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K7 Manual

1. eee ee eee ee 11 7 11 3 Troubleshooting Questionnaire ete up 11 8 41 4 Troubleshooting Examples Wie toos DU E E 11 9 11 4 1 Input circuit troubles and corrective actions s 11 9 11 4 2 Output circuit troubles and corrective actions ntt 0088 11 10 115 Error code list A eee eee tee nee 11 12 Appendix Appendix 1 System definitions mem 1 1 Appendix 2 Flag list em mme en eene App2 1 Appendix 3 DIMENSIONS eese App3 1 Chapter 1 General Chapter 1 General 1 1 How to Use This Manual This manual includes specifications functions and handling instructions for the IMO K7 PLC This manual is divided up into chapters as follows Chapters Chapter 1 Describes configuration of this manual unit s features and terminology Chapter 2 System configuration Describes available units and system configurations in the IMO K7series Chapter 3 General Specification Describes general specifications of units used in the IMO K7series Chapter 4 Names and functions Describes each kind of manufacturing goods titles and main functions Chapter 5 CPU Part Digital Input and Chapter 6 Output Parts Describes each kind of manufactured goods usage Guides on Each Chapter 7 Function Communications Chapter 8 Describes built in communication functions Function Installation and Chapter 9 Describes installation wiring and handling inst
2. gt gt gt gt lt gt gt gt gt gt gt cccooooooococ le s E ma E ma E o E oa E aa A a E oan E an cocoooooooocococ It is possible to set 40 operational pattern When click the pattern no parameter setting window is displayed as bellow 6 parameter explanation operational pattern No operation pattern No is each pulse out pattern No Max 40 patterns can be set 2 Output pulse count It sets output pulse number The setting range 0 42944967295 3 Max speed It sets operational speed at normal section The setting range 50 2000pps 50multiflier only 4 Acceleration Deceleration mode Acceleration Deceleration mode is designation of increasing decreasing velocity operation Disable uniform velocity operation enable increasing decreasing velocity operation 5 Acceleration deceleration slop Acceleration slop is available in case that acceleration deceleration mode is enable This is slop that pulse frequency reach to maximum pulse frequency from 0 pulse only integer 6 Bit device set a Direction contact signal setting of contact for direction signal output Chapter 7 Usage of Various Functions b continuous operation setting of contact for infinitive operation C emergency stop setting of contact for emergency stop 7 The number of acceleration pulse Automatically calculate at KGL WIN if the maximum pulse and slop are set by u
3. 8 108 Chapter 8 Installation and Wiring 9 1 Installation e NUR dee 9 1 9 1 1 Installation Environment m eee erent ee tee tee tee 9 1 9 1 2 Handling Instructions mmm 9 4 9 1 3 Connection of expansion module 9 7 92 Wiring E rc A veda iis pe FS 9 8 9 2 1 Power supply Wiring mmm 9 8 9 2 2 VO devices Wiring mmm 9 10 9 23 Grounding mee 9 10 9 24 Cable Specifications for Wiring sm 9 11 Chapter 10 Maintenance 10 1 Maintenance and Inspection Mois eet iraste dedit tds vete sn cy eee ee eR AIR NN ep ERE 10 1 10 2 Daily Inspection QUE Nu REUS PN RE Pe 10 1 10 3 Periodic Inspection ys ula aloe iQ ped ees vae o de ete eh DERE SEDIT 10 2 Chapter 11 Trouble Shooting 11 1 Basic Procedures of Troubleshooting 444 112 Troubleshooting eeu oer etes hye ule de tud 11 1 11 2 1 Troubleshooting flowchart used when the power LED turns off ns 112 11 2 2 Troubleshooting flowchart used when the error LED is flickering 11 3 11 2 3 Troubleshooting flowchart used when the RUN LED turns offre 8 11 4 11 2 4 Troubleshooting flowchart used when the I O devices doesn t operate normally 11 5 11 2 5 Troubleshooting flowchart used when a program can t be written to the CPU ere
4. To process 1 1 built in communication between K7 s must be set Enabled Chapter8 Communication Function Set according to the following table Parity bit Sets one of none Even Odd Stop bit Sets one of 1 or 2 Bit s e RS232C null modem or RS422 485 can be selected as a communication channel when communication is processed by built in functions of MK80S Base Unit or Cnet I F module G7L CUEC RS232C dedicated modem can be selected when communication is processed by Cnet Communication module G7L CUEC channel RS232C dial up modem can be selected when common modem communication calling the opponent station is processed by Cnet I F module G7L CUEC Notes RS232C dedicated modem and RS232C dial up modem communication can be processed only by Cnet I F module G7L CUEC supporting RS 232C not Cnet module G7L CUEC supporting RS 422 485 e t san interval waiting after sending request frame from Master MK80S before receiving a response Timeout in Master e default value is 500ms Mode e Setting must be done in consideration of maximum interval of sending and receiving cycle of a master PLC e f the time out is less than the maximum interval of the s r cycle error can occur Dedicated MasterK7 can read from and write on Slave K7 Master Slave Read status of can be select especially when you read Slave K7 for monitoring but not for the other slave PLC purposes lest it may cause decreasing
5. Data Type ASCII Hex Check Rule C Default C SUM 1 C SUM 2 XOR1 XOR 2 C MUL1 C MUL 2 Range ex H 0 T 0 Complement ex FF amp FF Cancel Chapter 8 Communication Function Data Tvpe ASCII adds 2 bytes BCC value in ASCII type to frame Hex adds 1 byte BCC value in Hex type to yp frame For the detailed setting BCC refer to 8 1 6 Execution of Commands It is that sum all the data from 2 data to the data before the data marked as BCC and input the result Default to the BCC area SUM 1 BCC method uses sum like defaults but the user can set the BCC area SUM2 BCC method is the same with SUM 1 but it s used when the user masks any value to the last BCC value XOR 1 BCC method is OR Exclusive OR Check Rule XOR2 BCC method is the same with XOR 1 but it s used when theuser masks any value to the last BCC value MUL 1 BCC method is MULTIPLY thatis multiplication MUL2 BCC method is the same with MUL 1 but it s used when the user masks any value to the last BCC value H signifies header S is for segment and T is for tail Range Ex1 When header is set as ENQ STX tail is set as EOT ETX and the range of setting BCC is to be from STX to ETX then set as H 1 T 1 Itis to set whether not to take complement number or to take the complement number of 1 or 2 at Complement BCC value If mask setting is done after taking a complement nu
6. Yes Contact the nearest service center Complete Chapter 11 Troubleshooting 11 24 Troubleshooting flowchart used when the 1 0 part doesn t operate normally The following flowchart explains corrective action procedure used when the module doesn t operate normally When the I O module doesn t work normally Is the indicator LED of the P40 on Measure the voltage of power Cansei Replace the connector of the Check the status of P40 by supply in P40 9 terminal board KGLWIN N ls the m cs it condition No Is the output terminal connector S It norma condition voltage of power supply for load connector appropriate applied wiring correct Yes Yes Separate the external wiring than check the condition of Continue output module Yes 4 Is it normal condition Check the status of P40 Replace the Unit Chapter 11 Troubleshooting Are the indicator LED of the Switch 1 and 2 on Check the status of the switch 1and 2 Check the status of the switch 1and 2 ls the terminal screw tighten securely Is input wiring correct Is input wiring correct Yes s the condition of the terminal board connector appropriate Is input wiring correct Separate the external wiring witch then check the status by forced input Correct wiring Retighten the terminal Replace the terminal Correct the wiring scre
7. for tail 3 It allows Max 1 second interval between characters 4 It checks errors using LRC 5 Frame structure ASCII data se twm m m nme _ 2 RTU mode 1 It communicates using hex data 2 There s no header and tail It starts with address and finishes frame with CRC 3 It has at least 3 5 character times between two frames 4 It ignores the current frame when 1 5 character times elapse between characters 5 It checks errors using 16 bit CRC 6 Frame structure hex data 1 The size constituting 1 letter is 1 character So 1 character is 8 bits that is 1 byte 2 1 character time means the time lapsed for sending 1 character Ex Calculation of 1 character time at 1200 bps 1200 bps means that it takes 1 sec to send 1200 bits To send 1 bit 1 sec 1200 bits 0 83 ms Therefore 1 character time is 0 83ms 8 bits 6 64ms 3 584 984 A B X executes frame division using intervals of more than 1 sec without LRC in processing internally 8 68 Chapter 8 Communication Function 3 Address area 1 Setting range is available from 1to 247 but 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 self address which can t be supported by MK80S Function code area 1 K7 supports only 01 02 03 04 05 06 15 and 16 among Modicon products function codes 2 If
8. 8 36 Chapter8 Communication Function de b7 b6 b5 b4 b3 b2 b1 b0 SSES Error status of slave PLC Operation mode of slave PLC Not used 1 Error b4 STOP 0 Normal b5 RUN b6 PAUSE b7 DEBUG 4 Status flag of the master PLC Status Information of master PLC is saved in D4448 b15 b3 b2 b1 b0 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 sending and before receiving 04449 04450 04451 04452 04453 04454 8 37 Chapter8 Communication Function 4 Example 7 base unit 7 base unit Master G7E DR10A Slave Station No 0 _ Station No 31 1 1 built in communication between K7 s Device M000 is increased by program per 1 second Writing M000 to output area P004 of slave Reading slav s output area P004 to master s output area P009 The following example uses the above diagram to explain the operation of K7 Base Unit The data of the master K7 Base Unit is increased by INCP instruction and sent to be written on the output contact point PO4of the slave K7 Base Unit And in return the master K7 Base Unit reads the data that is written on the output contact point of the slaveK7 to write them on the output contact point of extended digital input output module G7E DR10A 8 38
9. 5 As RUN LED and ERR LED are on the contents of the memory module is transferred into the program area of the base unit and ROM operation area of the flash memory It may take about 15 sec 6 Operate according to the set operation mode T Turn off the power of the basic unit 6 7 8 Remove the memory module 9 the power on Through the above steps the user can operate the PLC with program stored in the external memory module REMARK 1 When the PLC is operated with the external memory module it always operates with restart 2 Remove after the program transfer is finished 5 30 Chapter5 CPU Module 5 10 Batte 1 Specifications Specifications Pr 2 Handling Instructions 1 Dori t heat or solder its terminals 2 Dori t measure its voltage with a tester or short circuit 3 Dori t disassemble 3 Battery Replacement Backup battery needs periodic exchange In case of battery replacement at power off the built in super capacitor backup the program and retain variables about 30 minutes However it is recommended to complete the battery replacement as soon as possible or turn on the base unit during battery replacement Battery replacement Open the cover of the CPU module Release the existing battery from the holder and disconnect the connector Insert a new battery into the holder the exact direction and connect the connector Check basic unit s
10. Chapter8 Communication Function 1 Setting communication parameter of the master station and its program D Work on the master station 0 2 Open a new project file and a new program for the master station GL WIN for Windows Program New Projectl BE E Monitor Edit program that M000 is increased per 1second Double click parameter item for parameter settings 8 39 Chapter8 Communication Function If you click the Comm button in parameter window in KGLWIN you can see the following window of the communication parameter Basic Interrupt Comm PIDCTUN PID CAL Pulse Out Enable z r Protocol and Mode l eS Timeout in Master po ms Station Number 0 z Dedicated Baud Rate i Data Bit zl Read Status of Slave PLC List Parity Bit None Stop Bit Communication Channel C Master Transmission Mode 3c R5232C Null Modem or RS422 485 C Slave C 85232 Modem Dedicated Line Init Command User Defined C RS232C Dial up Modem ATZ C Master Het Slave Set parameters as the following table Protocol Communication Method and mode Commu 377 Station Baud rate Data bit Parity bit Stop bit Communication channel nication Dedicated RS232C null modem or 19200 1 RS422 485 8 40 Chapter8 Communication Function
11. 2 2 Chapter 2 System Configuration 3 RS 232C Communication over a long distance via modem by Cnet I F modules G7L CUEB GIL CUES Modem Modem 2 1 n Communications system This method can connect between one computer and main units for up to 32 stations Can be connected Max 32 stations 232 RS 422 Converter G7L CUEC GIL CUEC Chapter2 System Configuration 2 2 Product functional model The following describes functional model of the IMO K7 series 2 2 1 Product Function Block Product function block for the K7series is as follows Base Unit Expansion Modules Input power Input signal Input signal DC24V Power suppl y communi cations Speci al modul es Built in RS 232C Output signal Output signal Sub system Description e Signal processing function Operating system function Application program storage memory function Data storage memory function Application program execution function e The input signals obtained from the machine process to appropriate signal levels for processing e The output signals obtained from the signal processing function to appropriate signal levels to drive actuators and or displays Communications Provides the data exchange with other systems such as KGLWIN computers Interface 24 Chapter2 System Configuration 2 2 2 K80S Series System Equipment Dm em
12. Click List button to activate registration list window Dedicated nj t 5560 C0 00 CT P C Po C3 Set parameters like the following table and click OK button Siatonno sie wb M000 See the above P004 See the above Chapter8 Communication Function The registration list 0 registered in the registration list can be confirmed through a window like the following Double click the No 1 for receive parameter setting Station No ETE Area to read From Area to save to P004 Se the above 9006 Se tne above 8 42 Chapter8 Communication Function Set parameters like the following table and click OK button Program Chapter8 Communication Function 2 Parameter setting for slave station Set parameters as the following table Protocol Communication Method and mode Commu Station no Baud rate Data bit Parity bit Stop bit Communication channel Dedicated nication RS232C null modem 31 19200 1 slave RS422 485 Slave station does not need program Chapter8 Communication Function 8 1 8 Error code H0001 PLC systemerror Interface with PLC is impossible On Off the power Errors occurred when exchanging ASCII H0011 Dataerror data to numbers Check if other letters than capitals small letters numbers and 96 in device and d
13. Data status of the Modicon product s Coil 00020 00059 The status of Coil 57 58 59 are redundancy Data is sent starting from the low bit by byte unit If the deficient bit of a byte is filled with 0 An example of sending the above data is as follows Example 1 CD B2 0E 1B Program jg Program Auto Saved Project e a Output Coil 0000 WobBUS 00000 24 LM It designates slave station and function code No of station h11 17 function code h01 2 Address setting Address 0 at MODBUS protocol means address 1 actually So if you want to designate address 20 write address 19 8 Reading number setting Reading number is 37 from 20 to 56 4 This is MODBUS Communication instruction Data is sent starting from the low bit by byte unit If the deficient bit of a byte is filled with 0 An example of sending the above data is as follows The data transmission starts lower byte The remnant part of byte is filled with 0 Example 1 CD B2 0E 1B Stored data at D1000D1001 D1002 Stored data D1000 h CD 6B 01001 h B2 CE D1002 h 00 1B 8 76 Chapter 8 Communication Function Example program 2 It s supposed that K7 base 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 t
14. m Basic Base Unit 1 0 Points 12 DC inputs 8 relay outputs Program capacity 48 kbytes Built in function High speed counter Phase1 16 kHz phase2 8 kHz channel Under K7M DR20S pulse output 1 2 kHz development pulse catch pulse width 0 2ms 4 points external contact point interrupt 0 4ms 8points input filter 0 15ms all input PID control function RS 232C communication 1 0 Points 18 DC inputs 12 relay outputs Program capacity 48 kbytes Built in function High speed counter Phase1 16 kHz phase2 8 kHz channel K7M DR30S pulse output 1 2 kHz pulse catch pulse width 0 2ms 4 points external contact point interrupt 0 4ms 8points input filter 0 15ms all input PID control function RS 232C communication 1 0 Points 24 DC inputs 16 relay outputs Program capacity 48 kbytes Built in function High speed counter Phase1 16 kHz phase2 8 kHz channel K7M DR40S pulse output 1 2 kHz pulse catch pulse width 0 2ms 4 points external contact point interrupt 0 4ms 8points input filter 0 15ms all input PID control function RS 232C communication 1 0 Points 36 DC inputs 24 relay outputs e Program capacity 48 kbytes Built in function High speed counter Phase1 16 kHz phase2 8 kHz channel K7M DR60S pulse output 1 2 kHz pulse catch pulse width 0 2ms 4 points external contact point interrupt 0 4ms 8point
15. use channel 1 input range setting DC 4 20 mA A D conversion data registration area 04980 Output data type 48 4047 d D A module setting output range setting DC 4 20 mA D A conversion data registration area D4982 7 4 Chapter 7 Usage of Various Functions 3 8 b Program Explanation Use only PID operation without A T function b c Convert the measured temperature 0 250 C to current signal 4 20mA and input the current signal to the channel 1 of A D module Then the A D module converts the analog signal to digital value 0 4000 PID8 instruction will calculate manipulate value MV 0 4000 based on PID parameter settings P_GAIN TIME D TIME etc and PV from A D module Then the calculated MV is output to the channel 0 of D A module D A module will convert the MV 0 4000 to analog signal 4 20mA and output to the actuator power converter Use PID operation with A T function Convert the measured temperature 0 250 C to current signal 4 20mA and input the current signal to the channel 0 of A D module Then the A D module converts the analog signal to digital value 0 4000 A T function block will calculate manipulate value MV 0 4000 based on the SV and PV from A D module Simultaneously the A T module will calculate and D parameters The END output of A T module will be 1 when the A T operation is completed Then PID module will start o
16. 2 Select no to use for pulse catch input of the basic parameter window For details of KGLWIN refers to the manual 7 23 Chapter 7 Usage of Various Functions 1 8 points can be used to designate the pulse catch input The input address is from P000 to P007 2 General digital input operates if it is not designated as pulse catch input 7 24 Chapter 7 Usage of Various Functions 7 1 4 Input Filter Function External input of MK80S selects input on off delay time from the range of 0 15ms 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 In this case the user sets up the proper input on off delay time then the trouble by miss operation of input signal may be prevented because the signal which is shorter than set up value is not adopted 2 Operating Explanation input on off time input signal input image data time input signal input image data narrower width pulse than input correction no is not considered as input signal 3 Using method 1 Click twice the basic parameter on the project window of KGLWIN 2 The value of filter can be set up as unit of 1ms to the input on off delay time of the basic parameter window Input on off delay time is set up as defa
17. Is the ERR LED of the CPU module turned ON Yes T KGLWIN error message 8 Used initialization program initialization program 9 History of corrective actions for the error message in the article 7 10 Other tried corrective actions 11 Characteristics of the error e Repetitive Periodic Related to a particular sequence Related to environment Sometimes General error interval 12 Detailed Description of error contents 13 Configuration diagram for the applied system 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 Condition Cause Corrective Actions Leakage current of external device Input signal Such as a drive by non contact switch doesri tturn off AC input Leakage current External device Input signal Leakage current of external device doesn t turn off Drive by a limit switch with neon lamp Neon lamp AC input may be still on Leakage current External device Input signal Leakage current due to line capacity of doesn t turn off wiring cable 1 L Leakage current AC input External device Input signal Leakage current of external device doesn t turn off Drive by swit
18. Scan Program E O Interrupt 2 occurs Stop main program and execute interrupt routine 2 Fish routne 2 and eu to progam Chapter5 CPU Module 1 parameter setting 2 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 If an interrupt factor has higher priority occurs while other interrupt of lower priority is executing the interrupt routine of lower priority will be stopped and the interrupt of higher priority will be executed first Otherwise two interrupts are executed consequently 3 Process driven interrupt Available PDI is P000 P007 8 points assigned in parameter setting PDI occurs when the input status of P000 P007 is changed from Off to On or from On to Off mao 1 1 Total available interrupt points Time driven interrupt process driven interrupt 8 points Interrupt signal is ignored when self interrupt occurs more than 2 times during interrupt processing is executing oo Interrupt executing time BN LILT TL Interrupt signal ex rising edge 5 13 Chapter5 CPU Module 5 3 4 Error Handling 1 Error Classification Errors occur due to various causes such
19. 1 General Terms Definition Remarks Switch Current Sink Input Es j Source Input Switch j Output Output Sink Output Junction contact power 1 Source i Common Source Output A power source 1 5 Chapter2 System Configuration Chapter 2 System Configuration ThelMO K7Sseries 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 1 Basic system ex pansion main unit module expansion cable Total I O points 20 80 points Digital module e 2 modules Maximum numbers AID D A 2 modules of ex pansion modules posite module Total 3 modules timer PETE modules Cnet I F module Main unit e K7M DR20S K7M DR30S K7M DR40S K7M DR60S Digital I O module e G7E DR10A A D D A Expansion e G7F ADHA Composite module module Analog timer e G7F AT2A Cnet I F modules e G7L CUEB G7L CUEC 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 K80S has a built in RS 232C port and has also G7L CUEB for RS 232C G7L CUEC for RS 422 It is possible to construct communications systems on demand 1 1 1 Communications system 1 1 1 ratio of an external device computer to main unit using a built in port
20. 2 Chapter 9 Installation and Wiring b Average power consumption of input parts with points simultaneously ON e Wn lin XE X input points X the rate of points switched on simultaneously W lin input current effective value for AC A input voltage actual operating voltage V 6 Power consumption of the special module e Ws lv X 5 av X 24 W The sum of the above values is the power consumption of the entire PLC system e W Wew Wov Wout Win Ws W Check the temperature rise within the control panel with calculation of that total power consumption W The temperature rise in the control panel is expressed as T W UA W Power consumption of the entire PLC system obtained as shown above fa Control panel inside surface area n U if the control panel temperature is controlled by a fan ete if control panel air is not circulated 9 3 Chapter 9 Installation and Wiring 9 1 2 Handling Instructions Do not drop it off and make sure that strong shock should not be applied Do not unload the PCB from its case It can cause faults e During wiring be sure to check any foreign matter like wire scraps should not enter into the upper side of the PLC If any foreign matter has entered into it always eliminate it 1 Base unit or Expansion Module handling instructions The followings explains instructions for handling or installing the Base unit or Expansion Module 1 I O specific
21. 2 n 2 Tl T2 n x100 96 OFF 1 2 ON Chapter 5 CPU Module 5 3 1 Classification of program All functional elements need to execute a certain control process are called as a program In K series a program is stored in the RAM mounted on a CPU module or flash memory of a external memory module The following table shows the classification of the program The scan program is executed regularly in every scan If the scan program is Scan program not stored the CPU cannot execute not only the scan program but also other programs Time driven interrupt The TDI programs are executed with a constant time interval specified with program TDI parameter setting ds griven The PDI programs are executed only external interrupt input is applied and PD program the corresponding interrupt routine is enabled by El instruction Subroutine proarai The subroutine programs are executed when they are called by the scan prog program with a CALL instruction 5 3 2 Processing method The following diagram shows that how the CPU module process programs when the CPU module is powered on or switched to RUN mode Start operation Scan program END processing Subroutine program PDI program TDI program 5 11 Chapter5 CPU Module 5 3 3 Interrupt function When an interrupt occurs the CPU module will stop the current operation and execute the corresponding interrupt routine After finish
22. 5 8 1 Structure e e MH MM eee ene 5 36 5 8 2 Usage dehet hh hh hh hh he hh hh hn 5 37 5 9 External Memory Module M 5 39 5 9 1 Structure e e MM M eee 5 39 5 92 Usage ee he hh hh hh hh hh hh hn ntn hn nnn 5 39 5 10 hh hh hh nth hh nnn nnn 5 42 Chapter 6 Input and Output Modules 6 1 Input and Output Specifications Cubs pi SES n NC We but EA 6 1 62 Digital Input Specifications Festes velie Nuptiis hes Pede e etae cree UAE Dl Mem 6 2 6 2 1 Base Unit eie Sens ES C EUER ordre ONES UESTRE S EC ORO Per isis que s Ue Cd nier ere Melo 6 2 6 22 Extended Module e Bie Sele ei esse ues e PES S P 6 6 63 Digital output Specifications 6 7 6 3 1 unit M I ITI M 6 7 6 3 2 Extended Module vs ts Be Scie ow et V vae e des Lesen EE 6 10 Chapter 7 Usage of Various Functions 7 1 Built in function MH HH 7 4 7 1 1 High speed counter function 7 1 7 1 2 Pulse Output
23. AC power Supply Output Current nput Current IOUT Vdrop lin X lout x lin x Varop Current 24VDC line External 24VDC power i 1 1 lour Supply 2 Power consumption of each part 1 Power consumption of a power supply part Approximately 70 of the power supply module current is converted into power 35 of that 65 dissipated as heat i e 3 5 6 5 of the output power is actually used 35 65 5 x 5 12 x 24 W where 15v 5VDC circuit current consumption of each part 24v 24VDC circuit average current consumption of output part with points simultaneously switched ON Not for 24VDC power supplied from external or power supply part that has no 24VDC output 2 Total 5VDC power consumption The total power consumption of all modules is the power of the 5VDC output circuit of the power supply part e Wsy X 5 3 Average DC24V power consumption with points simultaneously switched ON The total power consumption of all modules is the average power of the DC24V output circuit of the power supply part e Wav X 24 W 4 Average power consumption by voltage drop of output part with points simultaneously switched ON Wout lout X X output points X the rate of points switched on simultaneously W lout output current actual operating current Voltage dropped across each output load V 9
24. Discharge by contact IEC 801 2 Radiated IEC 61131 2 electromagnetic 27 500 MHz 10V m IEC 801 3 Noise Immunity field noise Digital VO Digital VO Fast transient amp Powersupply GM IEC611312 burst noise Analog 801 4 Interface Free of corrosive gases and excessive dust 9 aiu _ E Air cooling NENNEN 1 IEC International Electrotechnical Commission An international civilian institute who establishes international standards in area of electric and electronics 2 Pollution degree An indicator which indicates pollution degree which determine insulation performance of equipment Pollution degree 2 Normally only non conductive pollution occurs Occasionally however a temporary conductivity caused by condensation shall be expected Chapter 4 Names of Parts Chapter 4 Names of Parts 4 1 Base Unit BUILT IN CNET RUN I PAU REM STOP L kon MODE e On Indicates local key switch or remote running mode CPU e Off with the following led gets off Condition RUN LED LED Indication gt Without normal power supply to the base unit gt While key switchis stopped gt Detecting an error makes operation stop Indicates Base Units operation ERR LED On Off of led self inspected error Off CPU is normally working 2 I O LED Indicates I O operating status 3 battery Folder for back up battery insta
25. ERR LED if it is flickering every 2 seconds ERR Flickering No Yes Complete Battery error 5 31 Chapter 6 Input and Output Modules Chapter 6 Input and Output Modules 6 1 Input Output Specifications Digital input that offers to K7 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 zn 2 100 gt 5 xX 50 S 9 8 20 10 Y 125V rlload DC 30V AC 250V r load Opening shutting of electric current Chapter 6 Input and Qutput Modules 6 2 Digital Input Specification 6 2 1 Base unit 1 Specification Er ee Specification K7M DR20S K7M DR30S K7M DR40S K7M DR60S Insulation method Photo coupler Rated input voltage DC24V Rated input current 7 mA Operating voltage range DC20 4 28 8V ripple less than 590 Max simultaneous input points 100 simultaneously On On voltage On current DC15V or higher 4 3 mA or higher Off voltage Off current DC5V or lower 1 5 mA or lower Input impedance Approx 3 3 100 102 approx 1 5 15ms or less Common terminal 12 points COM 18 points COM 12 points COM 18 points COM Operating indicator LED turns on at ON state of input 1 1 possible to s
26. Error code 4 8 30 Chapter8 Communication Function 8 1 7 1 1 Built in communication between K7 s 1 Introduction 1 1 built in communication between K7 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 Kseries Main functions are following t can organize device area into 64 data access blocks by WORD unit and set a communication time out limit for each block e t can reestablish flag in relation with error codes and slave PLC operating mode according to parameter setting e t can reset flag related with error codes and sending receiving error frequency of each parameter t monitors communication status using monitoring function of KGLWIN K7 base unit K7 base unit Master station no 1 G7E DR10A Slave station No 31 1 1 built in communication between K80S s This communication cabling map is the same for 3 1 1 Connecting between K7 in 8 1 2 System configuration method using built in communication 8 31 Chapter8 Communication Function 2 Parameter setting 1 Communication Parameter Setting Open a new project file from KGLWIN MK80S must be selected as PLC type After selecting communication parameter from KGLWIN and clicking twice this window comes up
27. Ex2 If number of data is H04 and the data is H12345678 ASCII code converted value of this is 31 32 33 34 35 36 37 38 and this contents is entered in data area Name directy highest value is entered first lowest value last 1 If data type is Bit data read is indicated by bytes of hex Namely if Bit value is 0 it indicated by H00 and if 1 by 1 4 Response format NAK response Error code Format name Header Station No Command Command type Frame check Hex 2 Byte MK Em ASCII value H15 H3230 H52 72 H5353 H31313332 d Explanation When command is lowercase 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 Hex and 2 bytes ASCII code 4 bytes indicate error type For the details see 8 1 8 Error Error code 4 codes 8 11 Chapter8 Communication Function 5 Example 805 base unit This example supposes when 1 WORD from M20 and 1 WORD from P001 address of station No 1 are read and BCC value is checked Also it is supposed that H1234 is entered in M20 and data of H5678 is entered in P001 Computer request format PC K7 Base Unit Command Variable Format Frame Format name Header Station No Command Devicelength Formatname Tail length name check H254D57 H25505730 ASCIIvalue H05 H3031 H72 H5353 H3032 H
28. In this mode errors of a program are searched and the operation sequence is traced Changing into this mode is only possible in the STOP mode In this mode a program can be checked with examination on its execution state and contents of each data 1 Processing when the operation mode changes 1 Data area is initialized at the starting time of the mode change complying with the restart mode which has been set on the parameters 2 The output image area is cleared and output refresh is executed 2 Operation processing contents 1 I O refresh is executed by one time every scan 2 Communications service or other internal operations are processed Chapter 5 CPU Module 3 Debug operation conditions Two or more of the following four operation conditions can be simultaneously specified Operation conditons Executed by the one Executes just an operation unit one step step operation Executed to the a Executes user program until the specified step break point specified breakpoint Executed according to P Execute user program until a device bit or word assigned is changed to the specified status the device status Executed by the M Execute user program for specified number of scans specified scan number 4 Operation method 1 Execute the operation after the debug operation conditions have been set in the KGLWIN 2 In interrupt programs each task can be specified to o
29. OR LOAD Replace the battery under 0050h Battery error Continue Battery Error Backup battery voltage error the present condition 11 13 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 Connect Option in menu Default Connection is RS 232C interface For the detail information about Connect Option refer to KGLWIN Manual 1 1 1 System Definitions 2 Editor option Monitor display type Select the desired type in the monitor display type 4 types click the O K button You can select a one type 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 Auto matically saved file is saved in the current directory The file is automatically deleted when the program window is closed Therefore if a program cannot be saved by Program Error before program is not saved you can recover some program by loading auto saved file 1 2 1 System Definitions 3 Page setup 1 Appendix 1 System Definitions 2 Basic Parameters The basic parameters are necessary for operation of the PLC Set the Latch ared Timer bound
30. Preset Single Register Force Multiple Coils 16 Preset Multiple Registers MASTER K Mappin Bit area Data area P area M area L area K area F area T area C area 8 Modbus addressing rules base unit starts its address from 0 and matches with 1 of Modicon products data address So K7 s address n matches 1 of Modicon products address This means that the output contact point 1 0001 of Modicon products is marked as communication address 0 and the input contact point 1 0001 of Modicon products is marked as communication address 0 in K7 9 The size of using data As for data size K7 base unit supports 128 bytes in ASCII mode and 256 bytes in RTU mode The maximum size of the Modicon products is different from each other kind So refer to Modicon Modbus Protocol Reference Guide 8 70 Chapter 8 Communication Function 10 Map of wiring Male Type Chapter 8 Communication Function 8 3 3 Parameters Setting 1 Setting communication parameter Open a new project file at KGLWIN should be selected in PLC types Open anew project file for each of the master and the slave 2 Selecta communication parameter at KGLWIN and double click to open the following window If communication mode is ASCII Be sure to set 7bit Chapter 8 Communication Function 3 Setthe contents as follows Setting contents Stati Set a number between 0 to 31 Dori t assign no
31. c uj Byte c Gc Taie EOTIBCC Cancel Setting 1 Default setting BCC Setting E Data Type tv ASCII C Hex Check Rule Desi C XOR1 C 2 C MUL 1 C MUL2 Range ex Complement Nons Mask ex FF amp FF Cancel The kinds of The last transmitting frame segment input The value of sum check BCC Type setting ASCII Type Hex Type ASCII Input 31 32 33 34 04 CE 05 31 3233 34 04 4341 05 31 32 33 34 04 Hex Input 12 34 04 4A 05 1234 04 34 41 05 12 34 04 4A 8 54 Chapter 8 Communication Function 2 SUM1 XOR 1 or MUL 1 setting BCC Setting SUM1 WIS The value of sum check b XOR 1 i The value of sum check BCC Type setting ASCII Type Hex Type ASCII Input 05 31 32 33 34 04 05 0531323334 04 30 35 0531323334 0405 Hex Input 05 12 34 04 27 05 1234 04 3237 05 1234 04 27 MUL 1 The last transmitting frame n The value of sum check BCC Type setting ASCII Type Hex Type ASCllinput 05x31x32x33x34x04 60 0531323334 04 36 30 0531323334 04 60 05x 12x 34x 04 20 051234 04 32 30 0512340420 d Complement setting Complement calculation as below bit 7 bit 0 x D bit 7 bit 0 1 f complement h 2C the last sum check value bit 7 bit 0 o 1 0 1 2 1 complement 1 h
32. change the setting of EN P EN Il and EN D 1 Please be careful to input 100 times scaled up values for P GAIN and 2 TIME D TIME S TIME and REF are 10 times scaled up not 100 times 7 38 Chapter 7 Usage of Various Functions b PID8AT instruction parameter setting and explanation PIDCTUN Item Edit Scan time S TIME is the period of reading data sampling and 10 times scaled up for more precious operation Generally it should be synchronized with external trigger input to perform proper PID operation The range of sampling time is 0 1 10 seconds and actual input range is 0 100 b Control target SV SV setting value the designated value and PV process value present value of MK80S PID operation have the range 0 4000 The range is set with the consideration of the resolution of A D and D A module of MK80S series 12 bits and offset value When setting the SV or PV please be careful convert the analog value of control object temperature velocity etc to digital value that are the output of A D convert module For example assume that PID control is used for temperature control with Pt100 operation range 0 250 C and the goal value is 100 C The equivalent digital output of A D module voltage output range 1 54 is 1600 if the A D module outputs 0 1V with 0 C and 4000 5V with 250 C Therefore the input of SV should be 1600 not 2 c Ripple type The K7 perfo
33. device memory can be read up to 16 at a time 2 PC request format Station Command Number Device Frame Formatname Header Command Device name Tail No type of blocks length check sano ASCII value H3230 52 72 H5353 H3031 H3036 H254D57313030 1 block setting can be repeated up to max 16 blocks Explanation When command is lowercase r only one lower byte of the value resulted by adding 1 Byte each to ASCII values from ENQ to EOT is converted into ASCII and added to BCC For example the BCC of the above frame is gotten as below H05 H32 H30 H72 H53 H53 H30 H31 H30 H36 H25 H4D H57 H31 H30 H30 H04 H03A4 Therefore BCC value is A4 This specifies how much of the blocks composed of device length device are in this Number of Blocks request format This can be set up to 16 Therefore the value of Number of blocks must be set between 5 value 3031 H10 ASCII value 3030 This indicates the number of name s characters that means device which is allowable up to 16 pod characters This value is one of ASCII converted from hex type and the range is from H01 ASCII value 3031 to H10 ASCII value 3130 For example if the device name is it has 4 characters to be H04 as its length If MW000 characters to be H06 length Name length of device Address to be actually read is entered This must be ASCII value within 16 characters and in Device name
34. following 0 20mA lt 4 20mA 4000 Pr 7 Chapter 7 Usage of Functions Conversion method is as below 1 scaling conversion value A D conversion data of 0 20 mA 800 x 4000 3200 example in case of 8 mA input at range 0 20 mA before the scaling conversion 8mA 5 1600 after the scaling conversion 1600 800 x 1 25 1000 2 scaling conversion value D A conversion data of 4 20 mA x 3200 4000 800 example in case of 1000 output at range 4 20 mA current output value before the scaling conversion 1000 x 5 5mA current output value after the scaling conversion 1000 x 0 8 800 1600 1600 x 54A 8mA 7 53 Chapter 7 Usage of Functions 6 Wiring 1 Caution for wiring gt Make sure that external input signal of the mixture module of AC and analog I O is not affected by induction noise or occurs the AC through using another cable gt Wire is adopted with consideration about peripheral temperature and electric current allowance Thicker than Max size of wire AWG22 0 3 is better gt If wire is put near to high temp radiated device or contacted with oil for a long time it may cause of electric leakage so that it gets broken or miss operation during wiring gt Be sure to connect with care of polarity while connecting to external 24V DC power supply gt In case of wiring with high voltage line or generation line it makes induction failure so then it may cause
35. fuse blown Replace the fuse Does the power led turn on Is the power supply cable connected Connect the power cable correctly Does the power led turn on Over current protection device activated 1 Eliminate the excess current 2 Switch the input power OFF then ON Write down the troubleshooting questionnaire and contact Does the power led turn on the nearest service center Complete 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 See App 2 System Warning Flag and remove the cause of the error Waming error Is ERR LED stil ficking Write down the Troubleshooting Complete Questionnaires and contact the nearest service center REMARK Though warning error appears PLC system doesn t stop but corrective action is needed promptly If not it may cause the system failure Chapter 11 Troubleshooting 11 2 3 Troubleshooting flowchart used when the RUN 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
36. is stored at F18 and upper word is stored at F19 7 5 Chapter 7 Usage of Various Functions 8 example program 1 1 phase operation mode U D by program 04999 h1010 U D set by sequence program M001 PR set by external PR input Ladder diagram F12 MOV h1010 D4999 E MOV 100 D0000 m MOV 01000 D0010 PV 00000 SV 00010 Time chart A phase pulse input U D input M001 Current value of HSC 0 1 2 3 ar 3 2 1 7 6 Chapter 7 Usage of Various Functions 2 1 phase operation mode U D by B phase 04999 h1100 UID set by external input B phase input PR set by sequence program M002 Ladder diagram F012 MOV h1100 04999 000 M001 PV 00100 p SV 01000 Time chart A phase pulse input B phase input U D PR input M002 Current valueofHSC 10 09 08 o ao 141 10 7 7 Chapter 7 Usage of Various Functions 3 2 phase operation mode 1 Multiplication Operation 04999 h2011 U D set automatically by the phase difference between A and B phase PR set by external PR input Multiplication 1 Ladder diagram F012 MOV h2011 D4999 00100 SV 01000 Time chart A phase pulse input B phase input U D CurrentvalueofHSC 10 141 122 n 14 4103 nR it 7 8 Chapter 7 Usage of Various Functions 4 2 phase operation mode 2 Multipli
37. or weaker by adjusting integration time Ki in action That is the more the integration time the longer the integration time as shown in Fig 2 5 the lesser the quantity added to or subtracted from the MV and the longer the time needed for the PV to reach the SV As shown in Fig 2 6 when the integration time given is short the PV will approach the SV in short time since the quantity added or subtracted become increased But If the integration time is too short then oscillations occur therefore the proper P and value is requested Integral action is used in either action in which P action combines with action or PID action in which P and D actions combine with action M MM M Fig 2 5 The system response when a long integration time given 7 29 Chapter 7 Usage of Various Functions Fig 2 6 The system response when a short integration time given c Derivative operation D action When a deviation occurs due to alteration of SV or external disturbances D action restrains the changes of the deviation by producing MV which is proportioned with the change velocity a velocity whose deviation changes at every constant interval in order to eliminate the deviation gt D action gives quick response to control action and has an effect to reduce swiftly the deviation by applying a large control action in the direction that the deviation will be eliminated at the earlie
38. rail Fig 10 3 9 6 Chapter 9 Installation and Wirin 9 1 3 Connection of expansion module The following explains the Connection of ex pansion modules to the base unit 1 Open the connector cover of the base unit 2 Insert the connector of the ex pansion module to the connector of the base unit Base unit expansion module expansion cable 9 7 Chapter 9 Installation and Wiring The followings explains the wiring instructions for use of the system 9 2 1 Power Supply Wiring 1 Use AC 100 240V 50Hz 60Hz as the main power 2 When voltage fluctuations are larger than the specified value connect a constant voltage transformer Use a power supply which generates minimal noise across wire and K7 and ground when excessive noise Generated connect an insulating transformer K7 base unit Constant voltage transformer 3 Use a power supply which generates minimal noise across wire and across PLC and ground When excessive noise is generated connect an insulating transformer 4 When wiring separate the PLC power supply from those for I O and power device as shown below Main power PLC AC100 240 9 ower power om m Tel Main circuit I O device 71 12 rated voltage transformer Man Grout deoe 9 8 Chapter 9 Installation and Wirin 5 To minimize voltage drop use the thickest max 2 wires
39. replacement and ventilation Especially the distance between the left side of the basic unit and the control panel should be 100 mm or more for periodic battery replacement 2 Make sure that 7 is installed in fig 9 1 for most effective heat radiation fig 9 1 3 Do not mount the base board together with a large sized electromagnetic contact or no fuse breaker which produces vibration on the same panel Mount them on different panels or keep the unit or module away from such a vibration source Chapter 9 Installation and Wiring 4 Mount the wire duct as it is needed If the clearances are less than those in Fig 9 1 follow the instructions shown below elf the wire duct is mounted on the upper part of the PLC make the wiring duct clearance 50 mm 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 e f the wire duct is mounted on the lower part of the PLC make optic or coaxial cables contact it and consider the minimum diameter of the cable 5 To protect the PLC from radiating noise or heat allow 100 mm or more clearances between it and parts Left or right clearance and clearance from other device in the left or right side should be 100 mm or more Other High voltage device device 100mm or more Heat generating device Fig 9 2 PLC mounting 6 K7 has hooks for DIN rail in the bas e unit and ex pansion modules DIN
40. restart mode set cold warm hot 3 The possibility of execution of the program is decided with check on its effectiveness 2 Operation processing contents refreshes and program operation are executed 1 Interrupt programs are executed with the detection of their start up conditions 2 Normal or abnormal operation and mounting conditions of the loaded module are checked 3 Communications service or other internal operations are processed 5 15 Chapter5 CPU Module 5 4 2 STOP mode In this mode programs are not operated 1 Processing when the operation mode changes The output image area is cleared and output refresh is executed 2 Operation processing contents 1 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 4 3 PAUSE mode In this mode the program operation is temporarily stopped If it returns to the RUN mode the operation continues from the state before the stop 1 Processing when the operation mode changes Data area and input image are not cleared and the operating conditions just before the mode change is maintain 2 Operation processing contents 1 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 4 4 DEBUG mode
41. slave Format use 7 base unit with G7L CUEC module connected G7L CUEC module supports RS 422 485 protocol RS 232C communication cable for K7 base unit is different from RS 232C cable for KGL WIN in pin arrangement and from the cable for Cnet module too The cable cari t be used without any treatment For the detailed wiring method refer to 8 1 2 It s possible to set baud rate type and M area size in KGL WIN For the detailed information refer to the appendix or KGLWIN manual 8 1 Chapter8 Communication Function 8 1 2 System configuration method According to the method of connection the system using MK80S 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 BASE computer language on the user s computer or utility program like MMI software can be used 7 base unit MK80S base unit RXD1 Female Type TXD1 RXD1 are for loader communication and TXD2 RXD2 are for Cnet 8 2 Chapter8 Communication Function 2 1 1 connection with a monitoring device like PMU PMU LGIS K80S base unit RS 232C interface MK80S base unit Pin assignment and direction Female Type 8 3 Chapter8 Communication Function 3 1 1 connection with other K7 For the detailed information refer to 8 1 7 1 1 Dedicated Protocol Communication K7 base unit K7 base unit RS 232C in
42. the leading falling edge of A phase and 1 Performance Specifications Items Specifications A phase B phase Preset Input signal Rated level 24VDC 15mA Signal type Voltage input Counting range 0 16 777 215 Binary 24 bits Up Down Sequence program or B phase input selection Auto select by phase difference of A phase and B 2 Input specification Rated input 24VDC 15 phase On voltage 14VDC or higher Off voltage 2 5VDC or lower 5n T Chapter 7 Usage of Various Functions 3 Names of wiring terminals Counter input a Preset input No Terminal No Names Usage P00 oA 24V A Phase input terminal 24V B Phase input terminal Preset 24V Preset input terminal External interface circuit it Terminal Sianal Input warranted nternal circui No ignal name NE pru A phase pulse lo jum 264 V B phase pulse imum Input DC24V 2 5 or lower Preset input 19 26 4 V DC24V 6V or lower COM input Common T 2 Chapter 7 Usage of Various Functions 5 Wiring instructions high speed pulse input is sensitive to the external noise and should be handled with special care When wiring the built in high speed counter of MK80S take the following precautions against wiring noise 1 Be sure to use shielded twisted pair cables Also provide Class 3 grounding 2 Do not run a twisted pair cable in parallel with power cab
43. timer The current value of timer set as preset value and the timer output relay is turned on when the input condition of TOFF instruction turns on When the input condition is turned off the current value starts to decrease The timer output relay is turned off when the current value reaches 0 Timer input condition E EE er TEENS Timer output relav Preset value PV Current value Chapter5 CPU Module 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 tumed on The current value can be cleared by the RST instruction only Timer input condition Sire EET OX Timer output relay Timer reset input Preset value PV CUM S UV uc uM a E NUN PT t1 t2 t3 Current value 4 Monostable timer In general its operation is same as off delay timer However the change of input condition is ignored while the timer is operating decreasing Timer input condition Timer output relay Preset value PV Current value Chapter5 CPU Module 5 Retriggerable timer The operation of retriggerable timer is same as that of monostable timer Only difference is that the retriggerabl
44. to 16 Therefore the value of Number of blocks must be set between 5 value 3031 H10 ASCII value 3030 Device This indicates the number of name s characters that means device which is allowable up to length Name 16 characters This value is one of ASCII converted from hex type and the range is from length of device HO1 ASCII value 3031 to H10 ASCII value 3130 Address to be actually read is entered This must be value within 16 characters and MER in this name digits upper lower case and only are allowable to be entered If the value to be written in MW100 area is A the data Format must be If the Data value to be written in MW100 area is the data Format must be In data area the ASCII value converted from hex data is entered Ex 1 If type of data to be currently written is WORD the data is H1234 ASCII code converted value of this is 31323334 and this content must be entered in data area Namely most significant value must be sent first least significant value last 8 16 Chapter8 Communication Function 1 Device data types of each block must be the same 2 If data type is Bit the data to be written is indicated by bytes of hex Namely if Bit value is 0 it must be indicated by H00 3030 and if 1 by H01 3031 3 Response format ACK response Sein tomar Fane Pange Ascvale eo Explanation When comman
45. value of channel 1 stores Era module 42 CO D4976 A T conversion value of channel 3 stores Expansion A T module 3 D4977 A T conversion value of channel 4 stores Expansion A T module 3 4 Program example 1 Program explanation Program which controls on delay time of output contact point within 0 to 20 sec By analog timer module 2 System configuration Base Unit Analog timer module 3 Program xou 04966 00000 2 Tow 1000 00000 pona A T conversion data is moved D000 always Chapter8 Communication Function Chapter 8 Communication Function 8 1 Dedicated Protocol Communication 8 1 1 Introduction 805 s built in Cnet communication uses only K7 base unit for a dedicated communication That is it doesn t need a separate Cnet module to facilitate the user intended communication system by utilizing reading or writing of any area in CPU and monitoring function 80 base unit serves as follows Individual continuous reading of device Individual continuous writing of device Reading CPU status e Monitor devices registration e Executing monitoring e 1 1 connection link between K series system configuration K7 base unit RS 232C Remark K7 built in communication function supports Cnet communication without any separate Cnet module It must be used under the following instructions K7 base unit supports 1 1 communication only for 1 N system having master
46. 0 as broadcasting station lest it may be a cause for on No mistaken operation Set 7 or 8 Data Bit ASCII mode Set as 7 bits RTU mode Set as 8 bits Set 1 or 2 bit s Stop Bit When parity bit is set Set as 1 bit When parity bit isn t set Set as 2 bits RS232C Nul Modem or RS422 485 It s a communication channel for the communication using MK80S base unit s built in communication and Cnet I F module G7L CUEC RS232C Modem Dedicated Line It s to be selected for the communication using an dedicated modem with Cnet module G7L CUEB RS232C Dial Up Modem It s to be selected for the general communication connecting through the telephone line by dial up modem and Cnet I F module G7L CUEB Communication Channel Footnote Using Cnet I F module G7L CUEB supporting RS232C RS232C dedicated or dial up modem communication can be done but not through Cnet I F module G7L CUEC supporting RS422 485 It s the time waiting a responding frame since the master MK80S base unit sends a request frame The default value is 500ms It must be set in consideration of the max periodical time for sending receiving of the master PLC If it s set smaller than the max send receive periodical time it may cause communication error Modbus Master If itis set as the master it s the subject in the communication system If it s set as the slave it only Slave responds to the request frame of the master Select ASCII mode or RTU mod
47. 1 380ms and the no of output pulses are 1 2 3 18 19 190 units Decreasing velocity inclination is 1 thus 190 units of pulses are needed The no of pulses in the uniform velocity region are 5000 190 190 4 620 units amp Whole spent time is 50 380ms Uniform velocity Time 4 620ms Deceleration time 380ms Pulses 4 620 Decelerating pulses 190 Acceleration time 380ms Accelerating pulses 190 velocity lt gt 2 step 1st step A Acceleration step 19 Deceleration example when acceleration is 1 7 17 Chapter 7 Usage of Various Functions Condition 2 Set up as acceleration slop 2 max frequency 1000 no of pulse out 5000 QD If I D velocity inclination is 2 2 pulses are output on the 1st step velocity 50pps Pulse velocity is 50 So time consuming is 40ms 4 pulses are output on the 2nd step velocity 100pps and time consumes 20ms By calculation in the same way the time to reach to 1000pps is 40ms 20 1 760ms and the no of output pulses are 2 4 6 36 38 380 units Decreasing velocity inclination is 2 thus 380 units of pulses are needed The no of pulses the uniform velocity region are 5000 380 380 4 240 units amp Whole spent time is 57 600ms Acceleration Uniform velocity Deceleration Time 760ms Time 4 240ms Time 760ms Pulses 380 _ Pulses 4 240 _ Pulses 380 24 step 1st step A Acceleration step 19 Deceleration Example Acc
48. 2D the last sum check value Chapter 8 Communication Function e Mask setting Masking method is as below bit 7 bit 0 BREE ane bit 7 bit 0 8 56 h D3 sum check value hFF masking value AND masking OR masking hFF Exclusive OR masking h2C Chapter 8 Communication Function 8 2 3 Instruction Available device Instruction IEEE Error Zero Cany steps 110 F111 F112 Dor Reel A O g SND8 Error Error flag turns on when designating area F110 is over aay c siw n Frame no which is designated at parameter Device which the communication status is stored B SND8 1 Function When the execution condition is on the communication starts with protocol at parameter which is designated early is a frame number at parameter which is designated D isa device which the communication status is stored 2 example of program P0020 SND 3 000 When input condition is on the communication starts with protocol at user defined parameter mumber 3 The communication state stores M000 and the format of lis as below bit 15 bit 8 bit 1 bitO Error code Error bit Done bit Done bit transfer complets normally this bit tums on during 1 scan e Error bit When communication error occurs e Error code When error bit turns on it stores error code 3 Error code S
49. 3035 3230 For ACK response after execution of lt K7 Base Unit Command Number of Number of Number of Frame Formatname Header Station No Command Data Data Tail type blocks data E H3031 H5353 H3032 H3032 31323334 H3032 H35363738 For response after execution of command PC lt 805 Base Unit mu v 5 wow ws Frame check BCC is automatically calculated internally 8 12 Chapter8 Communication Function 2 Continuous reading RSB of device 1 Introduction This is a function that reads the PLC device memory directly specified in accord with memory data type With this data is read from specified address as much as specified continuously 2 PC request format Station Command Device Number of data Frame Formatname Header Command Device Tail EC 128 Bytes check EH wwe ASCIIvalue my H3130 H52 72 H5342 H3036 H254D57313030 H3035 1 Number of data specifies the number according to the type of data Namely if the data type of device is word and number is 5 it means that 5 WORDS should be read 2 Max of MW in number of data can be used up to 64 3 Protocol of RSB doesn t have number of blocks 4 R r SB command of bit devices is not available Explanation
50. 4 External device malfunction The PLC user program detects malfunctions of external devices If a fatal error is detected the system enters into the STOP state and if an ordinary error is detected the system continues its operation REMARK 1 occurrence of a fatal error the state is to be stored in the representative system error flags and an ordinary error in the representative system warning flags 2 For details of flags refer to Appendix 2 Flag List Chapter5 CPU Module 5 4 Operation Modes The CPU module operates in one of the four modes the RUN STOP PAUSE and DEBUG mode The following describes the PLC operation processing in each operation mode 5 4 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 Execute input refresh Execute programs and tasks Checkthe availability of expansion units Execute communication and intemal service Execute output refresh Operation mode is changed Yes Operate with new mode No 1 Processing when the operation mode changes Initialization of data area is executed when the first scan starts 1 If the PLC is in the RUN mode when applying the power 2 If the operation mode has been changed into from the STOP mode into the RUN mode the initialization is executed complying with the
51. 5 AC240V 1A COS 0 7 100 000 or more Electrical AC200V 1A AC240V 0 5A 0 35 100 000 more DC24V 1A DC100V 0 1A 7ms 100 000 or more Response time Common method 1 point 1COM 2 points 1COM Operation indication LED is on at on status of output 2 Circuit It s the same with the output circuit of the base unit 3 Output wiring DC5V DC24V AC110 220V REMARK 1 Refer to 7 2 Special Functions for the special function units 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 7 The built in high speed counter of MK80S hereafter called HSC has the following features 3 counter functions as followings 1 phase up down counter Up down is selected by user program 1 phase up down counter Up down is selected by external B phase input 2 phase up down counter Up down is automatically selected by the phase difference between A phase B Multiplication 1 2 or 4 with 2 phase counter 2 phase pulse input multiplied by one Counts the pulse at the leading edge of A phase 2 phase pulse input multiplied by two Counts the pulse at the leading falling edge of A phase 2 phase pulse input multiplied by four Counts the pulse at
52. 5 9 1 Structure Installation connector 5 9 2 Usage 1 Saving the uset s program on the external memory module Turn the power of the base unit off Install the memory module When only basic unit is used Connect to the expansion connector of the basic unit When expansion unit is used Connect to the expansion connector of the last connected expansion unit Turn the dip switch for ROM mode setting of the base unit to OFF This switch is for Cnet ROM MODE 4 Tum the power of the base unit on 5 Connect KGLWIN and PLC 6 Select Online Flash memory Write external memory in menu and the following message box will displayed KGL WIN for Windows 8 Choose an item to be saved in the flash memory and press 9 Turn the power of the base unit off 10 Remove the external memory module Through the above steps a user can save a program into the external memory module 5 29 Chapter 5 CPU Module 2 Run the PLC with a program of external memory module 1 Tum the power of the base unit off 2 Install the memory module When only base unit is used connect to the expansion connector of the base unit And when expansion unit is used connect to the expansion connector of the last connected expansion unit 3 Set the dipswitch for ROM mode setting of the base unit to OFF position ROM MODE This switch is for Cnet 4 Turn on the power of the base unit
53. Data Area User Program Area 000 FFFF Data Register Parameter setting area Reserved for special usaae P3 User Program Area 7ksteps Timer preset value 256 words Timer elapsed value 256 words Counter preset value 256 words Counter elapsed value 256 words Step Controller 100 x 100 steps 00 00 S99 99 5 24 Chapter 5 CPU Module 5 7 I O No Allocation Method 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 Ewansion iOmedie 0 conversion mode 2 Analog timermoie Commuricaion mole 1 I O No allocation method m i eee Fixed 64 pons Fed 64 Fred 46 pons P090 Fired 16 points Expansion 2 P100 P10F Fixed 16 points Output P110 P11F Fixed 16 points Expansion 3 None AID A T Communication Special Basically I O allocation is fixed point method the area which is not used can be used internal relay The special module is not allocated 5 25 Chapter5 CPU Module 5 8 Built in Flash Memo K7 series includes a built in flash memory to store user program Also user can set the PLC automatically executes the user program of flash memory when the PLC is turned on It is similar with the ROM operation of other PLCs but it is different that no external memory is re
54. Error of exceeding the area limit of reading writing on the slave station Error when the data value to be read from or write on the slave station ish t allowed Error status of the slave station It s a responding code of the slave station for the master station to prevent the master station time out error when request command processing takes time The master station marks an error code and waits for a certain time without making any second request Error when request command processing takes too much time The master should request again Error when exceeds the time limit of the communication parameter as it communicates Errors when data is 0 or more than 256 bytes Error of setting parameters mode master slave Station Error Error when the station number of itself and the station number set by the 51 of instruction are the same 8 75 Chapter 8 Communication Function Example program 1 It s supposed that MK80S base 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 The Coil of the slave station is supposed to be as follows and the data that are read is saved in D1000 Sms ee 1 Sms 1 1 O f 2 6 qp p
55. F Stores the maximum scan time F0510 to F051F Stores the minimum scan time F0520 to F052F Present scan time Stores the present scan time F0530 to F053F Clock data Clock data e F0540 to F054F Clock data Clock data F0550 to F055F Clock data Clock data minute second minute second F0560 to F056F Clock data Clock data day of the week day of the week F0570 to F058F Unused F0590 to F059F Storing error step Stores the error step of the program FO610to FO63F to F063F Unused F0600 to FO60F Storing FMM step If a FMM related error has occurred its occurrence information is stored App2 3 Appendix 3 External Dimensions Appendix 3 External Dimensions unit mm 1 Base unit Sse App3 1
56. For response after execution of command lt K7 Base Unit San ti No SN E 8 24 Chapter8 Communication Function 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 sito ttn rn xm ASCIlvalue ws Explanation Register No uses the same number registered during monitor register for monitor execution Register No It is possible to set from 00 09 H00 H09 A When command is lowercase y only one lower byte of the value resulted by adding 1 byte B each to ASCII values from ENQ to EOT is converted into ASCII added to BCC 3 Response Format ACK response In case that the register Format of register No is the Individual reading of device Station Registrato Numberof Number of Frame Format name Header Command Tail 1 n Blocks data check vy Hos CK H3931383341 ASClivalue H3130 H59 79 H3039 H3031 H03 414242 Q In case that the register Format of register No is the continuous reading of device Station Registration Frame Format name Header Command Number of data Data Tail Check No H
57. Frame Example H06 MW000 H02 BCC H254D5730 ASCII value H05 H3041 H72 H5342 H3036 3030 2 For ACK response after execution of lt MK80S Base Unit Command Number of Format name Header Station No Command Data Tail Frame check ata Frame Example ex ASCll value 3041 H5342 H3034 3132333435363738 3 For response after execution of command PC 805 Base Unit Sn eue wax AsCIIvae H3041 m os 8 15 Chapter8 Communication Function 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 Frame Format name Header Station No Command Device Name Tail E E Length Check Frame Example EXETNEA W w HOOE2 BCC ASCII H254D5731 H30304 H3230 H57 77 H5353 H3031 H3036 value gt 1 block setting can be repeated up to max 16 blocks Explanation When command is lowercase r only one lower byte of the value resulted by adding 1 Byte each to ASCII values from ENQ to EOT is converted into ASCII and added to BCC This specifies how much of the blocks composed of device length device are in Number of blocks this request Format This can be set up
58. Function ee eee eee eee eee eee eee ee ee 7 9 7 1 3 Pulse Catch function 7 17 7 1 4 Input Filter function ee 7 19 7 1 5 PID Control function eee ee eee eee eee 7 21 7 1 6 External Interrupt function eee eee eee eee ee eee eee eee eee eee eee eee 7 40 7 2 Special Module eem 7 42 7 2 4 A D D A Combination 7 50 7 2 2 Analogue Timer 7 58 Chapter 8 Communication Function 8 1 Direct Protocol Communication 8 1 8 1 1 Introduction mm HH HII HH Heer 8 1 8 1 2 System Configuration method mmm 8 2 8 1 3 Frame Structure mH Henne 8 5 8 14 List of Commands HH HH HH Heer 8 8 8 1 5 Data Type eee 8 9 8 1 6 Execution of Commands MH 8 10 8 1 7 1 1 Built in Co
59. ID control The pseudo code of PID control is as following Step 1 Get constants that are used for PID operation h Bi K x integral gain Ti is _ 2 Nx h 2 Nxh _ QxXKXxN xTd 2x Td N xh derivation gain h anti windup gain Tt Step 2 Read SV and PV value PV adin ch1 Step 3 Calculate the proportional term PzKx bxSV PV Step 4 Update the derivative term initial value of D 0 D As x D Bd x PV old Step 5 Calculate the MV initial value of 0 1 0 Step 6 Check the actuator is saturated or not U sat MV U low U high Step 7 Output the MV value to the D A module Step 8 Update the integral term 1 1 SV PV A0 x U MV Step 9 Update the PV old value PV old PV 3 Instruction and parameter setting For the PID operation of MK80S following 2 instruction are included in the KGLWIN software version 2 0 or later PID8 Perform the PID operation 2 PID8AT Perform the auto tuning operation 7 3 6 Chapter 7 Usage of Various Functions Remarks 1 Refer the KGLWIN manual for the parameter setting 1 Parameter setting and explanation a PID8 instruction parameter setting and explanation a Scan time scan time is the period of reading data sampling and also 10 times scaled up Generally it should be synchronized with external trigger input EN input of function block to perform proper P
60. ID operation The range of sampling time is 0 1 10 seconds and actual input range is 0 100 b Manual operate value When manual operation is designates manual operation value designates input range 0 4000 c High frequency noise removal ratio high frequency noise removal ratio is used for derivative control operation and shows the ratio of high frequency noise depression If there is a lot of high frequency noise in the control system select the value as higher value Otherwise leave the 1 The range of parameter is 0 10 and it is not scaled up so input the designated value directly it is possible that parameter value designates D area also Be careful if designating D area value and designating value directly over 10 system operate abnormally d Tracking time constant TT tracking time constant parameter is used to designate anti_reset windup operation The range of TT is 0 01 10 and the actual input range that are 100 times scaled up is 0 1000 e Reference value Reference value may be useful parameter according to the control system type especially velocity pressure or flux control system The Reference value input is also 10 times scaled up and the actual range is 0 10 Differential time and integral time TIME and D TIME are 10 times scaled up For example input 18894 if the designated TIME value is 1889 4 The range of actual input is 0 20000 it is possible that parameter value designa
61. If wiring over 200 mm 7 88 in or longer distance trouble can be caused by leakage currents due to line capacity Refer to the section 11 4 Example 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 80 or less 3 When independent grounding is impossible use the joint grounding method as shown in the figure below B Class 3 grounding Class 3 grounding A Independent grounding Best B Joint grounding Good C Joint grounding Not allowed 4 Use 2 mi 14AWG or thicker grounding wire Grounding point should be as near as possible to the PLC to minimize the distance of grounding cable 9 1 0 Chapter 9 Installation and Wiring 9 2 4 Cable Specifications for wiring The specifications for wiring is as follows Cable Specifications Kinds of external connection Minimum _ Meimm Digital Input 0 18 AWG24 1 5 AWG16 Digital Output 0 18 AWG24 2 0 AWG14 ws sewn Be sure to use solderless terminal for power supply and I O wiring sure to use M3 type as terminal screw sure that terminal screw is connected by 6 9 torque Be sure to use fork shaped terminal screw as shown below cable solderness term
62. ME FOR run and END NEXT CALLx and SBRTx 0033h Program Check Code Check Error An error has occurred while checking Correct the error Error a program 0040h Code Check Error Code Check Error unreadable Correct the error step Missing the END Insert the END instruction instruction in the Miss END Error The program does fot have the END at the bottom of the instruction program program Missing the RET Insert the END instruction The subroutine does not has the RET instruction in the Miss RET Error at te at the bottom of the program program Missing the SBRT instruction in the Miss SBRT Error The subroutine does not has the Insert the SBRT subroutine SBRT instruction instruction program The JMP E Error The JMP JME instruction error Correct the pn eae instruction error instruction The FOR NEXT gt Correct the FOR NEXT instruction error FOR NEXT Error he FOR NEXT instruction error instruction The MCS MCS MCSCLR Correct the 5 0046h MCSCLR Stop Error he MCS MCSCLR instruction error MCSCLR instruction instruction error The MPUSH 0047h MPOP instruction Stop mr MPOP The MPUSH MPOP instruction error MT error 0048h Dual coil error Stop DUAL COIL Error Timer or counter has been duplicated Correct timer counter Input condition error or too much use Check and correct the EH DAMNUM of LOAD or AND
63. NE Click the OK button after setting as above 8 64 Chapter 8 Communication Function O CO IT CON Sa Am R SIZE HE Inpt Double click the Setting and then set the as below 8 65 Chapter 8 Communication Function You can see the frame list which is designated Click OK button 8 66 Chapter 8 Communication Function 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 stores 0000 When error occurs the number of sending error stores D001 Chapter 8 Communication Function 8 3 Modbus Protocol Communication 8 3 1 Introduction 805 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 16 Refer to Modicon Modbus Protocol Reference Guide http Avww modicon com techpubs toc7_ html 8 3 2 Basic Specification 1 ASCII mode 1 It communicates using ASCII data 2 Each frame uses colon for header CRLF Carriage Retum Line Feed HOD
64. O183AABB ASCII value H3130 H59 79 H3039 H3034 H3931383341414242 lu 8 25 Chapter8 Communication Function 4 Response Format response Registration Error code Format name Header Station No Command Tail Frame check No Hex 2Byte ae ae w ASCIIvalue H3130 H59 79 H3039 H31313332 os Explanation When command is lowercase y 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 Hex and 2 bytes ASCII code 4 bytes indicate error type For the details see 8 1 8 Error Error code codes 8 26 Chapter8 Communication Function 5 Example This example supposes that registered device No 1 of station No 1 is read and BCC value is checked And it is supposed that device M000 is registered and the number of blocks is 1 Computer request Format PC gt K7 Base Unit ttn o ma For response after execution of command lt K7 Base Unit Registration Number of Frame Format name Header StationNo Command Number of Blocks Tail m check Frame Example ACK H01 H23422339 H3233343232 ASCII value H06 3031 3031 H3031 H03 333339 For NAK response after execution of command lt K7 Base Unit Format name Header Station No Command Registration No Error code Fr
65. On 3200 8V is output When P84 becomes 3600 9V is output b System configuration Base Unit A D D A mixture module Digital extended module c Program Chapter 7 Usage of Functions 7 2 2 Analog timer 1 Performance specification The performance specification of the analog timer module are following Item Specification Output value range 8 Bit Digital output range 0 200 Setting type Setting by variable resistance Accuracy of timer 2 0 Accuracy about max value Operation method Storing data register automatically Internal current 50 mA consumption Number of module Max 3 modules installment Weight 200g 2 Names of parts and functions I No Indicate the operating status the G7F AT 2A RUNLED On normal operating Off DC 5V power off or the g7f at2a module fault ERR peni the length of timer through variable resistance to every Extension cabe cable Extension cable connection terminal 7 5 9 Chapter 7 Usage of Functions 3 Reading A T conversion value A T conversion value stores special data register as following register D4966 conversion value of channel 1 stores Expansion A T module 1 D4967 A T conversion value of channel 2 stores Expansion A T module 1 D4968 conversion value of channel 3 stores Expansion A T module 1 is conversion value of channel 4 stores Expansion A T module 1 D4970 conversion
66. UN Correct the content of the 0021h Parameter Stop Parameter Error Starts unit reservation information parameter or reallocate or Error continue differs from the types of real loaded replace the I O unit 0022h units The point of the reserved I O Correct the content of the parameter Maximum 1 0 Over Stop I O PARA Error information or real loaded I O units overruns the maximum point 0023h a 0 PARA Error FMM 0 Parameter Error Correct the parameter 0024h oa 1 Parameter FMM 1 PARA Error FMM 1 Parameter Error Correct the parameter 0025h FMM 2 PARA Error FMM 2 Parameter Error Correct the parameter 11 12 Chapter 11 Troubleshooting continued Error Code 0026h dk 3 PARA Error FMM 3 Parameter Error Correct the parameter A digit of other than 0 to 9 has met during BCD conversion 0030h Operation Error Operation Error g Correct the content of the An operand value is outside the error step defined operand range Error CPU state Message Cause Corrective Actions Check the maximum scan WDT Over Continue WDT Over Error Scan time has overrun the watch dog time of the program and stop time modify the program or insert programs Program replacement has Error of Program error has occurred at program not been completed during 0032h Change during Stop PGM Change Error change during run NO SBRT JME run JMP J
67. User s Manual Programmable Logic Controller IMO K7 IMO Precision Controls Contents Chapter 1 General nn nennen nnne 1 1 1 6 11 Guide to Use this Manual 1 1 1 2 13 Terminology 1 4 2 1 Overall Configuration ies der ud nup 2 4 2 1 1 Basic system eee 2 2 2 1 2 Cnet I F System meme 2 2 22 Product functional model 2 4 2 2 1 Product function Block 2 4 2 2 2 GM7 Series System Equipment Product 2 5 41 Base Unil rrr beer EE Rte eerie 4 1 4 1 1 20 point basic unit mmm meme 4 2 4 1 2 30 points Basic Unit 4 3 4 1 3 40 Points Basic Unite mH HH 4 3 A44 60 Points Basic Unit sco secco eot tetur te 4 3 4 2 Expansion Module 4 4 4 2 1 Digital Module mmm mme Hee eene 4 4 422ND DIA Combination Module 4 4 4 2 3 Analogue timer Module e tee eee 4 4 Chapter 5 CPU 5 1 Specifications ORE 5 1 52 Operation Processing WR Ve SA Pei dra usse MEN e esc e I vise Eu e NR ESOS 5 3 5 2 1 Operation Processing Method 9 e HMM cee cece ces 5 3 5 2 2 Operation Processing at momentary power failure occurrence 5 4 5 2 3 Scan time HI 5 5 524 Scan watchdog timer e M MM 5 5 5 2 5 Timer processing B
68. When command is lowercase r only one lower byte of the value resulted by adding 1 Byte each to ASCII values from ENQ to EOT is converted into ASCII and added to BCC Device This indicates the number of name s characters that means device which is allowable up to length Name 16 characters This value is one of ASCII converted from hex type and the range is from length of device Address to be actually read is entered This must be ASCII value within 16 characters and in Device name p this name digits upper lowercase and only are allowable to be entered 8 13 Chapter8 Communication Function 3 MK80S Base Unit response format MK80S of ACK response Command Number of Number of Frame Format name Header Station No Command Tail type blocks data check a ASCIIvalue H3130 52 72 H5342 H3031 H3134 H31313232 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 It means byte number of hex type and is converted into ASCII This number is determined by multiplying the data number of computer request Format by the data size in below table according to memory type B W D included in variable name of computer request Format Number of dai Das ge deus WORD W JP MLKF T CD S W In data area there are the values of hex data converted to ASCII code
69. alling 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 5 Higher or lower temperatures outside the range of 0 to 55 C 6 Relative humidity outside the range of 5 to 95 C 7 Corrosive or flammable gases 2 Precautions during installing 1 During drilling or wiring do not allow any wire scraps to enter into the PLC 2 Install it on locations that are convenient for operation 3 Make sure that it is not located on the same panel that high voltage equipment located 4 Make sure that the distance from the walls of duct and external equipment be 50mm or more 5 Be sure to be grounded to locations that have good ambient noise immunity 3 Heat protection design of control box 1 When installing the PLC in a closed control box be sure too design heat protection of control box with consideration of the heat generated by the PLC itself and other devices 2 It is recommended that filters or closed heat exchangers be used 9 1 Chapter 9 Installation and Wirin The following shows the procedure for calculating the PLC system power consumption 1 PLC system power consumption block diagram Base Unit 5VDC line Expansion module special Output part Input part module Transistor Output Current Input Current output part input part transistor
70. amaged to download with changes of parameter or to fail to back up the data caused by lower back up battery voltage than the standard For using user defined mode he she should program with instruction controlling sending of PLC as well as edit frames This section explains UDPC setting amp usage 8 47 Chapter 8 Communication Function 8 2 2 Parameter Setting 1 Setting Communications Parameter 1 Open a new project file from KGLWIN Select K7 as PLC type 2 After setting communication parameter at KGLWIN Double click it to activate this window 3 Set according to the following table Station No Baud Rate Data Bit Parity Bit Stop Bit RS232C Null Modem or RS422 485 It s communication channel for the communication using 805 base unit s built in communication and Cnet I F module G7L CUEC RS232C Modem Dedicated Line If s to be selected for the communication using an dedicated modem with Cnet I F module G7L CUEB RS232C Dial Up Modem It s to be selected for the general communication connecting through the telephone line by dial up modem and Cnet I F module G7L CUEB Footnote Using Cnet I F module G7L CUEB supporting RS232C RS232C dedicated or dial up modem communication can be done but not through Cnet I F module G7L Communication Channel RS422 485 f s the time waiting a responding frame since the master MK80S base unit sends a request frame Timeout in Master The default
71. ame check Frame Example Tor code H01 a RUN 8 27 Chapter8 Communication Function 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 Suo conan ascivaue ome Explanation When command is lowercase r only one lower byte of the value resulted by adding 1 Byte each to ASCII values from ENQ to EOT is converted into ASCII and added to BCC 3 Response Format ACK response Command PLC status data Frame Format name Header Station No Command Tail Hex 20 Byte check ascivaue non nsara ws qw Jw 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 4 Response Format NAK response Error code Format name Header Station No Command Command type Tail Frame check Hex 2 Byte mp sr ASCllvalue 3041 5272 5354 31313332 Explanation When command is one of lower case r only one lower byte of the value resulted by adding BCC 1 Byte each to ASCII values from NAK to ETX is converted into ASCII and added to BCC and sent CEPR Hex and 2 bytes ASCII 4 bytes indicate error type For the detail
72. ance between Connecting Visual check Proper clearance Correct terminals conditions 3 Connectors should not be Retighten connector mounting Loose connectors Visual check loose Screws Measure voltage between input 85 264V AC terminals 20 28V DC Battery time and battery capacity Check total power failure If Battery capacity reduction should not Battery life indicated Change the battery capacity time and the be indicated battery when specified reduction specified source service life is exceeded If fuse melting disconnection change Fuse Visual check No melting disconnection the fuse periodically because a surge current can cause heat Line voltage check Change supply power 10 2 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 1 Visual checks Check the following points Machine operating condition in stop and operating status Power On Off Status of I O devices Condition of wiring I O wires extension and communications cables Display states of various indic
73. ansmitting device P M L K F T C D and number of transmitting byte Ex2 If you want to transmit D000 0003 the setting is as below transmitting device D000 number of transmitting 6 bytes It is a radio button to select the input type of commands There re 2 kinds as hex or ASCII value Ex1 10R SB0696 MW100 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 C Hexinput ASCII Input Send by ASCII Converting Receive by Hex Converting If ARRAY is set the size of area is to be set by byte The unitis a byte ize Byte 8 51 Chapter 8 Communication Function Tail Used in Tail type Possible characters as headers 1 alphabet letter 1 numeric number or control characters as below Control character Available Control Code USmr Deu j Example 1 NUL ENQ 1 A Possible Example 2 NUL 12 ABC impossible Itis allowed to be only 3 consecutive characters Example 1 ENQ STX NUL Possible Example 2 AJ NUL ENQ STX impossible It s possible to use BCC that can detect errors BCC must be set as BCC to be used To set BCC contents click BCC Setting button on the right side Ex5 Tailer BCC Setting BCC setting set BCC when itis needed
74. ary Watchdog timer PLC operation mode Input setting Pulse catch m Latch area setting Set the retain area on the inner device 2 Timer boundary setting Set the 100ms timer boundary the rest of timer area allocates 10ms automatically 3 Watchdog timer setting For the purpose of the watch of normal program execution This parameter is used to set the maximum allowable execution time of a user program in order to supervisor its normal or abnormal operation Setting range is 1ms 6000ms 4 Input setting set the input filter constant and input catch contact point 5 Remote access enable setting This parameter enables remote access authority 1 4 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 Turns on when the CPU in the RUN mode F0001 Turns on when the CPU in the Program mode Pause mode Turns on when the CPU in the Pause mode Remotemode Tums on wren the CPU in tne User memory installation Turns on when a user memory is installed Execution of the STOP instruction Turns on when the STOP instruction is being operated 1 Scan On 1 Scan On 1 step run Turns on when the 1 step run is operated in the Debug mode F0021 Breakpoint run Turns on when the breakpoint run is operated in t
75. as PLC system defect system configuration fault or abnormal operation result Errors are classified into fatal error mode which stops system operation for system stability and ordinary error mode which continues system operation with informing the user of its error warning The main factors that occurs the PLC system error are given as followings PLC hardware defect System configuration error Operation error during execution of the user programs External device malfunction 2 Operation mode at error occurrence In case of error occurrence the PLC system write the error contents the corresponding flags and stops or continues its operation complying with its operation mode 1 PLC hardware defect The system enters into the STOP state if a fatal error such as the CPU module defect has occurred and continues its operation if an ordinary error such as battery error has occurred 2 System configuration error This error occurs when the PLC hardware configuration differs from the configuration defined in the K80S series The System enters into the STOP state 3 Operation error during execution of the user programs It the numeric operation error of these errors occurs during execution of the user programs its contents are marked on the error flags and the system continues its operation If operation time overruns the watchdog time or I O modules loaded are not normally controlled the system enters into the STOP state
76. ata correct and execute again Check commands Set a wrong device memory that is to H0021 Command error use commands other than w W r R x X y Y s S Wrong command type that is to use characters H0031 Command type error like wSS wSB using other letters from 55 or Set wrong device memory other than H1132 Device memory error P M L K T C F D S The number of data in execution is 0 or bigger H1232 Data size error than 128 bytes When use other characters than x X w W H2432 Data type error at MK80S When use b B d D at MK80S Ex1 Use commands like DB or DD Device request When omit 96 H7132 Format error When exceed assigned area H2232 exceeding error Ex1 MX2000 or DW5000 Monitor execution H0190 Exceeding limit of register No error H0290 Monitor register error Exceeding limit of register No 8 45 Check command type Check device type Correct length of data If data type is bite the number of data must be from 1 128 Check data type and execute again Check Format correct and execute again Correct the size within the assigned area and execute again Rearrange the monitor register no not to go over than 9 and reset Rearrange the monitor register no not to go over than 9 and reset Chapter8 Communication Function Continued Eror ye Eror condiion and causes When use commands that aren t supported Be familiar w
77. ations re check Re check the input voltage for the input part if a voltage over the maximum Switching capacity is applied it can cause faults destruction or fire 2 Used wire Select the wire with due consideration of ambient temperature and rated current Its minimum specifications should be AWG24 0 18 or more 3 Environment When wiring the I O part if it locates near a device generating an cause short circuit destruction or malfunction 4 Polarity Before applying the power to part that has polarities be sure to check its polarities 5 Wiring e Wiring 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 e If an inductive load has been connected to output part connect parallel surge killer or diode to a load Connect the cathode part of the part of the power supply Output part Output part 6 Terminal block Check its fixing During drilling or wiring do not allow any wire scraps to enter the PLC It can cause malfunction and fault 7 Be cautious that strong shock does not applied to the I O part Do not separate the PCB from its case 9 4 Chapter 9 Installation and Wiring 2 Mounting instructions The following explains instructions for mounting the PLC onto the control panel 1 Allow sufficient distance from upper part of the Unitfor easy module
78. ators such as POWER LED RUN LED ERR LED and I O LED After checking them connect peripheral devices and check the operation status of the PLC and the program contents 2 Trouble Check Observe any change in the error conditions during the following Switch to the STOP position and then turn the power on and off 3 Narrow down the possible causes of the trouble where the fault lies i e Inside or outside of the PLC 1 0 module or another module PLC program 11 2 Troubleshooting This section explains the procedure for determining the cause of troubles as well as the errors and corrective actions Flowchart used when the POWER LED is OFF zm Flowchart used when the ERR LED is flickering pe Flowchart used when the RUN turned OFF Flowchart used when the output load of the output module properly doesn t turn on Program cannot be written Flowchart used when program t be written to the PLC 11 1 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 Is the power supply operating Supply the power Yes Does the power led turn on Is the voltage within the rated See the power supply be within AC 110 240 V Does the power led turn on Is the fuse blown s the
79. atted data area Monitoring registration and command registration number of execution commands All contents of data Remark 1 If it is hexadecimal H is attached in front of the number of frames like H01 H12345 H34 H12 and H89AB 2 Sequence of command frame Sequence of command request frame Station No Fomatted data PLC ACK response Station Data or null PLC NAK response 8 6 Chapter8 Communication Function 8 1 4 List of commands Command list for communication Drm Treatment Code ASCII code code Code ASCII code Individual EE 5353 Reads device of Bit Word and type i reading device Continuos H72 Reads device Word in block unit adig r R H52 SB 5342 Continuous reading Bit is unavailable Individual w W 55 5353 Writes data to device of Bitand Word type Writing reading H57 device Continuos H77 Writes data to Word type in block unit d w W SB 5342 Continuous reading Bit is unavailable reading CPU H73 Reads flag list like PLC operation status and error Status readin r R H53 ST 5354 information For detailed flag contents refer to 9 MK80S manual Command ASCII code ASCII code Monitoring variable H78 Hoo Ho9 3030 3039 Register device to monitor register H58 Execution of H79 monitoring y Y H59 H00 H09 3030 3039 Execute registered device to monitor 1 K7 base unit identif
80. ber of data 8 22 Chapter8 Communication Function 3 Response Format ACK response Sao etn Ta 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 4 Response Format NAK response Registration Error code Format name Header Station No Command Hex 2Byte Frame Example H1132 ASCII value H3130 H58 7 H3039 H31313332 Explanation When command is one of lower case r only one lower byte of the value resulted by adding BCC 1 Byte each to ASCII values from NAK to ETX is converted into ASCII and added to BCC and sent Hex and 2 bytes ASCII code 4 bytes indicate error type For the details see 8 1 8 Error 8 23 Chapter8 Communication Function 5 Example This example supposes that device M000 of station NO 1 is monitor registered D Computer request K7 Base Unit Registration Format Registration Format name Station No Command Number of Frame check No Device length Device name E eee Pa H255457 ASCII value H05 H3031 H3031 525353 H3031 H3036 303030 2 For ACK response after execution of command PC lt K7 Base Unit etn o asciwvalue 3
81. cation Operation D4999 2012 UID set automatically by the phase difference between A and B phase PR set by external PR input Multiplication 2 times Ladder diagram F012 MOV h2012 D4999 qo PV 00100 SV 01000 Time chart A phase pulse input J J L B phase input U D Current value of HSC 7 9 Chapter 7 Usage of Various Functions 5b 2 phase operation mode 4 Multiplication Operation D4999 h2014 UID set automatically by the phase difference between A and B phase PR set by external PR input Multiplication 4 times Ladder diagram F012 MOV h2014 D4999 PV 00100 SV 01000 Time chart A phase pulse input B phase input U D Current value of HSC 10 1 12 14 16 18 1 20 1 22 1 24 1 25 1 28 1 24 19 17 45 11 13 45 47 19 21 23 25 24 22 20 18 16 14 7 10 Chapter 7 Usage of Various Functions 7 1 2 Pulse Output Function In the transistor output type of 7 the pulse output function maximum 2Kpps is internalized By using this function with stepping motor or servo motor driver MK80S is applicable to a simple positioning system 1 Usage ofthe Pulse Output Transistor output type of K7 outputs the signals of pulse and direction in an output contact point through the instruction PULSOUT The outputted pulse is connected to motor driver it is controlled position in the following figure K7M DT30S Choose a mode f
82. ch with LED indicator DC i nput Leakage current External device Input signal Sneak current due to the use of two doesn t turn off different power supplies DC input Connect an appropriate register and capacity which will make the voltage lower across the terminals of the input module AC input CR values are determined by the leakage current value Recommended value C 0 1 0 47 uF 47 120 Q 1 2W Or make up another independent display circuit Locate the power supply on the external device side as shown below AC input External device Connect an appropriate register which will make the voltage higher than the OFF voltage across the input module terminal and common terminal DC input Use only one power supply Connect a sneak current prevention diode DC input 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 When the output is off excessive voltage is applied to the load The load doesn t turn off When the load is C R type timer time constant fluctuates The load does not turn off Load is half wave rectified inside in some cases it is true of a solenoid When the polarity of the power supply is as shown D C is charged When the polarity is as shown in the voltage charged in C plus the line
83. communication speed 8 33 Chapter8 Communication Function 2 Setting registration list If you click master from exclusive use in protocol and sending List button will be activated Click the button to open the registration list window Dedicated SOOAMNMN e Con OW DAMME CO n2 C3 3 Total 64 data blocks can be assigned But it s not possible to set a register number 4 Sending and receiving data size can be set up to 60 WORDS There s no cycle for sending and receiving Setting device area Sending reading device area P M L K T C D S F saving device area P M L K T C D S Receiving reading device area P M L K T C D S F saving device area P M L K T C D S 8 34 Chapter8 Communication Function 6 This is a window you can change dedicated use 1 setting Private Item Edit Mode Send C Receive Station 0 31 Size Word fi 1 60 Area From 00000 Area 00000 P MLL K T C Area Cancel Help Station number set the number of the slave or opponent station Mode click send for writing data on the slave station or receive for reading from it Size data size for reading and writing of the master station can be specified up to 60 WORDs Area tem that is in the master station to t
84. conditions of terminal i Check the distance between solderless block or extension Proper clearance should be provided Correct cable terminals PWR LED Check that the LED is ON ON OFF indicates an error See chapter 11 be Run LED Check that the LED is ON during Run ON flickering indicates an error See chapter 11 ndica ting ERR LED Check that the LED is OFF during Run OFF ON indicates an error See chapter 11 LED Input LED Check that the LEO turns ON and OFF Oh WREN PUES GI See chapter 11 OFF when input is off Output LED Check that the LEO turns ON and OFF T ON See chapter 11 OFF when output is off 10 1 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 Checking Methods Judgment Corrective Actions Ambient 3 temperature Measure with DS Ambient Adjust to general standard thermometer and Environme Ambient Humidity 5 959 RH Internal environmental standard of hygrometer measure nt p control section i There should be no corrosive Ambience corrosive gas gases The module should be move the The module should be mounted Looseness Ingress unit securely Retighten screws Conditions dust or foreign material Loose terminal Re tighten screws Screws should not be loose Retighten Screws Visual check No dust or foreign material Dist
85. d 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 4 Response format NAK response Error code Format name Header Station No Command Command type Hex 2 Byte Fane ASCllvalue H3230 H57 77 H5353 H34323532 H03 Explanation aK When command is lowercase r only one lower byte of the value resulted by adding 1 Byte B each to ASCII values from NAK to ETX is converted into ASCII and added to BCC and sent Hex and 2 bytes ASCII ode 4 bytes indicate error type For the details see 8 1 8 Error Error code codes 8 17 Chapter8 Communication Function 5 Example This example supposes that is written in M230 of station No 1 and BCC value is checked D Computer request format PC K7 Base Unit Command Number of Frame Formatname Header StationNo Command Device Length Device Name Data Tail type blocks check Fane xe w ss H254D5732 ASCll value H3031 H5353 3031 3036 30304646 H04 3330 2 For ACK response after execution of command PC lt K7 Base Unit San Conan ye ack Ex soos em wm 3 For response after execution of command PC lt 7 Base Unit Format name Header Station No Command Command type Error code Frame check Frame Example NAK H01 w Er
86. device as shown 1 External device Input module sjulod 1963005 Sensor Power for Sensor adA jndjno uedo Same power for sensor and input Power for Sensor 2 U 2 e o lt Power for Sensor ed 1ndjno juauno ed jndjno Chapter 6 Input and Qutput Modules 6 2 2 Expansion Module 1 Specifications Module Specteaton Number of input points 6 points Operating voltage range DC20 4 28 8V ripple less than 5 Max Simultaneous input points 100 simultaneously On 15ms or less 1 ts possible to select from 1ms to 15ms by 1ms at KGLWIN Response time 2 Circuit diagram It s the same with the one for the base unit 3 Input wiring Chapter 6 Input and Qutput Modules 6 3 Digital Output Specification 6 3 1 Base unit 1 Specification Specifications G7M DR20A G7M DR30A G7M DR40A G7M DR60A Insulation method Relay insulation Rated load voltage current DC24V 2A r load AC220V 2A COS 1 1 point 5A 1COM Max load voltage current AC250V DC110V Surge Absorber None AC200V 1 54 AC240V 1A 0 7 100 000 or more AC200V 1A AC240V 0 5A 0 35 100 000 or more DC24V 1A DC100V 0 1A L R 7ms 100 000 or more Off 10 ms or less Common method 1 point 1COM 2 points 1COM 4 points 1COM Operation indicatio
87. e Time out in Master Mode 8 73 Chapter 8 Communication Function 8 34 Instruction and example 1 MODBUS Available Device Instruction Step Error Zero Carry K L F110 F111 F112 5 2 o ee IH vous 1 2 s H Device address which is registered communication parameter Device address which is stored communication data ES Device address which is displayed communication status Example program F0012 j MOV h0301 00000 It designates slave station no and function code MOV 0013 00001 It designates address MOV h0025 D0002 It designates no of reading M0020 M0020 turns on MODBUS communication starts MODBUS 00000 D1000 M100 Receive data stores D1000 M100 stores communication status S3 format is as below bit 15 bit 8 bit 1 bito CoE Error code Error bit NDR bit NDR when the communication ends normally this bit tums on during 1 scan Error bit when communication error occurs this bit tums on during 1 scan At that time error code stores bit 8 bit 15 8 74 Chapter 8 Communication Function Error code is as follow 03 07 Error type Function Address Data Value Slave Device Failure Acknowledge Slave Device Busy Time Out Number Error Parameter Error Error in inputting function code in instruction
88. e 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 Timer input condition Timer output relay Preset value PV Current value The accuracy of timer The Maximum timing error of timers of K series is 2 scan time 1 scan time Refer the programming manual for details Chapter5 CPU Module 5 25 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 K series have 4 counter instructions such as CTU CTD CTUD and CTR The maximum counter setting value is hFFFF 65535 The followings shows brief information for counter operation 1 Up counter CTU The counter output relay is turned on when the current value reaches the preset value After the counter relay output is turned on the current value will increase until it reaches the maximum counting value 65535 When the reset input is turned on the counter output relay and current value is cleared as 0 Input condition U Cxxx Reset condition lt S gt XXXX 2 Down counter CTD When the CPU is switched to the RUN mode the current value is set as preset value The current value is decreased by 1 with the rising edge of counte
89. eh hh hh hh hh hehehe hh hh hn 5 6 5 2 6 Counter processing nnn nn 5 8 53 5 10 53 1 configuration Mehrheit hh hn 5 10 5 3 2 Program execution procedure Been hh hh hehehe hh hh 5 11 5 3 3 TasKe Henn 5 14 5 3 4 Error handling Been hh heh hh hh hh hh hn 5 21 5 3 5 Precautions when using special modules 5 22 54 Operation modes HH Hehe nennen nennen nenne 5 23 5 4 1 RUN mode 9 HMM HH 5 23 5 4 2 STOP mode e I 5 24 5 4 3 PAUSE mode MH Hen 5 24 5 4 4 DEBUG mode 5 24 5 4 5 Operation mode Change Mesh hh hh ehh hh hn 5 25 55 Functions em eH Hehe Henne nennen 5 27 5 5 1 Restart mode M 5 27 5 5 2 Self diagnosis Mee hh hh hh hh hh hh hh hh hn 5 29 5 5 3 Remote function e n MM 5 29 554 1 0 Force On Off function e M MM teens 5 30 5 5 5 Direct operation function m 5 31 5 5 6 External device error diagnosis functione M 5 32 56 Configuration 5 34 57 I O No Allocation Method HMM 5 36 5 8 Built in Flash Memory Baek 5 35
90. elect from 1ms to 15ms 1ms at KGLWIN Response time 2 Circuit diagram Input no P000 P002 Internal circuit Internal circuit h 6 Input and Output Modules 3 Input wiring Base unit s wiring method is as follows DC input specifications offered by K80S is to be used for both electric current sink and electric current source 1 20 points base unit Ta av 7a an anan HMAS eb zi RUN per NARS guau AN d ERE RE K7M DR20S PROGRAMMABLE CON TROLLER 2 30 point base unit EBIB E D pes ui 2 zH D 7 e KE C h 6 Input and Output Modules 3 40 point base unit BULT AN CNET STOP m AI pres e a POE P10 Pie 4 60 point base unit BE Ta Taal m 199 LLL 1 PAU REM T SEDED 91 QIN KP NM L LL roo roz phe va To 59 E Chapter 6 Input and Qutput Modules 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
91. eleration is 2 Remark If the acceleration slop goes bigger the increasing time and pulse go bigger by direct proportion to inclination Then be careful of an occurring of the instruction error when the no of a d pulse becomes bigger than the no of whole pulse 7 1 8 Chapter 7 Usage of Various Functions 8 instruction Available Device Steps Instructions Inte Emor Zero ger F110 F111 F112 M P K L F T C S D D DUTY sl fot ee PLSOU D 5 5 Output pulse count no Output pulse contact 1 Functions A designates pattern no which is registered at parameter 91 designates device name which will be stored output pulse count no and error code 3 word S2 designates output device output P area 2 example of program M002 0 PLSOUT 5 00000 P0040 when the M0020 is jit outputs the pulse at 5 pattern to P0040 It stores the output pulse count no at D0000 and D0001 It stores error information at 00002 All output area is designated for pulse output contact but it t designate over 2 contact at the same time 7 19 Chapter 7 Usage of Various Functions 3 instruction Error List Error status Contents Treatment Noma Other PLSOUT instruction pulsating Change the other PLCOUT program Velocity designation error more than 2000 not a 02 Velocity designation adjustment multiple of 50 de
92. emporarily that is the slave station for the data to Area from save the data to be written be read that is in the master station to temporarily Area to that is in the slave station to write the data save the data to be read 8 35 Chapter8 Communication Function 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 Each device contains the Information of 2 station The information of each station is C es oua 25 saved in tbyte Error code Error code Contents Remarks 1 Timeout error for response 2 Received NAK 2 Sending receiving error contents of each station total 32 stations Error count number is saved following area according to station Station Device Station Device Remarks 0 1 D4416 16 17 D4424 2 3 04417 18 19 04425 Each device contains the Information 4 5 D4418 20 21 D4426 of 2 station 6 7 D4419 22 23 04427 The information of each station is 8 9 D4420 24 25 04428 saved in byte 10 11 D4421 26 27 D4429 12448 04422 28 29 04430 14 15 04423 30 31 04431 3 Slave PLC mode and error contents of each station total 32 stations Error Information of PLC is saved following area according to station Each device contains the Information of 2 station The information of each station is pums Dmm sevedintbyte
93. en an offset remains after the system is stabilized the PV can be reached to the SV by adding a certain value This value is called as bias value and user can define the bias value 7 27 Chapter 7 Usage of Various Functions SV Nf NSA SLL Fig 2 2 When the proportional constant Kp is large PV Olfset Fig 2 3 When the proportional constant Kp is small b Integral operation operation 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 The period of the time from when the deviation has occurred in action to when the MV of action become that of P action is called Integration time and represented as Ti 7 28 Chapter 7 Usage of Various Functions b c d Integral action when a constant deviation has occurred is shown as the following Fig 2 4 Deviation MV of P action action of D action Fig 2 4 The integral action with constant deviation The expression of action is as following PP Edt Ti As shown in the expression Integral action can be made stronger
94. g 2 11 the small reference value produces small deviation value and it makes the control system response be slow In general control system is required to be adaptable to various external internal changes Especially it should shows a stable transient response with the sudden change of the SV to be robust to load disturbances and or measurement noise PV Time Figure 2 11 The PI control with several reference values 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 When the control action is used the deviation term is integrated continuously It makes the output of control action very large especially when the response characteristic of system is slow This situation that the output of actuator is saturated is called as windup It takes a long time that the actuator returns to normal operating state after the windup was occurred The Fig 2 12 shows the PV and MV of PI control system when the windup occurs As shown as the Fig 2 12 the actuator is saturated because of the large initial deviation The integral term increase until the PV reache
95. ge solenoid current 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 The off response time can be delayed by one or more second as some loads make the current flow across the diode at the off time of the transistor output Output Surge current of the white lamp To suppress the surge current make the dark current transistor is of 1 3 to 1 5 rated current flow destroyed Output Outp 3 i NI Sink type transistor output A surge current of 10 times or more when turned on Source type transistor output 11 11 Chapter 11 Troubleshooting 11 5 Error code list Error Code Message CPU state Message Cause Corrective Actions Internal system Fault of some area of operating ROM Program RAM 0005h error Stop PGM RAM Error Program RAM is defected Contact the service center Defect of dedicated LSI for sequence 0006h Gate array error Stop G A Error instruction processing Contact the service center 0007h Stop Sub Power Error Extension Rack Power down or Error eee of the Turn the power off and 0008h OS WDT error Stop OS WDT Error CPU OS watch dog error restart the system Contact the service center Common RAM error Check the fuse LED of the 000 Fuse break error Continue VO Fuse Error Break of fuse used in output units or unit Turn the powe
96. hapter 7 Usage of Various Functions E pV gt Kx Td Actuator model TE 1 Tt Fig 2 13 The block diagram of anti windup control system Es Fig 2 14 The PV output characteristics with different Tt values 2 Realization of PID control on the PLC In this chapter it will described that how to get the digitized formula of the and terms Then the pseudo code of PID control will be shown P control The digitized formula of P control is as following xSV n PV n n sampling number K proportional gain constant b reference value SV set value PV present value control The continuous formula of control is as following e s ds I t integral term proportional gain constant Ti integral time e s deviation value By deviation about t we can obtain 7 35 Chapter 7 Usage of Various Functions d M SV PV deviation value dt Ti The digitized formula is as following In D IQ _ A ot h sampling period h Ti I n 1 2 Eo D Ti c D control The continuous formula of derivative term is as following d d dt dt N high frequency noise depression ration the object to be controlled PV The digitized formula is as following Use Tustin approximation method 21d hN 2 D n D n 1 y n D 2Td hN 2Td hN d Pseudo code of P
97. he Debug mode Scan run Turns on when the scan run is operated in the Debug mode F0023 Coincidentjunction value run Turns on when the coincident junction run is operated in the Debug mode F0024 Coincident word value run Turns on when the coincident word run is operated in the Debug F0030 Turns on when a EE EE error has occurred Ordinary error Turns on when an SEA ST error has occurred F0033 combination error Turns on when an I O error has occurred m EN When one or more bit s of F0040 to FOOSF turns on value Fuse error Turns on when a fuse of output modules has been disconnected F0039 Normal backup operation Turns on when the data backup is normal RTC data error Turns on when the RTC data setting error has occurred During program edit Turns on during program edit while running the program F003C Program edit error Turns on when a program edit error has occurred while running the 2 1 Appendix 2 Flag List Continued Relay Function Description When the reserved module set by the parameter differs F0040 to F005F error from the real loaded module or a I O module has been mounted or dismounted the corresponding bit turns on F0060 to FOO6F Storing error code Stores the system error code See Section 2 9 F0070 to Storing the disconnection state of When a fuse has disconnected in an output module the fuses corresponding bit to the s
98. he END processing is finished When the END instruction has not been executed within the set value due to an error occurred in the PLC or the long scan time of a sequence program the watch dog timer will times out When a watch dog timer error is occurred all outputs of the PLC are turned OFF and the ERR LED of the CPU will flashes RUN LED will be turned OFF Therefore when use FOR NEXT or CALL instruction insert WDT instruction to reset the watch dog timer 3 Battery check function When the voltage of the battery for back up the memory IC of CPU are lower than the minimum back up voltage the BAT LED of CPU module will be turned on 5 19 Chapter 5 CPU Module 5 5 2 Force On Off function It is possible to input output a designated data regardless of the result of program operation This function is useful to check operation of the input output modules and wiring between the output modules and external devices 1 Force On Off setting method Force on off setting is applied to input area and output area 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 This setting can be done when modules are not really loaded Select the set forced I O from KGLWIN Click Select the I O area and then double click ot t tz t K m hh ms mh msn nn tnm oft n m n t n mih m hmm sm hh nh sm t t t 0 n m n
99. ies capitals or small letters for main commands but not for the others 2 If it a main command in capitals it calculates BCC value But if it s not it doesn t Therefore when for frame check is used main commands must be in small letters 8 7 Chapter8 Communication Function 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 1 Data type of variable e Available types of device P M L K C T D S F e When variable is used attach 25H in front of the marking characters Data pe Marking characters X 58H 9 PX000 MX000 LX000 KX000 CX000 TX000 FX000 57H 9 PWO000 MWO000 1000 KW000 CW000 TW000 Word W 57H FWO000 DW000 SW000 e avaiable oo o Available Avail Data Register Available Word Only Step relay Available Word Only Special relay Read Only Both 1 Timer Counter used in word command means current values Remark 2 Data register and Step relay can uses only word commands 3 When Link module is used Link relay must not written it cause communication error 8 8 Chapter8 Communication Function 8 1 6 Execution of commands 1 Individual reading of device RSS 1 Introduction This is a function that reads PLC device specified in accord with memory data type Separate
100. inal fork shaped 6 2mm less 9 1 1 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 Check Items Judgment Corrective Actions Temperature 0 55 Adjust the operating temperature and humidity Ambient Humidity 5 9595 RH with the defined range environment TTT Vibration No vibration Use resisting rubber or the vibration prevention method Play of modules No play allowed Securely enrage the hook Connecting conditions of 9 No loose allowed Retighten terminal screws terminal screws Change rate of input voltage 15 to 1096 Hold it with the allowable range Check the number of Spare parts Spare parts and their Cover the shortage and improve the conditions Store conditions 10 2 Daily Inspection The following table shows the inspection and items which are to be checked daily Corrective Check Points Judgement Actions check for loose mounting screws Screws should not be loose Retighten Screws Check Items Connecting
101. ints Auxiliary relay ints ints ints 0 5usec step 000 P13F relay 100msec 000 T191 192 points Timer 10msec T192 T255 64 points 3 device _ __ _ mmsoeeusou Detect errors of scan time memory I O battery and power supply Bae ____ _ 5 1 Chapter 5 CPU Module Specifications K7M DR20S K7M DR30S K7M DR40S K7M DR60S PID control function Function block control auto tuning forced output adjustable operation scan time forward reverse operation control Cnet I F Function Master K exclusive protocol suppor Common use with MODBUS protocol support KGLWIN port User s protocol support Capacity 1 phase 16 kHz 1 channel 2 phase 8 kHz 1 channel Counter function has 3diffferant counter function as following 1 phase up down by program 1 phase up down by B phase input 2 phase up down by phase difference Multiplication Multiplication 1 2 or 4 adjustable function Data comparison Execute a task program when the elapsed counter value reaches to the function preset value Pulse catch Pulse output 2khz Transistor output only moras woes fost oroa ws Chapter5 CPU Module 5 2 Operation Processing 5 2 1 Operation Processing Method 1 Cyclic operation A PLC program is sequentially executed f
102. ist window which is designated 8 60 Chapter 8 Communication Function BCC Setting method is same frame 0 After the frame setting and BCC setting completes click the OK button You can see the frame list window which is designated as below 8 61 Chapter 8 Communication Function User Define OOP Program New Projecti INCP 000 MOVP mooo 204 004 0092 008 00000 100 00000 INCP 00001 When the data is received at frame no 1 link relay L001 tums 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 0000 When error occurs the number of sending error stores D001 When data is received K7 search the same protocol at frame list automatically Therefore K7 has not receive instruction If the same protocol exist K7 receive the data at the upper frame number Chapter 8 Communication Function 2 Setting and program of slave station Make the new project file and setting new parameter Click the list after set the communication method and communication channel Double click the frame list number 0 8 63 Chapter 8 Communication Function NONE 2 ni 55 input NO
103. ith the manual Syntax error Ex1 When use device Check if the system stopped like MX100 in RSB command reset Syntax error OVER RUN FRAME error Be familiar with the manual Confirm the setting of the communication H6020 error TIME OUT error ports of RS 232C reset H6030 Syntax error in commands Check if each sends frame has ENQ EOT Rearrange send frame not to go over 256 H6040 Syntax error When a FRAME text exceeds over 256 bytes bytes stare heat 800 ig 8 46 Chapter 8 Communication Function 8 2 User Defined Protocol Communication 8 2 1 Introduction User Defined Protocol Communication allows users who do communication between K7 Basic Unit and other kind of device to define the other company s protocol at Kseries PLC Ther re a number of kinds of protocols made by many companies that it s difficult to have all protocols in it So if a user defines a protocol that can be applied to his her purpose K7 Basic Unit executes the communication with the other kind of device through the defined protocol For this protocol frame must be defined in KGLWIN Version 2 0 or higher And exact knowledge about the contents of the protocol defined by the user is vital in making the communication possible KGLWIN Version 2 0 or higher can download a user defined protocol frame into K7 Basic Unit and it is saved it is not erased by power s offfon But protocol frames are d
104. k is rising edge off gt on PID operation executes at no 2 parameter e PID execution status stores 00000 and the output value of control result stores 00001 and P I D constant sequentially store D003 D004 D005 bE bD bC bB b9 b8 b7 b6 b5 b4 b3 b2 b1 D0000 Auto tuning end bit 4 l Done normal execution signal 7 4 2 Chapter 7 Usage of Various Functions 6 Program Example System configuration G7F ADHA K7 Base unit KGLWIN V2 0 or later MV DC4 20mA RS 232C 1 54 PV DC4 20mA 1 5V Temp Sensor Electric oven 0 200 Transformer 2 Initial setting a PID operation parameters Auto Manual operation setting Auto Forward Reverse operation Forward SV setting 960 60 C 1120 70 C 1280 80 1600 100 Current value setting D4980 AD conversion value of AD module Ch1 BIAS setting 0 If only P control is used input proper value other 0 EN P EN EN D setting Pz1 EN 1 1 EN_D 1 PID operation REF 10 TT 50 1 MV_MAX MV_MIN MVMAN MV_MAX 4000 MC_MIN 0 MAMAN 2000 S_TIME S_TIME 100 sampling time 10 seconds b Auto tuning parameters PV setting 960 60 C 1120 70 C 1280 80 C 1600 100 C S_TIME S_TIME 100 sampling time 10 seconds Current value setting D4980 AD conversion value of AD module Ch1 wave select designation value 1 c A D module setting Channel setting
105. lave Device Busy It s sending or waiting to receive 09 Parameter Eror Communication parameter setting error Link enable setting error Frame Type Error Frame does not setting or frame does not sending 8 57 Chapter 8 Communication Function 8 2 4 Example of Use 1 This example is supposed that there s a communication between MK80S s by the user defined protocol The system configuration is as follows and the cable is the same with the one of 1 1 dedicated protocol communication 7 base unit 7 baseunit Master Station no 0 Slave Station No 1 1 1 dedicated protocol communication between K7 s The data in M area of the master station is sent to the slave station and the slave station saves the received data in M area outputs as direct variable and sends the data back to the master This process repeats between the master and the slave 8 58 Chapter 8 Communication Function 1 The Programming and setting communication parameter of the master station 1 Select the communication parameter and then select communication method and communication channel And then select user Defined at protocol and mode item list item is activated Click the list Double click the number 0 8 59 Chapter 8 Communication Function NONE gt X SII nut EOTIBCC BCC Seina Designate BCC Setting as above Click the OK button and then you can see the frame l
106. les or other lines which may generate noise NE 3 Before applying a power source for pulse generator be sure to use a noise protected power supply 4 1 phase input connect the count input signal only to the phase input for 2 phase input connect to phases and B 6 Wiring example Voltage output pulse generator 24V Pulse Generator 2 open collector output pulse generator 24V Pulse Generator 7 3 Chapter 7 Usage of Various Functions T Instruction When use the built in high speed counter of K80S the HSC instruction should be used The instruction format of HSC is as following When the value of operation mode 04999 PV or SV is not proper the instruction error flag F110 turns and the HSC instruction is not executed Operation mode Input terminal Multiplication 04999 i Description U D Set by sequence program h1000 Pulse y seq prog input PR Set by sequence program U D Set by sequence program h1010 Preset input i E input PR Set by preset input dico U D Set by U D input Se inpu n1100 Wp input input PR Set by sequence program U D Set by U D input h1110 Pulse U D input Preset input d Set by preset input input input A phase B phase 2 phase Preset PR Set by sequence program 1 multiplication PR Set by sequence program 2 multiplica
107. llation installation Indicates power supply to the system PWR LED e On When the supply is normal Off When the supply is abnormal Indicates base unit operation 1 Chapter 4 Names of Parts Indicates base units drive mode RUN Indicates program operation STOP Stopped program operation PAU REM usage of each modules are as follows gt PAUSE temporary stopping program operation gt REMOTE Indicates remote drive era Oe ee mmr Key switch mode creation ACO ZAV Pat P42 P44 Chapter 4 Names of Parts 4 1 2 30 points base unit K7M DR30S PROGR AMMABLE K7M DR4DS PROGRANNABLE K7M DR60S PROCRANNABLE Chapter 4 Names of Parts 4 2 Expansion Module 4 2 1 Digital Module 4 2 2 AID D A Combination Module je 9 Analog Input Voltage current selecting jumper pin Mw Chapter 5 CPU Module Chapter 5 CPU 5 1 Specifications The following table shows the general specifications of the K7 series Specifications Remarks K7M DR20S K7M DR30S K7M DR40S K7M DR60S Cycle execution of stored program Time driven interrupt Process driven Program control method interrupt control method Indirect mode Refresh method Direct by program command Mnemonic Ladder diagram OO Pomos mese 00 e e 40 M000 M191F 3 072po
108. lot turns on F0090 20 ms cycle clock F0091 100 ms cycle clock Turning On Off is repeated with a constant cycle F0092 200 ms cycle clock F0093 1 sec cycle clock Off F0095 10 sec cycle clock F0096 F0097 F0098 to F009F F0100 User clock 0 Turning On Off is repeated as many times as the scan specified F0101 User clock 1 by Duty instruction i 0103 User clock 3 N2 scan Off F0104 User clock 4 F0105 User clock 5 F0106 User clock 6 N1 scan Off F0107 User clock 7 F0108 to FO10fF F0110 Operation error flag Turns on when an operation error has occurred F0112 Carry flag Turns on when a carry occurs due to the operation F0113 All outputs off Turns on when an output instruction is executed F0114 Common RAM R W error Tums on when a memory access error of the special module has occurred F0121 Turns on if S lt 5 when using the CMP instruction F0124 GTE flag Turns on if S gt 5 when using the CMP instruction App2 2 Appendix 2 Flag List liens Relay Function Description F0140 to F014F FALS No error code generated by FALS instruction is stored to flag F0150 to F015F PUT GET error flag When a common RAM access error of special modules has occurred an output module the corresponding bit to the slot on F180 to F19F Current value of high speed the current value of high speed counter counter F18 lower word F19 upper word F200 to F49F F0500 to FO50
109. m error history When the system is stopped by error occurrence the CPU stores the error occurrence time and error code to the special data register area The most recent 16 error occurring times and error codes are stored in the special data register 1 Special data register for error history D4901 D4904 The latest error information D4905 D4908 The 24 latest error information 04961 04964 The 16 latest error information Device 2 Description of each word Contents Description D4901 D4902 D4903 D4904 3 Clear error data Use a data cleat function of KGLWIN or KLD 150S 5 23 apter5 CPU Module 5 6 Memory Configuration P00 P13 M000 M189 M190 M191 K00 K31 F00 F63 LOO L63 T000 T191 T192 T255 C000 C255 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 stores data during operation Bit Data Area Auxiliary relay 3 040 points Special auxiliary rela 32 points Keep relay 512 points Special relay 1 024 points Link relay 1 024 points Timer relay 100ms 192 points Timer relay 10ms 64 points Counter relay 256 points D0000 D4500 T000 T255 T000 T255 C000 C255 C000 C255 S00 599 Word
110. m n Dr LI 5 20 5 CPU Module Set forced O by bit Set forced I O data enabl by bit When forced I O set enables forced I O function is executing Click 5 21 Chapter5 CPU Module 2 Special data register for forced set 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 All Forced I O enable M1910 Forced I O enable by bit D4700 D4731 Forced I O set data D4800 D4831 3 Force on off Processing timing and method 1 Force Input After data have been read from input modules at the time of input refresh the data of the junctions which have been set to force on off will be replaced with force setting data to change the input image area And then the user program will be executed with real input data and force setting data 2 Force output When a user program has finished its execution the output image area has the operation results At the time of output refresh the data of the junctions which have been set to force on off will be replaced with force setting data and the replaced data will be output However the force on off setting does not change the output image area data while it changes the input image area data 3 Force on off processing area Input output areas for force on off setting are larger than the real I O areas If remote I O is specified using
111. mber the user can set any value to do masking Sets any value and method of masking Mask Ex1 When masking by XOR method using a value FF Ex2 When masking by OR method using a value When masking by AND method using a value HFF amp FF Xx Keys on Keyboard for setting masking method 6 1 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 01 0 When frame receiving is done K7 base unit check if ther s any match between the received frame and the declared frame in frame list If there is let the Link relay L n flag blink and save the received data in the assigned area 8 53 Chapter 8 Communication Function BCC calculation example When frame is set as below the result of calculation is as follow Header Tx Fix write Segment 1 Segment 5 Type const fiz Type NONE C ASCII Input C ASE Segment 2 Segment Type NONE NONE c e Segment 3 Segment 7 Type NONE EE Type NONE cmi Segment 4 Segment 8 Type NONE s a Type NONE conr
112. mmunication Function 3 Response Format ACK response Stan Coma ype meme xk wo wo s ex esca He 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 4 Response Format NAK response Error code Format name Header Station No Command Command type Hex 2 Byte Frame Example ENQ H10 W w H1132 ASCIIvalue H05 H3130 H57 77 H31313332 Expanao 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 Hex and 2 bytes ASCII code 4 bytes indicate error type For the details see 8 1 8 Error Error code F codes 8 20 Chapter8 Communication Function 5 Example This example supposes that 2 byte HAA15 is written in 0000 of station No 1 and value is checked D Computer request K7 Base Unit Station Command Device Number of Frame Formatname Header Command Device Data Tail No type Length data check ena w se 414131353 ASCllvalue 05 H3031 H77 H5342 H3036 H254457303030 H04 0353646 2 For ACK response after execution of command lt K7 Base Unit m Conan ye Fane rage aSCll
113. mmunication between GM7 s HMM 8 30 8 1 8 Error Codes n 8 48 82 User Defined Protocol Communication 8 50 8 2 1 Introduction mmm 8 50 8 2 2 Parameter Setting mmm 8 51 8 2 3 Function Block e HMM 8 58 8 24 Example of Use 1 sme 8 59 8 2 5 Example of Use 2 8 76 8 3 Modbus Protocol Communication 8 85 8 3 1 Introduction eee eee ee ee ee 8 85 8 3 2 Basic Size 8 85 8 3 3 Parameter Setting eee 8 89 8 3 4 Function Block 8 91 8 3 5 of Use
114. n which is designated at parameter Chapter 7 Usage of Various Functions 7 1 6 External Interrupt Function In K7 Series can perform max 8 points of external contact interrupt by using input of base unit without special interrupt module 1 Usage This function is useful to execute a high speed execution regardless of scan time 2 Operating explanation External input signal End the interrupt program process then resume to execute scan program Scan program In case of occurrence of external pd interrupt signal pause being executed Scan program and process interrupt program External contact interrupt program 3 Function 1 Max 8 points can be used to external interrupt input within P000 P007 2 Inputting 8points of base unit are set functions like following A phase B phase Preset High speed counter Input Input Input External interrupt 8points are available 8 Max 8points of external contact interrupt are available to use But the no of them is decreased by using other interrupt time driven interrupt 7 48 Chapter 7 Usage of Various Functions 4 Designate contact point no of priority and movement condition of the task program which is moved by interrupt inputting Time driven Interrupt E execution periodic set interrupt input executing condition Ri si ng Falli ng Ri si ng Falling interrupt input contac
115. n LED is on at on status of output Electrical Response time 2 Circuit Internal circuit 6 Input and Output Modules Chapter 3 Output wiring 1 20 points base unit wy DC24V AC110 220V DC5V 2 30 point base unit K7M DR30S AC110 220V DC24V DC5V Chapter 6 Input and Qutput Modules 3 40 point base unit 240 Pan Pay qP47 Pa T Savoy Comicon 2 P43 p45 047 dw P48 CONS p40 4 60 point base unit 7 06605 PROCRAMMABLE DC5V DC24V AC110 220V DC24V 461072401 T P42 P44 P4G T Pic 11 LS COND COMUNE 547 i RING 845 DC5V DC24V AC110 220V DC24V DC24V Chapter 6 Input and Qutput Modules 6 3 2 Expansion Module 1 Specifications Specifications Output point 4 points Insulation method Relay insulation Rated load _ Voltagelc rrent DC24V 2A r load AC220V 2A COS 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 Onoff frequency 1 200 hr Surge Absorber None Mechanical More than 20 000 000 Rated on off voltage current load 100 000 or more AC200V 1
116. n program can be executed by setting the execution condition The user can set variously the program execution mode 1 3 Chapter 1 General 1 3 Terminology The following table gives definition of terms used in this manual Definition Example CPU module Power Supply module module A standard element that has a specified function which configures the system Devices such as I O board which inserted onto the mother board or base unit A single module or group of modules that perform an independent Operation as a part of PLC system A system which consists of the PLC and peripheral devices A user program PLC system can control the system A peripheral device for the MASTER K series It executes program creation edit compile and debugging A computer software for Windows 95 98 A hand held loader used for program creation edit compile and debugging KLD 1508 for MASTER K series Image Area Internal memory area of the CPU module which used to hold I O statuses Supervisors the pre set execution times of programs and warns if a Watch Dog fimer program is not completed within the pre set time Abbreviation of the word Factory Automation Monitoring S W It is used to call S W packages for process supervision Fieldbus network Computer network RS232C RS422 485 Abbreviation of Real Time Clock It is used to call general IC that contains clock function 1 4 Chapter
117. o be as follows and the data that are read is saved in M015 Status X X of tf 1 f _ 3 Status 1 t t 1 f o0 EH A C The status of input contact 10219 10220 are redundancy Data is sent starting from the low bit by byte unit If the deficient bit of a byte is filled with 0 An example of sending the above data is as follows Example 1 DB 35 Program tz Program Auto Saved Project 5 Bi mi N MODBUS 0000 It designates slave station and function code No of station h11 17 function code h02 2 Address setting Address 0 at MODBUS protocol means address 1 actually So if you want to designate address 10197 write address 10196 3 Reading number setting Reading number is 22 from 10197 to 10220 4 This is MODBUS Communication instruction The data transmission starts lower byte The remnant part of byte is filled with 0 Example 2 AC DB35 Stored data at D200 D201 Stored data D200 AC DB D201 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 inst
118. of miss operation and out of order 2 Wiring example 7 Analog input Voltage input Current input Terminal Terminal Current output 1 NC less than E cem il l Wz 1 Be sure to use two core twisted shield wire Be careful to use that analog output is 1 channel 7 5 4 Chapter 7 Usage of Functions 7 converstion characteristics 1 Analog input characteristics Voltage input Digital output value 9 gt a a 5 2 o T Di a 5 0025 77 5V 10V Input voltage Analog input voltage conversion characteristics voltage input In voltage input digital amount 0 is output by OV input and 4 000 is output by 10V input Therefore input 2 5mV equals to digital amount 1 but value less than 2 5mV cari t be converted b Current input Digital output value Digital oytput value lt o 10 mA Analog input current Input Current A D conversion characteristics Current input Current input OmA becomes output 0 10mA does 2000 and 20mA does 4000 therefore input 5 A equals to digital amount 1 but value less tan 5 wA can t be converted So abandon it 7 55 Chapter 7 Usage of Functions 2 Analog output characteristics a Voltage output 9 o o gt 2 J 2 E gt 2 o lt c lt Analog output voltage 2000 20012002200 200 200 2000 Digital input Digital inp
119. of parts Stepping motor AC100 240V l Output direction Output pulse JUUL No Terminal No Names Usage P40 Pulse output Pulse output terminal of right direction P41 Direction output Direction output terminal COMO Direction output common terminal Remark If the motor drive is not input direction but is input right opposite direction pulse the opposite direction pulse can be output through using 2 instruction PULSOUT to P41 contact point 7 13 Chapter 7 Usage of Various Functions 4 Internal circuit and external wiring 12 24V power supply input 12 24V 9 DO P40 pulse output P41 direction output COMO output common Internal circuit K7M DT30S Motor Transistor output driver 24V power supply external wiring Remark Be careful about the counter plan of the noise during the wiring in the pulse output 1 Use twisted pair shields wire for wiring and execute 3rd contact point 2 Be sure to separate from the power supply line and I O lines on which noise usually occurs 3 Length of wire should be as short as possible 4 Be sure to use the stable power supply for the pulse output and separate it from I O power supply T 14 Chapter 7 Usage of Various Functions 5 The setting of pulse out parameter The setting of pulse out parameter set KGLWIN Setting windows is as below ehem stis hes ccoocoooooococdoc ccccoooococococo
120. og Timer 1 Watchdog timer is used to detect a delay of abnormal operation of sequence program Watchdog time is set in menu of basic parameter of KGLWIN 2 When watchdog timer detects an exceeding of preset watchdog time the operation of PLC is stopped immediately and all output is off 3 If an exceeding of preset watchdog time is expected in sequence program use WDT instruction instruction make elapsed watchdog time as zero 4 In order to clear watchdog error restarting the PLC or mode change to STOP mode are available REMARK Setting range of watchdog 1 6 000ms unit 10ms Chapter 5 CPU Module 5 2 5 Timer Processing The K series uses up count timers There are 5 timer instructions such as on delay TON off delay TOFF integral TMR monostable TMON and re triggerable TRTG timer The measuring time range of 100msec timer is 0 1 6553 5 sec and that of 10msec timer is 0 01 655 35 sec Please refer the programming manual for details 1 On delay timer The current value of timer starts to increase from 0 when the input condition of TON instruction turns on When the current value reaches the preset value the timer output relay turns on When the timer input condition is turned off the current value becomes 0 and the timer output relay is turned off Timer input condition Tp SR cst 5 Timer output relay Preset value PV Current value 2 Off delay
121. oller gets a sampling data from actuator is changeable for optimizing to the system characteristics Manual MV Manipulation Set Value PID value En calculation module Present Value Figure 1 1 Block diagram of PID control system 7 26 Chapter 7 Usage of Various Functions 2 Specification 1 Control operation Proportional operation P operation a P action means a control action that obtain a manipulate value which is proportional to the deviation E the difference between SV and PV b The deviation E is obtained by multiplying a reference value to the actual difference between SV and PV It prevents the deviation from a sudden change or alteration caused by external disturbance The formula of deviation is as following Kpx bx SV PV Kp the proportional constant gain b reference value SV set value PV present value c When E happens MV by P operation is like Fig 2 1 Time Time Fig 2 1 MV by P operation d Kp is too large the PV reaches to the SV swiftly but it may causes a bad effect like oscillations shown in the Fig 22 e Ifthe Kp is too small oscillation will not occur However the PV reaches to the SV slowly and an offset may appear between PV and SV shown in the Fig 2 3 The manipulation value MV varies from 0 to 4 000 User can define the maximum value of MV MV MAX and minimum value MV MIN within the range 0 4 000 g Wh
122. peration enable disable For detailed operation method refer to the KGL WIN User s Manual Chapter 9 Debugging 5 4 5 Operation mode change 1 Operation mode change methods The following method is used to change the operation mode 1 Change by the mode setting switch of CPU module 2 Change by the KGLWIN connected with the CPU module communications port 3 Change by the KGLWIN connected to the remote CPU module through Cnet 4 Change by the STOP instruction during program execution 2 Operation mode change by the mode setting switch of CPU module The following shows the operation mode change by the mode setting switch of CPU module PRU teat RUN PAU REM Local RUN PAU REM 2 Local PAUSE PAU REM STOP Local STOP REMARK 1 1 If the operation mode changes from RUN mode to local RUN mode by the mode setting switch the PLC operates continuously without stopping 5 17 Chapter 5 CPU Module 3 Remote operation mode change 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 the STOP PAU REM Mode change using Mod tti Mode ch by th x M Mode Change pub ie s FAM or computer link switch position KGLWIN Remote STOP Remote RUN ERE EN ERE RE Remote STOP Remote PAUSE x O O Remote STOP gt DEBUG Remote RUN Remote PAUSE Remote RUN Remote STOP li o o Remo
123. peration with PID parameters that are calculated by A T module D A module will convert the MV 0 4000 to analog signal 4 20mA and output to the actuator power converter G7F ADHA module is supplied 2channels for A D exchange and channel for D A exchange module 7 44 Chapter 7 Usage of Various Functions 4 parameter setting and Program a case of using PID function only PID Cal Item Edit a gt mu 00200 00000 gt 20000 PID execution completes at 10 second each time At that time bit 0 of D200 turns on and output MV value F095 is 10 second clock PID execution scan time is equal to input clock certainly Data move for SV setting value This value is moved before the PID instruction execution 7 45 Chapter 7 Usage of Various Functions b In case of using combined function of PID operation and Auto tuning This program is an example of PID operation performing with computed P 1 D values by the auto tuning performing It is performed in 80 of auto tuning SV PID process is performed from 80 of SV PID execution scan time should be equal to input clock certainly 5 04980 60000 As a result of PID8AT execution Proportional gain P Differential time D Integral time l are stored D0102 D0103 D0104 Chapter 7 Usage of Various Functions When PID auto tuning ends PID8 and PID8AT input period should be equal to execution scan time M100 turns o
124. possible 6 Do not bundle the 100 VAC and 24VDC cables with main circuit high voltage large current wires or the signal wires If possible provide more than 80 mm distance between the cables and wires T As measure against very large surge e g due to lightening connect a surge absorber as shown below Surge absorber for lightening Remark 1 Ground the surge absorber E1 and the PLC E2 separately from each other 2 Select a surge absorber making allowances for power voltage rises 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 9 9 Chapter 9 Installation and Wirin 9 22 Input and Output Devices Wiring 1 Applicable size of wire to the terminal block connector is 0 18 to 2 mm However it is recommended to use wire of 0 3mm for convenience 2 Separate the input and output lines 3 signal wires must be at least 100 mm 3 94 in away from high voltage and large current circuit wires 4 When the I O signal wires cannot be separated from the main circuit wires and power wires ground on the PLC side with batch shielded cables Under some conditions it may be preferable to ground on the other side Shield cable 5 If wiring has been done with of piping ground the piping 6 Separate the 24VDC cables from the 110VAC and 220VAC cables T
125. power Momentary power failure exceeding 20ms REMARK 1 Momentary power failure The PLC defining power failure is a state that the voltage of power has been lowered outside the allowable variation range of it The momentary power failure is a power failure of short interval several to tens ms Chapter5 CPU Module 5 2 3 Scan Time The processing time from a 0 step to the next 0 step is called scan time 1 Expression for scan time Scan time is the addition value of the processing time of scan program that the user has written of the task program processing time and the PLC internal processing time 1 Scan time Scan program processing time Interrupt program processing time PLC internal processing time Scan program processing time The processing time used to process a user program that is not specified to a task program Interrupt program processing time Total of the processing times of interrupt programs executed during one scan PLC internal processing time Self diagnosis time refresh time Internal data processing time Communications service processing time 2 Scan time differs in accordance with the execution or non execution of interrupt programs and communications processing etc 2 Flag Scan time is stored in the following system flag area F50 Maximum scan time unit 1 ms F51 Minimum scan time unit 1 ms F52 Current scan time unit 1 ms 5 2 4 Scan Watchd
126. quired 5 8 4 Structure You can see dip switches as shown when you open I O terminal block cover BUILT IN CNET Terminal block cover ROM MODE 5 26 Chapter 5__ CPU Module 5 8 2 Usage Set the base unit to the STOP mode Select the Flash memory of on line menu the following window shows Flash Memory 1 read read the program and parameter to CPU memory from fresh memory 2 write write the program and parameter to fresh memory from CPU memory 3 verify verify the program and parameter between CPU memory and fresh memory 5 27 Chapter 5 CPU Module 4 dip switch for operating flash memory Dip switch position Description upper switch is for Cnet ON OFF When power is on the program saved in the flash memory operates ROM MODE Upper switch is for Cnet CPU recognizes that there is no program in the flash memory and starts to ON OFF drive program from RAM ROM MODE REMARKS 1 The flag for flash memory operation is Dip switch for flash memory operation is placed in deep place to prevent a mistaken operation caused by terminal block cover etc Use a small driver to operate it Driver Terminal block cover 5 28 Chapter 5 CPU Module 5 9 External Memory Module 805 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
127. r input signal The counter output relay is turned on when the current value reaches 0 Input condition U CTD Cxxx Reset condition lt S gt XXXX If the retentive counter area is used for down counter the reset input has to be turned on to initialize counter 5 9 Chapter 5 CPU Module 3 Up down counter The current value is increased with the rising edge of up count input signal and decreased with the rising edge of down count input signal The counter output relay is turned on when the current value is equal or greater than the preset value Up Input condition U Down Input condition Reset condition S Xxxx 4 Ring counter The current value is increased with the rising edge of the counter input signal and the counter output relay is tumed 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 Input condition U Cxxx Reset condition lt S gt XXXX 1 Maximum counting speed The maximum counting speed of counter is determined by the length of scan time Counting is possible only when the on off switching time of the counter input signal is longer than scan time Maximum counting speed C max x gt times sec n duty t scan time 2 Duty Duty is the ratio of the input signal s on time to off time as a percentage If T1 lt T2 n iu x100 96 T1
128. r insulation between I O terminals and PLC power supply nsuanon No isolation between channels Connect terminal 9 Points 2 terminals Internal current 20 mA Consumption Common External power DC 21 6 264V 80m upply Weight 240g 1 Offset gain value t be changed it is fixed 2 Analog inputting is set the current since this is manufactured 3 Extend to use max 2 Modules 7 50 Chapter 7 Usage of Functions 2 Names of parts and functions Explain about names of parts and functions Analog input terminal Voltage Input Jumper pin of analog input Voltage Input Right is CH 1selecting Connect upper Connect lower parts by left is 0 selecting Parts by jumper jumper pins pins i gt Only one type of output Current Voltage is available on a module Extension cable gt This cable is used to connect while analog mixture module is used Extension cable connector The connector connects extension cable when extended module is used 7 51 Chapter 7 Usage of Functions 3 parameter setting 4 Reading A D conversion value conversion value stores special data register as following register 5 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 series converts range automatically as
129. r off stop Mixed and replace the fuse 000 Instruction code Stop OP Code Error Instructions unreadable by the CPU Contact the service center error are included during execution Flash memory Read to Write from the inserted Flash Check and replace the 000Ch User Memory Error memory is not performed flash memory Mounting dismounting of I O units CNN UNT during operation or connection fault i 0010h I O slot error Stop Slot Error dafector extension cable restart the system Replace the I O unit or defect extension cable Points of mounted units overrun oo11h Maximum lO Stop MAX I O Error the maximum I O points FMM Replace I O unit error mounting number over error MINI MAP over Common RAM Error Common RAM interface error Contact the service center 0012h Special card Stop Special Error Special Card Interface error Contact the service center interface error 0013h FMM 0 I F error Stop FMM 0 I F Error FMM 0 I F Error Contact the service center 0014h FMM 1 I F error FMM 1 I F Error FMM 1 I F Error Contact the service center 0015h FMM 2 error FMM 2 I F Error FMM 2 Error Contact the service center 0016h FMM I F error FMM 3 I F Error FMM 3 I F Error Contact the service center 0020h Paramore ERE Stop Parameter Error A written parameter has changed or Correct the content of the checksum error parameter When the power is applied or R
130. r time that the deviation occurs gt D action can prevent the large changes of control object due to external conditions b The period of time from when the deviation has occurred to when the MV of D action become the MV of P action is called derivative time and represented as Kd c The D action when a constant deviation occurred is shown as Fig 2 7 Deviation Manipulation quantity in D action 1 Manipulation quantity Time Fig 2 7 Derivative action with a constant deviation 7 30 Chapter 7 Usage of Various Functions d The expression of D action is as following dE Kpx Td dt e Derivative action is used only in PID action in which P and actions combine with D action d PID action a PID action controls the control object with the manipulation quantity produced by P I D action b PID action when a given deviation has occurred is shown as the following Fig 2 8 Deviation PID action action Pl action a P action Fig 2 8 PID action with a constant deviation e Forward Reverse action a control has two kind of action forward action and reverse action The forward action makes the PV reaches to SV by outputting a positive MV when the PV is less than SV b A diagram in which forward and reverse actions are drawn using MV PV and SV is shown as Fig 2 9 ff Reverse action Forward action Fig 2 9 MV of forward reverse ac
131. rd direction pulse and reverse direction pulse through different contact points Forward direction P50 Reverse direction P51 Forward operation Reverse operation Target velocity 1Kpps Forward direction Target position 5000 Reverse dir start point Target position 10000 Reverse direction Forward dir Start point Target velocity 1 Velocity Profile Parameter setting Program F210 turns on while the pulse output is operating 7 22 Chapter 7 Usage of Various Functions 7 1 3 Pulse Catch Function In the base unit 8 points of pulse catch input contact points P000 P007 are internalized Through using this contact point short pulse signal short as 0 2ms 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 But in this case through pulse catch function even narrow interval of pulse signal as 0 2ms min can be detected 2 Operating Explanation input signal input image data step executing contents scan1 CPU senses input when pulse signal min 0 2ms is input then saves the status scan2 used to turn on the region of input image scan3 used to turn off the region of input image 3 using method click twice the basic parameter on the project window of KGLMIN
132. re processed not repeatedly but at every pre set interval Interval in the 805 series can be set to between 0 001 to This operation is used to process operation with a constant cycle 3 Event driven interrupt operation method situation occurs which is requested to be urgently processed during execution of PLC program this operation method processes immediately the operation which corresponds to interrupt program The signal which informs the CPU of those urgent conditions is called interrupt signal The K7 CPU has two kind of interrupt operation methods which are internal and external interrupt signal methods 5 22 Operation processing at momentary power failure occurrence The CPU detects any momentary power failure when the input line voltage to the power supply falls down below the defined value When the CPU detects any momentary power failure the following operations will be executed 1 Momentary power failure within 20 ms 1 The operation processing is stopped with the output retained 2 The operation processing is resumed when normal status is restored at Lg 3 The output voltage of the power supply retains the defined value Input power 4 The watchdog timer WDT keeps timing and interrupt timing normally while the operations is at a stop Momentary power failure exceeding 20ms 2 Momentary power failure exceeding 20 ms The re start processing is executed as the power is applied Input
133. rm auto tuning operation based on the frequency response method PID parameters are obtained by On Off operation during 1 cycle of PV variation The RIPPLE parameter shows at which cycle the CPU module will perform auto tuning operation If 0 is selected the CPU will get PID parameters during the first cycle of PV variation If 1 is selected the second cycle will be used refer Fig 3 1 for detailed information Other choice of RIPPLE parameter is not allowed In general case select 1 for proper auto tuning operation The On Off operation will be occur at the 80 of PV value Perform A T operation at the cycle Perform A T operation at the 2 cycle 80 of PV Fig 3 1 The ripple parameter 7 39 Chapter 7 Usage of Various Functions a Error codes of auto tuning function block PID8AT The following table shows error codes and descriptions of PID8AT instruction Amer gost Description Countermeasure STAT output Normal operation SV is out of range Change the SV within 0 4000 It may caused by fault of A D module Check the A D PV is out of range medie S TIME is out of range Change the 5 TIME within 0 100 Ripple is out of range Change the Ripple to 0 Or 1 7 40 Chapter 7 Usage of Various Functions 2 instruction 1 Instruction Flaa Set Error ai when designation area is over and F110 the instruction isri t executed Designation area Registration No at parame
134. rom 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 This processing is classified into the following stages Operation Start Stage for the start of a scan processing it is executed only one time when the power is applied or reset is executed It executes the Initialization following processing gt reset gt Execution of self diagnosis gt Data clear gt 1 0 address allocation or type Input part conditions are read and stored into the input image area Input image area refresh before start the processing of a program Program is sequentially executed from the first step to the last step Program operation processing Program operation processing Program starts Program ends The contents stored in the output image area 5 output to output part when operation processing of a program is finished Output image area refresh 2 END processing following processing is executed i Self diagnosis END processing Change the present values of timer and counter etc Processing data communications between computer link module and communications module Checking the switch for mode setting 5 3 Chapter5 CPU Module 2 Time driven interrupt operation method In time driven interrupt operation method operations a
135. rom the pulse out function by parameter setting and operate following 3 modes 1 Trapezoidal operation The pulse output function operates in order of acceleration uniform velocity deceleration velocity increasing decreasing 2 Uniform velocity operation Operates with the uniform velocity without increasing decreasing operation velocity time 3 Infinite operation Operate infinitely without an increasing decreasing operation until meet the emergency stop command velocity time 7 11 Chapter 7 Usage of Various Functions 2 Functional Specification E of output 1 point Output type Output velocity Max 2Kpps Min 50pps Output pulse 0 2147483647 Execution type of the increasing decreasing velocity Designation of acceleration Type of the direction designation Right opposite direction pulse output Load power supply DC 12V 24V Usable range of the load power supply DC102 264V Maximum load current 150mA Initiative electric current Less than 0 4A 10ms Maximum power dropdown under On Less than DC 0 5V Electric current leakage under Off Less than 0 1mA On delayed time Less than 1ms Off delayed time Less than 1ms 1 Several points can be used for the pulse output point if they are not output at the same time Thus it is possible that right direction pulse is output as P040 opposite direction pulse is output as P041 7 12 Chapter 7 Usage of Various Functions 3 Names
136. rorcode 2 BCC ascii m ius 8 18 Chapter8 Communication Function 4 Continuous writing of device WSB 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 Comma Number of data Header Command Tail name No nd type Max 128 Byte Frame ENQ H100 W w SB H06 MW100 H02 H11112222 EOT Example ASCII H254D57 H31313131 H05 H3130 H57 77 H5342 H04 value 313030 32323232 1 Number of data specifies the number according to the type of device Namely if the data type of device is WORD and number of data is 5 it means that 5 WORDs should be written 2 Number of data can be used up to 64 Explanation When command is lowercase r only one lower byte of the value resulted by adding 1 Byte each to ASCII values from ENQ to EOT is converted into ASCII and added to BCC Device This indicates the number of name s characters that means device which is allowable up to length Name length 16 characters This value is one of ASCII converted from hex type and the range is from of variable NM Address to be actually read This must be ASCII value within 16 characters and in this evice name digits upper lower case and only are allowable to be entered Remark 1 Protocol of WSB doesn t have the number of blocks 8 19 Chapter8 Co
137. ructions for reliability of the PLC system Wiring Maintenance Chapter 10 Describes the check items and method for long term normal operation of the PLC system and Inspection Chapter 11 Troubleshooting Describes various operation errors and corrective actions System Definition Describes parameter setting for basic and communications module Appendix 2 Flag List Describes the types and contents of various flags Appendix 3 Dimensions Shows dimensions of the main uints and expansion modules REMARK 1 This manual does not describe the programming method For their own functions refer to the related user s manuals 1 1 Chapter 1 General 1 IMO K7 series features 1 Open network by us of communications protocol in compliance with international standard specifications 2 High speed processing with an operation dedicated processor included 3 Various special modules that enlarge the range of application of the PLC 2 MK80S series is extremely compact to fit a wide range of applications 1 High speed processing High speed processing of 0 5us step with an operation dedicated processor included 2 Various built in functions The main unit can perform many functions without using separate modules It is possible to construct various systems just using the main unit e Fast Processing Applications Pulse catch Allows the main unit to read 4 inputs each having a pulse width as small as 0 2ms High speed counter S
138. s input filter 0 15ms all input PID control function RS 232C communication Chapter 2 System Configuration fem ee ere point Digital 1 O module G7E DR10A O Points 6 DC 4 relay outputs AD charnel DIA otam 2channel D A 1 channel Composite module Expansion module Analog timer G7F AT2A Fong 4points module Digital output range 0 200 G7L CUEB RS 232C 1 channel 2 Cnet I F module G7L CUEC e RS 422 1 channel i 2 6 Chapter 3 General Specifications Chapter 3 General Specifications 3 1 General specifications The following shows the general specifications of the K series Specifications Operating ambient 1 0 55 C Operating ambient M 5 95 RH non condensing Humidity Storage ambient 4 5 95 RH non condensing Humidity Occasional vibration Ampitude Storage ambient 2 25 70 C Temperature 10 lt f lt 57Hz 0 075mm 5 Vibrations 57 f 150Hz 9 8 6 1G 3 Continuous vibration 10 times for each X IEC 61131 2 Amplitude Y Z axis 10 lt f lt 57Hz 0 035mm 57 f 150Hz 4975059 e Maximum shock acceleration 147 mis 15G e Duration time 11ms 61131 2 e Pulse wave half sine pulse 3 shocks per axis on X Y Z axis Square wave LGIS Intemal Impulsenoise Standard IEC 61131 2 Electronic discharge Voltage 4 kV
139. s see 8 1 8 Error codes 8 28 Chapter8 Communication Function Explanation PLC status data data Format is 20 bytes in hex Format and converted into ASCII code Its contents are constituted as below table after converting ASCII code into hex data Status data Format Status data order 5 PLC status data Type of CPU Version Number N CPU Mode Reserved o amp 2005 07 K300S KAP 15AS K1000S K7P 30AS Version No Ex Bit 0 0 0 1 0 0 1 0 Indicates Version 1 2 CPU Mode Ex Bit FERES 0 0 0 0 p RUN Mode STOP Mode PAUSE Mode P DEBUG Mode Connection Ex Bit 0 0 E Local Connection Remote Connection 8 29 Chapter8 Communication Function 5 Example This example supposes that the status of K7 Base Unit of station No 1 is read D Computer request K7 Base Unit Sto ascive wv 2 For response after execution of command lt K7 Base Unit Suu conan pe Sas dat See status data Frame Example ACK H01 R r ST ETX BCC Format wem m 3 For response after execution of command lt K7 Base Unit Sao mm imos 2 ASCllvalue H3031 H52 72 H5354
140. s to the SV deviation 0 and then start to decrease while the PV is larger than SV deviation 0 However the MV keeps the saturated status until the integral term is small enough to cancel the windup of actuator As the result of the windup the actuator will output positive value for a while after the PV reached to the SV and the system show a large overshoot A large initial deviation load disturbance mis operation of devices can cause windup of actuator 7 33 Chapter 7 Usage of Various Functions PV SV Time Time MV without windup Integral term Proportional term There are several methods to avoid the windup of actuator The most popular two methods are adding another feedback system to actuator and using the model of actuator The Fig 2 13 shows the block diagram of the anti windup control system using the actuator model As shown in the Fig 2 13 the anti windup system feedback the multiplication of gain 1 Tt and Es to the input of integral term The Es is obtained as the difference value between actuator output U and manipulation value of PID controller MV The Tt of the feedback gain is tracking time constant and it is in inverse proportion with the resetting speed of integral term Smaller Tt will cancel the windup of actuator faster but too small Tt can cause anti windup operation in derivative operation The Fig 2 14 shows several Tt value and PV in the PI control system 7 3 4 C
141. saved Ex 1 When memory type included in variable name of computer request Format is W WORD and data number of computer request Format is 03 data number of PLC ACK response after execution of command is indicated by H06 2 03 06 bytes Byte and ASCII code value 3036 is entered in data area Ex 2 In just above example when data contents of 3 WORDS 1234 5678 and 9ABC in order actual ASCII code converted values are 31323334 35363738 39414243 and the contents are entered in data area 8 14 Chapter8 Communication Function 4 Response format NAK response Error code Format name Header Station No Command Command type Tail Frame check Hex 2 Byte wk wo r se ex pscivaue Domo w H3130 H5342 H31313332 Explanation E When command is lowercase 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 Hex and 2 bytes ASCII code 4 bytes indicate error type For the details see 8 1 8 Error Error code codes 5 Example This example supposes that 2 WORDs from M000 of station No 10 is read and BCC value is checked Also it is supposed that data in M000 and in M001 is as follow 000 H1234 M001 H5678 D Computer request format PC gt 80 Base Unit Command Format name Header Station No Command Device length Devicename Number of data Frame check
142. ser Calculation method is as below The number of acceleration pulse maximum pulse 50 50 maximum pulse 100 50 100 50 50 50 x acceleration slop x 2 ex maximum pulse 1000pps acceleration slop 1 The number of acceleration pulse 1000 50 50 900 50 50 100 50 50 50 x 1x2 380 deceleration pulse is also 380 8 acceleration time Automatically calculate at KGL WIN if the maximum pulse and slop are set by user Calculation method is as below acceleration time maximum pulse 50 50 x acceleration slop x 10 ex maximum pulse 1000pps acceleration slop 1 acceleration time 1000 50 50 x 1 x 10 380ms deceleration time is also 380ms Remark Acceleration slop and deceleration slop ofK7 pulse output are set up as the same Set up proper value by the sort of motor because if a d slop increases the arrival time to the designated max Cycle also increases 7 16 Chapter 7 Usage of Various Functions 7 pulse out operation explanation Condition 1 Set up as acceleration slop 1 max frequency 1000 no of pulse out 5000 If as acceleration slop 1 1 pulse is output on the 1st step velocity 50pps Pulse velocity is 50 so time consuming is 20ms 2 pulses are output on the 2nd step velocity 100pps and time consumes 20ms By calculation in the same way the time to reach to 1000pps is 20ms x 20
143. signated 0 Th f velocity pul bi th f all 03 e no of a c velocity pulse is bigger than no of al Acceleration adjustment pulse is to output No output contact point where is designated to the pulse Output contact point designation output No output contact point where is designated to th i uS dU OTe ae Output contact point designation direction output 7 20 Chapter 7 Usage of Various Functions 9 Output Direction Input type of servo motor driver or stepping motor driver is subdivided into 2 Output direction of control can be selected in the pulse output parameter Selecting method of output direction When driver gets input forward direction pulse and reverse direction pulse contact point and the forward reverse direction signals one levels Output pulse P50 Output dir P51 Forward direction output Reverse direction output Set velocity 1Kpps decelerationslop acceleration slop 1 4 Initial position Set position 5000 velocity Profile Parameter setting Example of a program When the M000 is on direction contact P51 is set and pulse outputs at pattern 0 forward direction output When the M001 is on direction contact P5 is reset and pulse outputs at pattern 0 reverse direction output Be careful If direction bit use another purpose pulse output operates abnormally 7 2 1 Chapter 7 Usage of Various Functions b Driver gets input forwa
144. t No b For the details refer to KGLWIN manual 7 49 Chapter 7 Usage of Functions 7 2 Special module 7 2 1 AID D A Combination module 1 Performance specification The performance specification of the analog mixture module are following Item Specifications Voltage DC0 10V input resistance more than 1 MQ Input range DC 0 20 mA input resistance 250 Classified by Current DC 4 20 mA input resistance 250 parameter 12Bit 48 4047 1 Setting by jumper pin for V I selection on upper part of product Voltage Current Up voltage Down Current selection 2 Voltage current selected by the program 3 When current input is used short the V and terminal 2Channels Voltage Current DC 24 mA voltage DCO 10V External load resistance 2 1 MQ Output range DC 0 20 mA External load resistance 510 Classified by parameter DC 4 20 mA External load resistance 510 12Bit 48 4047 Digital output of channel Absolute max input Digital Input Voltage Current selection No of channel 1Channel Voltage DC 12V Current DC 24 mA Voltage DC0 10V 2 5m 1 4000 Max resolution oren DCO 20mA 5 1 4000 DC4 20 6 25 1 3200 Analog output Separated from terminal Absolute max output Accuracy 0 5 Full scale Max conversion speed 2 ms CH scan time Insulat Photo couple
145. t declare frame format Send It is that declares send frame Receive It is that declares receive frame When Frame 0 window is activated Tx Rx term is set as Not defined and all the segments are not in activation 8 50 Chapter 8 Communication Function Segment 1 8 Enter segment by segment to separate fixed sending data area CONSTANT and device area Array To set a segment type ther re NONE defined CONST fixed data area NONE gt ARRAY Device area CONST declares commands and fixed data that are used for communication frame and ARRAY is used to input and save the data NONE HEX CONST needed for interactive communication ARRAY type must be always set by byte Fees y byt This field is to declare commands and fixed data that wil be used in communication frame and constant data to be declared by inputting ASCII input must be done within 10 characters and hex within 20 characters If the number exceeds the limit set the next segment as the same type and continue to input there an dedicated protocol communication 10RSBO6 MW10006 is frame to execute reading 6 word data from M100 atthe slave station no 16 Ex1 10RSB06 MW10006 Segment 1 Type const 10RSB06 HexInput ASCII Input Size Byte Segment 2 Type 0006 C HexInput ASCII Input Size Byte If the segment is declared as ARRAY type designate tr
146. te RUN gt DEBUG o E O Remote PAUSE gt Remote RUN queo oer Remote PAUSE gt Remote STOP EE e Remote PAUSE gt Remote DEBUG DEBUG gt Remote STOP DEBUG gt Remote RUN DEBUG gt Remote PAUSE 4 Remote operation mode change enable disable It is possible to disable the mode change for system protection so that some parts of the operation mode sources cannot change the mode If remote operation mode change has been disabled the operation mode change is possible only by the mode setting switch and KGLWIN To enable the remote operation change set the parameter Enabling the PLC control by communications to enable For details refer to the Appendix 1 System Definitions 5 18 Chapter5 CPU Module 5 5 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 the PLC power supply is turned on and when an error occurs the PLC is in the RUN state 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 The default value is set as 200msec and it is changeable with parameter setting Refer the MASTER K programming manual for details on the parameter setting The CPU resets the watch dog timer before step 0 is executed after t
147. ter 0 7 execution status registration area PID8 PIDCalculation a Usage e when the condition of execution is on PID operation executes only rising edge condition ri is registration No at parameter 0 7 b Example program F0093 c 2 00000 e When the input condition F0093 1second clock is rising edge off gt PID operation executes at no 2 parameter PID execution status registrate 00000 and the output value of control result registrate 00001 bD bC bB b9 b8 b7 b6 bd 04 b3 b2 b1 MV upper limit E Done normal execution signal MV lower limit 44 7 41 Chapter 7 Usage of Various Functions 2 PIDBAT Fe Step no Error Zero Carry F110 F111 F112 Flaa Set Error It tums ari when designation area is over and F110 the instruction isr t executed Designation area Registration No at parameter 0 7 execuionstatusregistaionarea execution status registration area PID8AT PID auto tuning Calculation a Usage e when the condition of execution is on PID auto tuning operation executes only rising edge condition and calculates P l D constant ri is registration No at parameter 0 7 S1 is execution status and P I D constant registration area b Example program F0093 p MM PID8AT 2 00000 e When the input condition F0093 1second cloc
148. terface 7 base unit Pin assignment and direction Pin no Signal RXD1 Male Type 8 4 Chapter8 Communication Function 8 1 3 Frame Structure 1 Base Format 1 Request frame external communication device K7 base unit Max 256 Bytes Station Command Frame check Command Structurized data area number type BCC 2 ACK Response frame K7 base unit external communication device when receiving data normally max 256 Bytes Station Command Frame check Command Structurized data area or null code number type BCC 3 NAK Response frame K7 base unit external communication device when receiving data abnormally max 256 Bytes Header Command Frame check Station Command Error code ASCII 4 Byte NAK type BCC 1 Used control codes are as follows Be familiar with the following control codes Because they are importantly used for communication Control codes Name Contents Request frame initial code enaren ResponsefomeendngASOlcode NQ CK AK OT ETX 8 5 Chapter8 Communication Function 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 e Station No When the main command is R r or W and the command type is numerical means a data type All of the terms indicating size of all data in the Form
149. tes D area also 7 3 7 Chapter 7 Usage of Various Functions g Proportional gain The 805 can handle only integer not the floating point type Therefore to enhance the accuracy of operation the PID8 instruction is designed to input the GAIN data as the 100 times scaled up For example if the designated P GAIN is 98 actual input data of GAIN should be 9800 If the designated P GAIN is 10 99 input 1099 to the P GAIN h Mode command set In MK80S only the following 4 operation modes are available Other operation modes such as PD or are not END permitted 0 disable P operation Pl operation Hee iei PID operation quem On Off operation Bias value The Bias data is used for the compensation of offset in the proportional control j SV Target SV setting value the designated value and PV process value present value of K7 PID operation have the range 0 4000 The range is set with the consideration of the resolution of A D and D A module of K7 series 12bits and offset value The following table shows error codes and descriptions of PID8 instruction STAT output oo Een Oo OO O O O REF is out of range Change the REF within 0 10 TT is out of range Change the TT within 0 1000 N is out of range Change the N within 0 1000 10 EN and or EN D is set as 1 Only P Pl and PID controls are available Please when EN P is 0
150. the interrupt routine the CPU resume the sequence program from the stopped step K series provides 2 types of interrupt The TDI Time driven interrupt occurs with the constant period and PDI Process driven interrupt occurs with the status of external input Before to use interrupt function in sequence program the parameter setting should be done properly Then the corresponding interrupt routine should be written after END instruction Refer chapter 4 for details If interrupt routines are not matched with parameter settings an error occurs and the operation of CPU will be stopped To execute an interrupt routine use the instruction to enable the corresponding interrupt The interrupt routine is not executed if an interrupt factor occurs before execution of an El instruction Once an interrupt is enabled with El instruction it keeps the enabled status until DI instruction is executed to disable the interrupt When a CPU is turned to RUN mode all interrupts are disabled by default When multiple interrupt factors occur simultaneously interrupt routines are executed according to the priority given to the each interrupt If an interrupt factor that has higher priority occurs while other interrupt that has lower priority are executing the interrupt routine of lower priority will be stopped and the interrupt of higher priority will be executed first The following figure shows how a CPU handles multiple interrupts Program starts
151. the response format is confirm ACK it uses the same function code 3 If the response format is it returns as it sets the 8th bit of function code as 1 Ex If function code is 03 we write here only function code part Because only function codes are different Request 0000 0011 Confirm 0000 0011 H03 Confirm 1000 0011 H83 retums as it sets the 8th bit of function code of request frame Data area 1 It sends data using ASCII data ASCII mode or hex RTU mode 2 Data is changed according to each function code 3 Response frame uses data area as response data or error code Check CRC Check area 1 LRC Longitudinal Redundancy Check It works in ASCII mode It takes 2 complement from sum of frame except header or tail to change into ASCII code 2 CRC Cyclical Redundancy Check It works in RTU mode It uses 2 byte CRC check rules REMARK 1 All numerical data can use hexadecimal decimal and binary type If we convert decimal 7 and 10 into each type Hexadecimal or 16807 16 0A Decimal 7 10 Binary 280111 281010 8 69 Chapter 8 Communication Function T Function code types and memory mapping Modicon PLC Function code name Ead addres Read Coil Status OXXXX bit output Read bits Read Input Status 1XXXX bit input Read bits Read Holding Registers 4XXXX word output Read words Read Input Registers Force Single Coil
152. this area the force on off function is as just available in it as in the basic I O areas 4 Precautions Turning the power off and on changes of the operation mode or operation by reset switch K1000S does not change the previous force on off setting data They remain within the CPU module and operation is executed with the same data Force I O data will not be cleared even in the STOP mode f a program is downloaded or its backup breaks the force on off setting data will be cleared The operating program in memory differs from the program in the flash memory so that if operation restarts with the program in the flash memory the on off setting data will be also cleared When setting new data disable every I O settings using the setting data clear function and set the new data REMARK 1 For detailed operation refer to the KGLWIN uset s Manual Chapter 7 Force I O setting 5 22 Chapter5 CPU Module 5 5 3 Direct Operation function This function is usefully available when an input junction state is directly read during execution of a program and used in the operation or the operation result is directly output to an output junction Direct input output is executed by use of the IORF instruction If this instruction is used the input output image area will be directly updated and applied to the continuing operations REMARK 1 For detailed operation refer to the K7 Manual for instruction 5 5 4 Syste
153. this name digits upper lower case 90 only is allowable to be entered 8 9 Chapter8 Communication Function 1 Numerical data of frame Ex is hex value and H is unnecessary during preparing real frame 2 Device data type of each must be same If data type of the first block is WORD and the second block is BIT error occurs 3 Response format ACK response Station Command Numberof Number Frame Format name Header Command Tail blocks of data check se para ASCII value mu H3230 H52 72 H5353 H3031 H3032 H41394633 b uas H04 1 block max 16 blocks possible Expanaon 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 Number of data means byte number of hex type and is converted into ASCII This number is determined according to data type X W included in device name of computer request Format Number of data Number of data in accordance with its data type is as follows Data type Available variable Number of data X P MLKT C F X P M L K T C D S F W e n data area there are the values of hex data converted to ASCII code saved Ex 1 The fact that number of data is HO4 ASCII code value H3034 means that there is hex data of 4 bytes in data Hex data of 4 bytes is converted into ASCII code in data 8 10 Chapter8 Communication Function
154. tion 7 31 Chapter 7 Usage of Various Functions c Fig 2 10 shows examples of process control by forward and reverse actions respectively temperatu temperature PESO time zm z Reverse action for Cooling Forward action for Heating time Fig 2 10 PV of forward reverse action f Reference value In general feedback control system shown as the Figure 2 10 the deviation value is obtained by the difference of PV and SV P and D operations are performed based this deviation value However each of P and D operations use different deviation values according to the characteristics of each control actions The expression of PID control is as following lp dEd MV K Ep Ei s ds Td lt j val M dt MV Manipulate value K Proportional gain Ti Integral time Td Derivative time Ep Deviation value for proportional action Ei Deviation value for integral action Ed Deviation value for derivative action The deviation values of P and D action is described as following equations Ep bxSV PV Ei SV PV Ed The b of the first equation is called as reference value It can be varied according to load disturbance of measurement noise SV MV PV Fig 2 11 Diagram of simple feedback system 7 32 Chapter 7 Usage of Various Functions 9 The figure 2 11 shows the variation of PV according to the several different reference values b As shown in the Fi
155. tion _ 4 Set by sequence program 4 multiplication PR Set by preset input 1 multiplication PR Set by preset input EN __ 4 multiplication h2004 h2011 A phase B phase input input 1 2 2 Preset input The U D and PR input of sequence program must be programmed with dummy input even they are set as external input When the PR and or U D is set as external input the input conditions of sequence program is ignored 7 4 Chapter 7 Usage of Various Functions 1 EN input Counter enable When the EN input turns on the counter starts counting pulse When the EN is off the counting is stopped and the current value of high speed counter is cleared as 0 2 U D input Up down When the U D input is off the high speed counter operates as up counter When the is off it operates as down counter 3 PR input Preset When the PR input is on the current value of high speed counted is replaced with the preset value PV 4 Output relay F070 The F070 bit will be turn on when the current value of high speed counter F18 lower word F19 upper word is equal of greater than the set value SV 5 Carry flag The carry flag turns on when the current value of high speed counter is underflow 0 gt 16 777 215 during down counting or overflow 16 777 215 during up counting 6 Current value The current value of high speed counter is stored at two words F18 and F19 The lower word
156. ult value of 8ms 3 Setup input on off delay time is conformed to all input is used It can be selected to 0 15ms 7 25 Chapter 7 Usage of Various Functions 7 1 5 PID control function 1 Introduction This chapter will provide information about the built in PID Proportional Integral Differential function of K7 Basic Unit The K7 series does not have separated PID module and the PID function is integrated into the Basic Unit The PID control means a control action in order to keep the object at a set value SV It compares the SV with a sensor measured value PV Present Value and when a difference between them E the deviation is detected the controller output the manipulate value MV to the actuator to eliminate the difference The PID control consists of three control actions that are proportional P integral 1 and differential D The characteristics of the PID function of K7 is as following the PID function is integrated into the CPU module Therefore all PID control action can be performed with instruction PID8 PID8AT without any separated PID module Forward reverse operations are available P operation operation PID operation and On Off operation can be selected easily The manual output the user defined forced output is available By proper parameter setting it can keep stable operation regardless of external disturbance The operation scan time the interval that PID contr
157. upport high speed counting up to 1 phase 16kHz 2 phase 8kHz External interrupts Using in applications that have a high priority event which requires immediate responses The input filter function help reduce the possibility of false input conditions from external noise such as signal chattering The filter time can be programmed from 0 to 15 ms Using built in pulse output without separate positioning module it can control stepping motor or servo motor Using RS 232C built in port it can connect with external devices such as computers or monitoring devices and communicate 1 1 with IMO K7 e t has PID control function with which it can easily constitute a system without separate module 3 It can easily do On Off of the system using RUN STOP switch 4 5 It can constitute various system using separate Cnet module It can easily save the user program by simple manipulation in KGLWIN 6 Strong self diagnostic functions It can detect the cause of errors with more detailed error codes 7 It can prevent unintentional reading and writing using password Chapter 1 General 8 Debugging function On line debugging is available if the PLC Operation mode is set to debug mode executed by one command executed by break point settings executed by the condition of the device executed by the specified scan time 9 Various program execution function External and internal interrupt program as well as sca
158. ut value D A conversion characteristic voltage output Input of digital amount 0 outputs analog amount OV 4000 does 10V Digital input 1 equals to 2 5mV of analog amount b Current output 2000 20012002200 200 200 Analog output current 2000 Digital input Digital input value c 9 5 5 Q E 2 o o 9 c c lt D A conversion characteristic Current output In current output digital amount 0 exchanges to 0mA and 4 000 does 20 Analog amount of digital input 1 equals to 5 7 5 6 Chapter 7 Usage of Functions 5 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 b System configuration Base Unit A D D A mixture module Digital extended module allocation Base unit input P000 Base unit output P050 PO7F Expansion unit input P080 PO8F Expansion unit output P090 c Program Chapter 7 Usage of 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
159. vabe sns wo 3 For response after execution of command PC lt K7 Base Unit raean NK o w e Errorcode 4 TX asciva m iu 8 21 Chapter8 Communication Function 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 Registration Frame Format name Header Station No Command Registration Format Tail No check enge ascii mw Explanation When command is lowercase x only one lower byte of the value resulted by adding 1 byte each to ASCII values from ENQ to EOT is converted into ASCII added to BCC This can be registered up to 10 0 to 9 H00 H09 and if an already registered No is Register No registered again the one currently being executed is registered This is used to before EOT in command of Formats of separate reading of variable Register Format continuous reading and named variable reading X Register Format Register Format of request Formats must select and use only one of the followings Individual reading of device Number of blocks 2 Byte Device length 2 Byte Device name 16 Byte BERE 1 block max 16 blocks Continuous reading of device RSB Device length 2 Byte Device name 16 Byte Num
160. value is 500ms Mode t must be set in consideration of the max periodical time for sending receiving of the master PLC _ Ifits set smaller than the max send receive periodical time it may cause communication error User Define Master If it is set as the master it s the subject the communication system If it s set as the slave Slave it only responds to the request frame of the master 8 48 Chapter 8 Communication Function 2 Setting frame 1 Select one out of user defined terms of protocol and mode in communication parameter registration List button is activated 9 2 Click List button to activate the following window User Defined 15 Not defined SS decat Sie o a f 8 49 Chapter 8 Communication Function D Frame specification Header Used in Header type Possible characters as headers are 1 alphabet letter 1 numeric number or control characters as below Control character Available Control Code 18 DC2 h12 bDC3 h13 DC4 n14 SYN h16 ETB h17 FSM sini Eme foam o 1 Example 1 NUL ENQ 1 A Possible Example 2 NUL 12 ABC impossible Itis allowed to be only 3 consecutive characters Example 1 ENQ STX NUL Possible Example 2 AJ NUL ENQ STX impossible Send Receive Not defined It is the initial value that doesri
161. voltage are applied across D Max voltage is approx 24 2 If a resistor is used in this way it does not pose a problem to the output element But it may make the performance of the diode D which is built in the load drop to cause problems Leakage current by surge absorbing circuit which is connected to output element in parallel Leakage current by surge absorbing circuit which is connected to output element in parallel Sneak current due to the use of two different power supplies E1 E2 sneaks E1 is off E2 is on sneaks 11 10 Corrective Action e Connect registers of tens to hundreds across the load in parallel Connect C and R across the load which are of registers of tens KQ When the wiring distance from the output module to the load is long there may be a leakage current due to the line capacity Drive the relay using a contact and drive the C R type timer using the since contact Use other timer than the C R contact some timers have half ware rectified internal circuits therefore be cautious 2 Timer Use only one power supply Connect a sneak current prevention diode If the load is the relay etc connect a counter electromotive voltage absorbing code as shown by the dot line Chapter 11 Troubleshooting Output circuit troubles and corrective actions continued Condition Cause Corrective actions The load off Over current at off state The lar
162. w board connector Unit replacement is Check the status of the switch needed 1and 2 Unit replacement is needed Check from the beginning Chapter 11 Troubleshooting 11 25 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 C PU Switch to the remote STOP mode and execute the program write No Is the mode setting switch set the remote STOP After reading error code by using peripheral Is ERR LED blinking device correct the contents Complete Chapter 11 Troubleshooting 11 3 Troubleshooting Questionnaire When problems have been met during operation of the 7 series please write down this Questionnaires and contact the service center via telephone or facsimile For errors relating to special or communication modules use the questionnaire included in the User s manual of the unit 1 Telephone amp FAX No Tell FAX 2 Using equipment model 3 Details of using equipment CPU model OS version No Serial No KGLWIN version No used to compile programs 4 General description of the device or system used as the control object 5 The kind of the base unit Operation by the mode setting switch Operation by the KGLWIN or communications External memory module operation 6

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