only MASTER-K120S main unit for a dedicated communication. That is, it doesn’t need a separate Cnet I/F module to facilitate the user-intended communication system by utilizing reading or writing of any area in CPU, and monitoring function.
Chapter 8 Communication Functions 8.1.2 System configuration method According to the method of connection, the system using MASTER-K120S built-in communication can be composed. 1) Connecting system configuration (link between MASTER-K’s) (1) 1:1 connection with general PC a) Communication program made by C or BASIC computer language on the user’s computer, or utility program like FAM or CIMON can be used.
Chapter 8 Communication Functions (2) 1:1 connection with a monitoring device like PMU PMU(LGIS) MASTER-K120S main unit RS-485 interface RS-232C interface PMU 1 2 3 4 5 MASTER-K120S main unit Pin assignment and direction Pin No. Pin no.
Chapter 8 Communication Functions . (3) 1:1 connection with other MASTER-K120S MASTER-K120S main unit MASTER-K120S main unit RS-232C interface RS-485 interface MASTER-K120S main unit 5 9 4 8 3 7 2 6 1 Male Type Pin assignment and direction MASTER-K120S main unit Pin no. Pin no.
Chapter 8 Communication Functions 8.1.3 Frame Structure 1) Base Format (1) Request frame(external communication device → MASTER-K120S main unit), (Max. 256 Bytes) Header Station (ENQ) number Command Command type Structurized data area Tail Frame check (EOT) (BCC) (2) ACK Response frame (MASTER-K120S main unit → external communication device, when receiving data normally) (max.
Chapter 8 Communication Functions Remark 1) The numerical data of all frames are ASCII codes equal to hexadecimal value, if there’s no clear statement. The terms in hexadecimal are as follows. • Station No. • When the main command is R(r) or W (w) and the command type is numerical (means a data type) • All of the terms indicating size of all data in the Formatted data area. • Monitoring registration and command registration number of execution commands.
Chapter 8 Communication Functions 8.1.4 List of commands Classification Command Main command Items Reading device Writing device Treatment Command type Code ASCII code Code ASCII code Individual r(R) Continuous r(R) Individual w (W) Continuous w(W) CPU Status reading Classification Item r(R) H72 (H52) H72 (H52) H77 (H57) H77 (H57) H73 (H53) SS 5353 Reads data from device of Bit, Byte, Word type. SB 5342 Reads device Word in block unit.
Chapter 8 Communication Functions 8.1.5 Data type It’s possible to read and write device in built-in communication. When device is used, be aware of data type.
Chapter 8 Communication Functions 8.1.6 Execution of commands 1) Individual reading of device(R(r)SS) (1) Introduction This is a function that reads PLC device specified in accord with memory data type. Separate device memory can be read up to 16 at a time. (2) PC request format Station Format name Header Ex. of frame ENQ H20 ASCII value H05 H3230 No.
Chapter 8 Communication Functions (3) Response format (ACK response) Station Format name Header Ex. of frame ACK H20 ASCII value H06 H3230 No. Command Number of Number type blocks of data R(r) SS H01 H02 HA9F3 ETX H52(72) H5353 H3031 H3032 H41394633 H04 Command data Tail ...... Frame check BCC 1 block(max.
Chapter 8 Communication Functions (4) Response format (NAK response) Format name Header Station No. Command Command type Ex. of frame NAK H20 R(r) SS ASCII value H15 H3230 H52(72) H5353 Item Error code Tail Frame check H1132 ETX BCC H31313332 H03 (Hex 2 Byte) Explanation When command is lowercase(r), only one lower byte of the value resulted by adding 1 BCC Byte each to ASCII values from NAK to ETX is converted into ASCII and added to BCC.
Chapter 8 Communication Functions ③ For NAK response after execution of command(PC ← MASTER-K120S main Unit) Format name Header Station No. Command Command type Error code Tail Frame check Ex. of frame NAK H01 r SS Error code (2 bytes) ETX BCC ASCII value H15 H3031 H72 H5353 Error code (4 bytes) H03 2) Continuous reading(R(r)SB) of device (1) Introduction This is a function that reads the PLC device memory directly specified in accord with memory data type.
Chapter 8 Communication Functions (3) MASTER-K120S Main unit response format (MASTER-K120S of ACK response) Command Number of Number of type blocks data R(r) SB H01 H52(72) H5342 H3031 Format name Header Station No. Command Ex.
Chapter 8 Communication Functions (4) Response format (NAK response) Format name Header Station No. Command Command type Ex. of frame NAK H10 r SB ASCII value H15 H3130 H72 H5342 Item Error code Tail Frame check H1132 ETX BCC H31313332 H03 (Hex 2 Byte) Explanation When command is lowercase(r), only one lower byte of the value resulted by adding 1 Byte BCC each to ASCII values from NAK to ETX is converted into ASCII and added to BCC, and sent.
Chapter 8 Communication Functions 3) Individual writing of device(W(w)SS) (1) Introduction This is a function that writes the PLC device memory directly specified in accord with memory data type. (2) PC request format Command Number of Device type blocks Length W(w) SS H01 H06 H57(77) H5353 H3031 H3036 Format name Header Station No. Command Frame (Example) ENQ H20 H05 H3230 ASCII value Device Name Data %MW100 H00E2 H254D5731 H30304 3030 532 .....
Chapter 8 Communication Functions (3) Response format (ACK response) Format name Header Station No. Command Command type Tail Frame check Frame (Example) ACK H20 W(w) SS ETX BCC ASCII value H06 H3230 H57(77) H5353 H03 Item BCC Explanation When command is lowercase(r), only one lower byte of the value resulted by adding 1 Byte each to ASCII values from ACK to ETX is converted into ASCII and added to BCC, and sent.
Chapter 8 Communication Functions (5) Example This example supposes that "HFF" is written in M230 of station No. 1 and BCC value is checked. ① Computer request format (PC → MASTER-K120S main unit) Command Number of type blocks w SS H01 H06 H77 H5353 H3031 H3036 Format name Header Station No.
Chapter 8 Communication Functions 4) Continuous writing of device(W(w)SB) (1) Introduction This is a function that directly specifies PLC device memory and continuously writes data from specified address as much as specified length. (2) Request format Format Station Comman Comma Device No. d nd type Length ENQ H10 W(w) SB H06 H05 H3130 H57(77) H5342 H3036 Header name Frame (Example) ASCII value Device Number of data Data Tail H11112222 EOT (Max.
Chapter 8 Communication Functions (3) Response Format (ACK response) Format name Header Station No. Command Command type Tail Frame check Frame (Example) ACK H10 W(w) SB ETX BCC ASCII value H06 H3130 H57(77) H5342 H03 Item Explanation When command is lowercase(r), only one lower byte of the value resulted by adding 1 Byte BCC each to ASCII values from ACK to ETX is converted into ASCII and added to BCC, and sent.
Chapter 8 Communication Functions (5) Example This example supposes that 2 byte H’AA15 is written in D000 of station No. 1 and BCC value is checked. ① Computer request Format (PC → MASTER-K120S main unit) Format name Header Frame (Example) ENQ ASCII value H05 Station No.
Chapter 8 Communication Functions 5) Monitor register(X##) (1) Introduction Monitor register can separately register up to 10 in combination with actual variable reading command, and carries out the registered one through monitor command after registration. (2) PC request Format Frame Format name Header Station No. Command Registration No.
Chapter 8 Communication Functions (3) Response Format (ACK response) Format name Header Station No. Command Registration No. Tail Frame check Frame (Example) ACK H10 X(x) H09 ETX BCC ASCII value H06 H3130 H58(78) H3039 H03 Item Explanation When command is lowercase(r), only one lower byte of the value resulted by adding 1 Byte BCC each to ASCII values from ACK to ETX is converted into ASCII and added to BCC, and sent.
Chapter 8 Communication Functions (5) Example This example supposes that device M000 of station NO. 1 is monitor registered. ① Computer request Format (PC → MASTER-K120S main unit) Format name Header Station No. Command Registration Format Registration No.
Chapter 8 Communication Functions 6) Monitor execution(Y##) (1) Introduction This is a function that carries out the reading of the variable registered by monitor register. This also specifies a registered number and carries out reading of the variable registered by the number. (2) PC request Format Format name Header Station No. Command Registration No. Tail Frame check Frame (Example) ENQ H10 Y(y) H09 EOT BCC ASCII value H05 H3130 H59(79) H3039 H03 Item Register No.
Chapter 8 Communication Functions (4) Response Format (NAK response) Registration Error code No. (Hex 2Byte) Y(y) H09 H59(79) H3039 Format name Header Station No. Command Frame (Example) NAK H10 ASCII value H15 H3130 Item Tail Frame check H1132 ETX BCC H31313332 H03 Explanation When command is lowercase(y), only one lower byte of the value resulted by adding 1 Byte BCC each to ASCII values from NAK to ETX is converted into ASCII and added to BCC, and sent.
Chapter 8 Communication Functions 7) Reading PLC Status(RST) (1) Introduction This is a function that reads flag list including operating status of PLC and error information. (2) PC request Format Format name Frame (Example) Header ENQ Station No.
Chapter 8 Communication Functions (4) Response Format ( NAK response) Format name Header Station No. Command Command type Frame (Example) NAK H0A R(r) ST ASCII value 15 3041 5272 5354 Error code Tail Frame check H1132 ETX BCC 31313332 03 (Hex 2 Byte) * When command is one of lower case(r), only one lower byte of the value resulted by adding 1 Byte each to ASCII values from NAK to ETX is converted into ASCII and added to BCC, and sent.
Chapter 8 Communication Functions 8.1.7 1:1, 1:n Built-in communication between MASTER-K120S's 1) Introduction 1:1 built-in communication between MASTER-K120S's is that which constitutes a built-in communication system with the method of 1(master) : 1(slave). Setting Base parameter and communication parameter in KGLWIN can easily constitute this system. Communication protocol currently applied is the same with Cnet I/F used for MASTER-K. Main functions are following.
Chapter 8 Communication Functions 2) Parameter setting (1) Communication Parameter Setting • Open a new project file from KGLWIN - MASTER-K120S must be selected as PLC type. • After selecting communication parameter from KGLWIN and clicking twice, this window comes up. (a) When uses Ch.0 : Built-in RS-232C or External Cnet I/F module (b) When uses Ch.
Chapter 8 Communication Functions • Set according to the following table Item Contents Station No. Sets one of station from 0 to 31. Baud rate Sets one of 1200, 2400, 4800, 9600, 19200, 38400, 57600 bps Data bit Sets one of 7 or 8 Bits Parity bit Sets one of none, Even, Odd Stop bit Sets one of 1 or 2 Bit(s) • RS232C null modem or RS422/485: can be selected as a communication channel when communication is processed by built-in functions of MASTER-K120S Main unit or Cnet I/F module (G7L-CUEC).
Chapter 8 Communication Functions • Click the ‘List’ button to open the registration list window. • Total 64 data blocks can be assigned. But it's not possible to set a register number. • Sending and receiving data size can be set up to 60 Words. • Set device area - Sending: reading device area P,M,L,K,T,C,D,S saving device area : P,M,L,K,T,C,D,S - Receiving : reading device area P,M,L,K,T,C,D,S saving device area : P,M,L,K,T,C,D,S • Designate station no., size, mode, area in following windows.
Chapter 8 Communication Functions 3) Flag related with operating status (1) Sending/receiving error count for each station (total 32 stations) Error code is saved following area according to station Station 0,1 2,3 4,5 6,7 8,9 10,11 12,13 14,15 Device D4400 D4401 D4401 D4403 D4404 D4405 D4406 D4407 Station 16,17 18,19 20,21 22,23 24,25 26,27 28,29 30,31 Device D4408 D4409 D4410 D4411 D4412 D4413 D4414 D4415 Remarks Each device contains the Information of 2 station The information of each station is sa
Chapter 8 Communication Functions • Error bit b7 b6 b5 b4 b3 b2 b1 Error status of slave PLC 1 : Error 0 : Normal Reserved Operation mode of slave PLC b4 : STOP b5 : RUN b6 : PAUSE b7 : DEBUG b0 (4) Status flag of the master PLC Status Information of master PLC is saved in D4448 b15 b3 b2 b1 b0 D4448 ----------b1 : be set in case station is duplicated b2 : be set in case device area over (5) Max/min/current sending/receiving cycle of set parameter Contents: the interval between after sendi
Chapter 8 Communication Functions 4) Example MASTER-K120S main unit (Slave : Station No. 31) MASTER-K120S main unit (Master : Station No. 0) G7E-DR10A 1:1 built-in communication between MASTER-K120S • Device M000 is increased by program per 1 second. • Writing M000 to output area P004 of slave • Reading slave’s output area P004 • Writing it to master’s output area P009 The following example uses the above diagram to explain the operation of MASTER-K120S main unit.
Chapter 8 Communication Functions ④ Set parameters as the following table. Protocol Communication Method Communication and mode Station no.
Chapter 8 Communication Functions ⑧ The registration list ‘0’ registered in the registration list can be confirmed through a window like the following. ⑨ Double click the No. 1 for receive parameter setting and Set parameters like the following table and click ‘OK’ button. Station No.
Chapter 8 Communication Functions (2) Program (2) Parameter setting for slave station. ① Set parameters as the following table. Protocol Communication Method Communication Enable and mode Station no. Baud rate Data bit Parity bit Stop bit 31 19200 8 None 1 Communication channel RS232C null modem or RS422/485 ② Slave station does not need program. ③ Baud rate, parity bit, data bit, stop bit setting must be same with master station.
Chapter 8 Communication Functions 8.1.8 Error code Error code H0001 H0011 H0021 Error type PLC system error Data error Command error Error condition and causes Interface with PLC is impossible. Errors occurred when exchanging ASCII data to numbers. Treatment Off/On the power Check if other letters than capitals/small letters, numbers, and (‘%’,’_’,’.’) in device and data, correct and execute again.
Chapter 8 Communication Functions 8.2 User Defined Protocol Communication 8.2.1 Introduction User Defined Protocol Communication allows users who do communication between MASTER-K120S main unit and other kind of device to define the other company’s protocol at MASTER-K PLC. There’re a number of kinds of protocols made by many companies, that it’s difficult to have all protocols in it.
Chapter 8 Communication Functions 2) Setting frame (1) Click “List” button to activate the following window. (2) Select one of 1∼15 in frame list to open the following window. ① Frame specification • Header - Used in [Header] type. - Possible characters, as headers are 1 alphabet letter, 1 numeric number, or control characters as below.
Chapter 8 Communication Functions Example 1) [NUL] , [ENQ] , [1] , [A] : Possible Example 2) NUL, ENQ , [12] , [ABC] : impossible - It is allowed to be only 3 consecutive characters. Example 3) [ENQ][STX][NUL] : Possible Example 4) [A][NUL][ENQ][STX] : impossible • Send / Receive - Not defined : It is the initial value that doesn’t declare a frame format. - Send : It is that declares send frame. - Receive : It is that declares receive frame.
Chapter 8 Communication Functions Item Contents It is a radio button to select the input type of commands. There’re 2 kinds as hex or ASCII value. Ex1) ASCII : 1 0 R S B 0 6 % M W 1 0 0 Ex2) Hex : 31 30 52 53 42 30 36 25 57 44 31 30 30 If ARRAY is set, it asks whether it would convert data to ASCII to send (at send frame), or convert to hexadecimal to receive(at receive frame). If ARRAY is set, the size of area is to be set by byte. The unit is a byte. • Tail - Used in [Tail] type.
Chapter 8 Communication Functions Check Rule • BCC setting: set BCC when it is needed. Item Contents Data Type ASCII adds 2 bytes BCC value in ASCII type to frame. Hex adds 1 byte BCC value in Hex type to frame. For the detailed setting BCC, refer to 8.1.6 “Execution of Commands”. Default It is that sum all the data from 2nd data to the data before the data marked as [BCC] and input the result to the [BCC] area SUM 1 BCC method uses sum like defaults, but the user can set the BCC area.
Chapter 8 Communication Functions • Frame size - ASCII communication : max. 128 bytes - Hex communication : max. 256 bytes • Link relay (L) - It’s a flag to indicate whether a user defined frame is received in the order set by the user. - If the received frame is matched with the declared frame in frame list number 3, L003 starts blinking (0 → 1 → 0). • When frame receiving is done, MASTER-K120S main unit check if there’s any match between the received frame and the declared frame in frame list.
Chapter 8 Communication Functions The kinds of Input segment The last transmitting frame The value of sum check BCC Type setting ASCII Type Hex Type ASCII Input 31 + 32 +33 +34 +04 = CE 05 31 32 33 34 04 43 41 05 31 32 33 34 04 CE Hex Input 12 + 34 +04 = 4A 05 12 34 04 34 41 05 12 34 04 4A (2) SUM 1 , XOR 1 or MUL 1 setting.
Chapter 8 Communication Functions ④ Complement setting : Complement calculation as below example> 1’s and 2’s Complements of D3 bit 7 1 1 0 1 0 0 1 bit 0 1 = h D3(sum check value) 0 1 0 1 1 0 bit 0 0 1’ complement = h 2C(the last sum check value) 0 1 0 1 1 0 bit 0 1 bit 7 0 bit 7 0 2’ complement = 1’ complement + 1 = h 2D(the last sum check l ) ⑤ Mask setting : Masking method is as below bit 7 1 1 0 1 0 0 1 bit 0 1 = h D3 (sum check value) 1 1 1 1 1 1 bit 0 1 =
Chapter 8 Communication Functions 8.2.3 Instruction 1) User defined communication instruction(SNDCOM) User defined communication instruction SNDCOM Available Device Instruction M P K L F T C S #D D integer Flag Error (F110) Zero (F111) Carry (F112) ○ Ch n1 ○ ○ ○ ○ D ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 7 ○ Designation Flag Set Error (F110) ■ SNDCOM No.
Chapter 8 Communication Functions 3) Error code Code Error type explanation 06 Slave Device Busy It’s sending or waiting to receive 09 Parameter Error Communication parameter setting error, Link enable setting error 10 Frame Type Error Frame does not setting or frame does not ‘sending’ 8.2.4 Example of Usage This example is supposed that there’s a communication between MASTER-K120S’s by the user-defined protocol.
Chapter 8 Communication Functions ③ Double click the number ‘0’ ④ Designate the header, segment, send/receive , tail as below and then click the BCC Setting 8-49
Chapter 8 Communication Functions ⑤ Designate BCC Setting as below and Click the OK button, then you can see the frame list window which is designated 8-50
Chapter 8 Communication Functions ⑥ Double click the number 1 frame ⑦ BCC Setting method is same frame 0. ⑧ After the frame setting and BCC setting completes, click the OK button. ⑨ You can see the frame list window which is designated as below.
Chapter 8 Communication Functions ⑧ Program • When the data is received at frame no. 1, link relay L001 turns on during 1 scan. At that moment, M000 increases and the value of M000 moves output relay P004. • The new value of M000 is sending again every 1 second period (F092 is 1second period flag) • The number of sending normally stores D000. • When error occurs, the number of sending error stored in D001. 2) Setting and program of slave station ① Make the new project file and setting new parameter.
Chapter 8 Communication Functions ③ Double click the frame list number ‘0’ ④ Click the BCC Setting after set the header , segment , tail as below.
Chapter 8 Communication Functions ⑤ Click the OK button after BCC setting as below. Then you can see the frame list which is designated.
Chapter 8 Communication Functions ⑥ Set the frame number ‘1’ as below and click the BCC Setting ⑦ BCC Setting method is same as master station.
Chapter 8 Communication Functions ⑧ After the frame setting and BCC setting completes, click the OK button. ⑨ You can see the frame list window which is designated as below ⑩ Program • When the data is received at frame no. 0, link relay L000 turns on during 1 scan. At that moment P004 increases and the value of P004 moves M000. • The new value of P004 is sending again every 1 second period (F092 is 1second period flag) • The number of sending normally is stored in D000.
Chapter 8 Communication Functions 8.3 Modbus Protocol Communication 8.3.1 Introduction MASTER-K120S built-in communication supports Modbus, the Modicon product’s communication protocol. It supports ASCII mode, using ASCII data and RTU mode using Hex data. Function code used in Modbus is supported by instruction and especially function code 01, 02, 03, 04, 05, 06, 15 and 16. Refer to "Modicon Modbus Protocol Reference Guide" 8.3.2 Basic Specification 1) ASCII mode (1) It communicates, using ASCII data.
Chapter 8 Communication Functions 3) Address area (1) Setting range is available from 1 to 247, but MASTER-K120S supports from 0 to 31. (2) Address 0 is used for broadcast address. Broadcast address is all slave device recognize and respond to like the selfaddress, which can't be supported by MASTER-K120S. 4) Function code area (1) MASTER-K120S supports only 01, 02, 03, 04, 05, 06, 15, and 16 among Modicon products' function codes.
Chapter 8 Communication Functions 7) Function code types and memory mapping Code Function code name Modicon PLC Data address Remark 01 Read Coil Status 0XXXX(bit-output) Read bits 02 Read Input Status 1XXXX(bit-input) Read bits 03 Read Holding Registers 4XXXX(word-output) Read words 04 Read Input Registers 3XXXX(word-input) Read words 05 Force Single Coil 0XXXX(bit-output) Write bit 06 Preset Single Register 4XXXX(word-output) Write word 15 Force Multiple Coils 0XXXX(bit-output
Chapter 8 Communication Functions 10) Map of wiring MASTERK120S main unit 5 4 3 2 Quantum (9PIN) Connecting no. and direction Pin no. Pin no. Signal 1 1 CD 2 2 RXD 3 3 TXD 4 4 DTR 5 5 SG 6 6 DSR 7 7 RTS 8 8 CTS 9 9 9 8 7 6 1 Male Type • Use RS-485 connector when using channel 2. 8.3.3 Parameters Setting 1) Setting communication parameter (1) Open a new project file at KGLWIN. • K120S should be selected in PLC types.
Chapter 8 Communication Functions (3) Set the contents as follows. Item Setting contents Set a number between 0 to 31 (Don’t assign no. 0 as broadcasting station lest it may be a cause Station No. for mistaken operation) Baud Rate Set one from 1200, 2400, 4800, 9600, 19200, 38400, or 57600 bps. Set 7 or 8. Data Bit ASCII mode: Set as 7 bits. RTU mode: Set as 8 bits. Parity Bit Set as one of None, Even, or Odd. Set 1 or 2 bit(s). Stop Bit When parity bit is set: Set as 1 bit.
Chapter 8 Communication Functions 8.3.4 Instruction and example 1) MODBUS communication instruction(MODCOM) MODCOM MODBUS communication Available device Instruction M P K L F T C S D #D integer Ch Flag Error (F110) Zero (F111) Carry (F112) ○ S1 ○ ○ ○ ○ S2 ○ ○ ○ S3 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 7 ○ Designation Flag Error (F110) No.
Chapter 8 Communication Functions • S3 format is as below. bit 15 bit 8 bit 1 Error bit Error code bit 0 NDR bit • NDR : when the communication ends normally, this bit turns on during 1 scan. • Error bit : when communication error occurs, this bit turns on during 1 scan. At that time error code stores bit 8 ~ bit 15. • Error code is as follow Code Error type Meaning 01 Illegal Function Error in inputting function code in instruction.
Chapter 8 Communication Functions 2) Example program 1 It’s supposed that MASTER-K120S main unit is the master and it reads Coil Status of the station no. 17, a Modicon product. The master reads status of the Coil 00020 ~ 00056 of the slave station no. 17.
Chapter 8 Communication Functions 3) Example program 2 It’s supposed that MASTER-K120S main unit is the master and it reads Coil Status of the station no. 17, a Modicon product. The master reads status of the input contact 10197 ~ 10218 of the slave station no. 17. The input contact of the slave station is supposed to be as follows and the data that are read is saved in M015.
Chapter 8 Communication Functions 4) Example program 3 The master writes data D1000 ~ D1003 to contact 40000 of the slave station no. 10. ① ② ③ ④ ① : It designates slave station and function code ( No. of station : h0A(10) , function code : h10 ) ② : Address setting Address ‘0’ of function code ‘16’ at MODBUS protocol means address ‘40000’ actually. ③ : Writing number setting ( Writing number is 4) ④ : This is MODBUS Communication instruction.
Chapter 8 Communication Functions 8.4 No Protocol Communication 8.4.1 Introduction No protocol communication is useful when communication between MASTER-K120S main unit and other kind of devices with user defined protocol is impossible. User defined protocol is very convenient when there are enough interval between frames or a kind of frame is less than 16. But, When the kind of frame is greater than 16 or frames are continued without interval, user defined protocol is not available.
Chapter 8 Communication Functions • Receiving format can be designated as below. Upper byte(hex) H00(Receiving by Length of frame) Lower byte(hex) H03 (Receives when length of frame data is 3) H01(Receiving by last byte) H03 (Receives when last frame data is 03(ETX)) - When designated as length of frame : Stores received data to devices when number of received byte is equal to designated lower byte value of receiving format.
Chapter 8 Communication Functions 8.4.3 Instructions 1) No protocol receive(DRCV) DRCV No protocol receive Available Device Instruction M P K L F T C S D #D Cw ○ ○ ○ ○ D ○ ○ ○ SS ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ Flag ■ DRCV Flag Error (F110) Zero (F111) Carry (F112) ○ Ch Error (F110) Integer No. of step ○ 9 ○ Designation Error flag turns on, when designating area is over.
Chapter 8 Communication Functions 1) No protocol send(DSND) DSND No protocol send Available Device Instruction M P K L F T C S D #D n ○ ○ ○ ○ S ○ ○ ○ SS ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ Error (F110) Zero (F111) Carry (F112) ○ 9 ○ Designation Flag ■ DSND Flag ○ Ch Error (F110) Integer No. of step Error flag turns on, when designating area is over.
Chapter 8 Communication Functions 8.4.4 Examples Assume that a electrical weighing machine sends data which has unfixed size continuously. MASTER-K120S can communicates with it using no protocol. MASTER-K120S Main unit Electrical weighing machine For no protocol communication, one of following ending condition is designated. One is size of received data and the other is whether it has some pre-defined data. In this example, assume that received data is as following. “ ENQ(1Byte) + Station No.
Chapter 8 Communication Functions 1) Communication Parameter Setting • Open a new project file from KGLWIN - K120S must be selected as PLC type. • After selecting communication parameter from KGLWIN and clicking twice, this window comes up. • Designate baud rate, data bit, parity bit, stop bit, and protocol.
Chapter 8 Communication Functions 8.5 Remote connection and communication I/F module 8.5.1 Remote connection MASTER-K120S series can connect to other PLC by built-in Cnet interface or communication I/F modules. 1) Remote connection by built-in Cnet I/F Remote connection by built-in Cnet I/F is available by dedicated communication protocol only. If KGLWIN and Master station is connected physically, it can connect to each slave station using remote connection function.
Chapter 8 Communication Functions • Open a new project file from KGLWIN • After selecting menu-project-option, click ‘connection option’ • Click ‘Remote 1’ in depth of connection -. Type : Select GLOFA Cnet. -. Base : Select ‘0’. -. Clot : set to 0 when uses channel 0, and ‘1’ when uses channel 1 -. Station No.
Chapter 8 Communication Functions • Dedicated modem and dial-up modem are both available and Set connection option of KGLWIN as below.
Chapter 8 Communication Functions 8.5.2 Communication I/F module MASTER-K120S series supports various kinds of communication I/F module.
Chapter 8 Communication Functions RDA RDA RDA RDA RDB RDB RDB RDB SDA SDA SDA SDA SDB SDB SDB SDB SG SG SG SG Master Slave Slave Slave Wiring Example : RS-485 I/F 3) Usage of G7L-FUEA/RUEA G7L-FUEA and G7L-RUEA are Field Bus Interface module of LGIS and they support High speed link communication service by parameter setting.
Chapter 8 Communication Functions • Clicking List button then this window comes up. • Designate self-station No. and set link items after double clicking entry list • For the details, refer to User’s manual of Fnet I/F module 4) Usage of G7L-PBEA/DBEA G7L-PBEA support profibus slave function only and G7L-DBEAsupports DeviceNet slave interface function only. • After selecting communication parameter from KGLWIN and select FIELDBUS slave as below • Clicking List button then this window comes up.
Chapter 9 Installation and Wiring Chapter 9. Installation and wiring 9.1 Installation 9.1.1 Installation Environment This unit has high reliability regardless of its installation environment, but be sure to check the following for system reliability. 1) Environment requirements Avoid installing this unit in locations which are subjected or exposed to: (1) Water leakage and dust. (2) Continuous shocks or vibrations. (3) Direct sunlight. (4) Dew condensation due to rapid temperature change.
Chapter 9 Installation and Wiring 4) Power consumption block diagram of PLC systems Main Unit I5V 5VDC line power Expansion module Input supply part AC power Supply CPU part I24V 24VDC line External 24VDC power Supply output part (transistor) input part Output Current. (IOUT)×Vdrop special module Input Current (IIN)×Vdrop Output Current (IOUT) Load Input Current (IOUT) Output part Input part (Transistor) Output Current.
Chapter 9 Installation and Wiring (6) Power consumption of the special module • WS = I5V X 5 + I24V X 24 (W) (7) The sum of the above values is the power consumption of the entire PLC system. • W = WPW + W5V + W24V + Wout + Win + Ws (W) (8) Check the temperature rise within the control panel with calculation of that total power consumption(W).
Chapter 9 Installation and Wiring (6) Wiring • Wiring I/O wires with high voltage cable or power supply line can cause malfunction or disorder. • Be sure that any wire does not pass across during input LED(I/O status will not be clearly identified). • If an inductive load has been connected to output part, connect parallel surge killer or diode to a load. Connect the cathode of diode to the ‘+’ part of the power supply.
Chapter 9 Installation and Wiring (4) Mount the wire duct as it is needed. If the clearances are less than those in Fig below, follow the instructions shown below • If the wire duct is mounted on the upper part of the PLC, make the wiring duct clearance 50 ㎜ or less for good ventilation. Also, allow the distance enough to press the hook in the upper part from the upper part of the PLC.
Chapter 9 Installation and Wiring 9.1.3 Connection of expansion module The following explains the Connection of expansion modules to the main unit. (1) Open the connector cover of the main unit. (2) Insert the connector of the expansion module to the connector of the base unit. ④ ② ③ ①: Main unit ②: Connector cover ① ③: expansion module ④: expansion cable (3) Close the connector cover of the main unit.
Chapter 9 Installation and Wiring 9.2 Wiring The followings explains the wiring instructions for use of the system. 9.2.1 Power Supply Wiring (1) When voltage fluctuations are larger than the specified value, connect a constant-voltage transformer. (2) Use a power supply which generates minimal noise across wire and across PLC and ground.
Chapter 9 Installation and Wiring (7) As a measure against very large surge(e.g. due to lightening),connect a surge absorber as shown below. PLC E1 E2 Surge absorber for lightening (8) Use a insulating transformer or noise filter for protection against noise. (9) Twist every input power supply wires as closely as possible. Do not allow the transformer or noise filter across the duct. Remark 1) Ground the surge absorber(E1) and the PLC(E2) separately from each other.
Chapter 9 Installation and Wiring 9.2.3 Grounding (1) This PLC has sufficient protection against noise, so it can be used without grounding except for special much noise. However, when grounding it should be done conforming to below items. (2) Ground the PLC as independently as possible. Class 3 grounding should be used (grounding resistance 80Ωor less). (3) When independent grounding is impossible, use the joint grounding method as shown in the figure below (B).
Chapter 10 Maintenance Chapter 10 Maintenance Be sure to perform daily and periodic maintenance and inspection in order to maintain the PLC in the best conditions. 10.1 Maintenance and Inspection The I/O module mainly consist of semiconductor devices and its service life is semi-permanent. However, periodic inspection is requested for ambient environment may cause damage to the devices. When inspecting one or two times per six months, check the following items.
Chapter 10 Maintenance 10.3 Periodic Inspection Check the following items once or twice every six months, and perform the needed corrective actions. Check Items Ambient Environment Ambient temperature Ambient Humidity Checking Methods Judgment -. Measure with thermometer and hygrometer -. measure corrosive gas Connecting conditions Looseness, Ingress 5 ~ 95%RH The module should be move the unit There should be no corrosive gases The module should be mounted securely.
Chapter 11 Troubleshooting Chapter 11 Troubleshooting The following explains contents, diagnosis and corrective actions for various errors that can occur during system operation. 11.1 Basic Procedures of Troubleshooting System reliability not only depends on reliable equipment but also on short downtimes in the event of faults. The short discovery and corrective action is needed for speedy operation of system. The following shows the basic instructions for troubleshooting.
Chapter 11 Troubleshooting 11.2.1 Troubleshooting flowchart used when the POWER LED turns OFF. The following flowchart explains corrective action procedure used when the power is supplied or the power led turns off during operation. Power LED is turned OFF Supply the power. Is the power supply operating? No Yes No No Is the voltage within the rated Is the fuse blown? No Does the power led turn on? Yes Yes Replace the fuse.
Chapter 11 Troubleshooting 11.2.2 Troubleshooting flowchart used when the ERR LED is flickering The following flowchart explains corrective action procedure use when the power is supplied starts or the ERR LED is flickering during operation. ERR LED goes flickering. Check the error code, with connected KGLWIN. Yes Warning error? See App-2 “System Warning Flag” and remove the cause of the error.
Chapter 11 Troubleshooting 11.2.3 Troubleshooting flowchart used when the RUN LED turns off. The following flowchart explains corrective action procedure to treat the lights-out of RUN LED when the power is supplied, operation starts or operation is in the process. RUN LED is off. Turn the power unit off and on. No Is RUN LED off? Yes Contact the nearest service center.
Chapter 11 Troubleshooting 11.2.4 Troubleshooting flowchart used when the I/O part doesn’t operate normally. The following flowchart explains corrective action procedure used when the I/O module doesn’t operate normally. When the I/O module doesn’t work normally. No Is the indicator LED of the P40 on? Yes Measure the voltage of power supply in P40 Correct wiring.
Chapter 11 Troubleshooting Continue No Are the indicator LED of the switch 1 and 2 on? Yes Check the status of the switch 1and 2 Check the status of the switch 1and 2 Is input wiring correct? Is input wiring correct? Is the terminal screw tighten securely? Yes No NO No Yes Yes Separate the external wiring witch then check the status by forced input Yes Is the condition of the terminal board connector appropriate? Is input wiring correct? No Correct wiring Correct the wiring No Retighte
Chapter 11 Troubleshooting 11.2.5 Troubleshooting flowchart used when a program cannot be written to the CPU part The following flowchart shows the corrective action procedure used when a program cannot be written to the PLC module. Program cannot be written to the PC CPU Is the mode-setting switch set the re mote STOP? No Switch to the remote STOP mode and execute the program write. Yes Is ERR.
Chapter 11 Troubleshooting 11.3 Troubleshooting Questionnaire When problems have been met during operation of the MASTER-K120S series, please write down this Questionnaires and contact the service center via telephone or facsimile. y For errors relating to special or communication modules, use the questionnaire included in the User’s manual of the unit. 1. Telephone & FAX No Tell) FAX) 2. Using equipment model: 3. Details of using equipment CPU model: .( ) OS version No.( ) KGLWIN version No.
Chapter 11 Troubleshooting 11.4 Troubleshooting Examples Possible troubles with various circuits and their corrective actions are explained. 11.4.1 Input circuit troubles and corrective actions The followings describe possible troubles with input circuits, as well as corrective actions.
Chapter 11 Troubleshooting 11.4.2 Output circuit troubles and corrective actions The following describes possible troubles with input circuits, as well as their corrective actions. Condition Cause Corrective Action When the output is yLoad is half-wave rectified inside (in some cases, it is true y Connect registers of tens to hundreds KΩ across the off, excessive of a solenoid) load in parallel. voltage is applied to yWhen the polarity of the power supply is as shown in ①, the load.
Chapter 11 Troubleshooting Output circuit troubles and corrective actions (continued). Condition Cause Corrective actions The load off y Over current at off state [The large solenoid current y Insert a small L/R magnetic contact and drive the load response time fluidic load (L/R is large) such as is directly driven with using the same contact. is long. the transistor output.
Chapter 11 Troubleshooting 11.5 Error code list Error Code 0001h Message Internal system error System Error Cause Fault of some area of operating ROM, or H/W defect Stop Contact the service center. 0002h OS ROM error Stop OS ROM Error Internal system ROM is defected Contact the service center. 0003h OS RAM error Stop OS RAM Error Internal system RAM is defected Contact the service center.
Chapter 11 Troubleshooting (continued) Error Code 0026h 0030h Error FMM 3 Parameter Error Operation Error CPU state Stop Stop Continue Message Cause FMM 3 PARA Error FMM 3 Parameter Error • A digit of other than 0 to 9 has met during BCD conversion. Operation Error • An operand value is outside the defined operand range. Corrective Actions Correct the parameter. Correct the content of the error step. WDT Over Error Scan time has overrun the watch dog time.
Appendix 1 System Definitions Appendix 1. System Definitions 1) Option (1) Connect Option You should set the communication port (COM1∼4) to communicate with PLC. • Select the Project-Option-Connection Option in menu. • Default Connection is RS-232C interface. • For the detail information about Connection Option, refer to KGLWIN Manual.
Appendix 1 System Definitions (2) Editor option • Monitor display type - Select the desired type in the monitor display type(4 types). • Source File Directory : - You can set directories for the files to be created in KGLWIN. - In Source Directory, KGLWIN saves source program files of program, parameter etc. • Auto save - This function is to set the time interval for Auto saving (Range : 0 ~60 min) - Automatically saved file is saved in the current directory.
Appendix 1 System Definitions (3) Page setup You can select print option when the project print out .
Appendix 1 System Definitions 2) Basic Parameters The basic parameters are necessary for operation of the PLC. Set the ‘Latch area’, ‘Timer boundary’’ , ‘Watchdog timer’, ‘PLC operation mode’, ‘Input setting’, ‘Pulse catch’ (1) Latch area setting Set the retain area on the inner device. (2) Timer boundary setting Set the 100ms/10ms/1ms timer boundary.
Appendix 2 Flag List Appendix 2. Flag List 1) Special relay (F) This flag is useful to edit user program. Relay Function Description F0000 RUN mode F0001 Program mode F0002 Pause mode Turns on when the CPU in the Pause mode F0003 Debug mode Turns on when the CPU in the Debug mode F0006 Remote mode Turns on when the CPU in the Remote mode F0007~F000B Unused F000C User memory installation Turns on when a user memory is installed.
Appendix 2 Flag List (Continued) Relay Function Description F0040 to F005F I/O error When the reserved I/O module (set by the parameter) differs from the real loaded I/O module or a I/O module has been mounted or dismounted, the corresponding bit turns on.
Appendix 2 Flag List (Continued) Relay Function Description F190 to F193 Borrow flag for HSC Turn on when borrow is occurred on the HSC current value F200 to F20F Unit ID F0210 to F021F HSC error code Stores error of HSC Ch0 F0220 to F022F HSC error code Stores error of HSC Ch1 F0230 to F023F HSC error code Stores error of HSC Ch2 F0240 to F024F HSC error code Stores error of HSC Ch3 F0250 to F027F Unused F0280 to F045F Positioning flags F0500 to F050F Maximum scan time Stores the
Appendix 2 Flag List 3) Data relay (D) When communication function is used, its status are stored in D register, and they can be monitored. And If correspond communication function is unused, these flags can be used as general data register. (1) When FNET module is connected Relay Keyword Function D4500 _C0STNOL Communications module D4502 _C0STNOH station No. D4504 _C0TXECNT D4505 D4506 _C0RXECNT _C0SVCFCNT D4507 _C0SCANMX D4508 _C0SCANAV D4509 _C0SCANMN D4510 _C0LINF D4510.
Appendix 2 Flag List (2) When communication mode is dedicated master mode (Channel 0) Relay Function Relay Function D4400 Communication Error Code of station 0 and1 D4432 Mode and Error of Slave station 0 and 1 D4401 Communication Error Code of station 2 and 3 D4433 Mode and Error of Slave station 2 and 3 D4401 Communication Error Code of station 4 and 5 D4434 Mode and Error of Slave station 4 and 5 D4403 Communication Error Code of station 6 and 7 D4435 Mode and Error of Slave station 6
Appendix 2 Flag List (3) When communication mode is dedicated master mode (Channel 1) Relay Function Relay Function D4300 Communication Error Code of station 0 and1 D4332 Mode and Error of Slave station 0 and 1 D4301 Communication Error Code of station 2 and 3 D4333 Mode and Error of Slave station 2 and 3 D4301 Communication Error Code of station 4 and 5 D4334 Mode and Error of Slave station 4 and 5 D4303 Communication Error Code of station 6 and 7 D4335 Mode and Error of Slave station 6
Appendix 2 Flag List (4) D register for Forced I/O setting I/O Forced I/O designation register Forced I/O data register P000 D4700 D4800 P001 D4701 D4801 P002 D4702 D4802 P003 D4703 D4803 P004 D4704 D4804 P005 D4705 D4805 P006 D4706 D4806 P007 D4707 D4807 P008 D4708 D4808 P009 D4709 D4809 P010 D4710 D4810 P011 D4711 D4811 P012 D4712 D4812 P013 D4713 D4813 P014 D4714 D4814 P015 D4715 D4815 P016 D4716 D4816 P017 D4717 D4817 P018 D4718 D4818 P019 D47
Appendix 2 Flag List (5) System error history(when RTC module is attached) Relay Description D4900 Error pointer D4901 Year, Month D4902 Day, Time D4903 Minute, Second D4904 Error code (6) Clock data Relay Description D4990 Year, Month D4991 Day, Time D4992 Minute, Second D4993 Day of week, Century App2-8
Appendix 3 External Dimensions Appendix 3 External Dimensions (unit: mm) 1) Main unit Model A B 85 95 135 145 K7M-DR(T)40U 165 175 K7M-DR(T)60U 215 225 K7M-DR10/14UE K7M-DR20/30UE 95 105 115 K7M-DR(T)20/30U A B 73 2) Extension module (1) Standard type 95 105 115 5 95 73 App3-1
Appendix 3 External Dimensions (2) Slim type(G7E-DC08A,G7E-RY08A,G7F-ADHB,G7F-DA2V,G7F-RD2A) App3-2