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Manual GLOFA-GM4 Programmable Logic Controllers

1. Appendix 2 Flag List 7 Detailed System Error and Warning Flag List Keyword Type eis Name Description GM4AB The number ofso This flag detects that I O configuration parameters of each slot differ IO TYER N UINT 0 to 31 whose module type is from the real loaded module configuration or a particular module is ag GM4C f P loaded onto the slot where modules cannot be loaded and indicates 0 to 56 inconsistent the lowest slot No of the detected slot numbers n GM4A B The location of slo This flag detects that I O configuration parameters of each slot differ IO TYERRInl BYTE 0 3 where module type is from the real loaded module configuration or a particular module is JF M4C loaded onto the slot where modules cannot be loaded and indicates Otoe meons pent the slot locations in the bit map of base units GM4AB The number of slot This flag detects that module configuration of each slot has been IO DEER N UINT 0 to 31 where module changed that is module mounting dismounting error has been 372 GM4C mounting dismounting occurred and indicates the lowest slot No of the detected slot 0 to 56 error occurred numbers n GM4A B The location of slot This flag detects that module configuration of each slot has been IO DEERRIn BYTE 0to3 where module changed that is module mounting dismounting error has been Sao GM4C mountin
2. APP2 2 Appendix 2 Flag List 6 Representative System Warning Flag List Keyword Type BitNo Name Description Representa This flag treats the below warning flags relating to continuous operation CNF _WAR WORD tive System warning 7 in batch keyword _RTC_ERR BOOL Bit 0 RTC data error This flag Indicates that RTC data has error D_BCK_ER BOOL Bit1 Data backup error This flag indicates This flag indicates that hot restart time had been overrun or backup of Impossible hot the operation data needed in hot restart had not normally performed at _H_BCK_ER BOOL Bit2 fare restoration from power failure and hot restart was impossible so that a restart operation by the parameters warm or cold restart has been started This flag indicates that the program had been stopped during restore from power failure due to causes such as power off and then cold Abnormal restart has been executed and the continuous operation which retains AB_SD_ER BOOL Bit3 the data is impossible Usable in the initialization program Automatically ASAS shutdown SEPA a reset when the initialization program has finished The same things given above will be applied when the program has been stopped by the ESTOP function Task collision This flag indicates that task collision has occurred as execution request _TASK_ERR BOOL Bit 4 plus cycle and for
3. p There is flash run mode if PLC run the program of the flash memory is overrided to current downloaded Program Does current downloaded Program write to tlash memory incase of storing downloaded program to the flash memory click Yes Y If notclick Yes Y flash operation mode is released and the program in the flash memory is erased 2 2 In case of changing flash operation mode from None Set Run Mode to Set Run Mode Flash Run Mode Setting Flash Run Mode Setting Flash Run Mode Flash Run Mode Within flash run mode setting Source code is copyed in flash memony when Program download Within flash run mode setting Source code is copyed in flash memony when Program download Set Run Mode C None Set Run Mode cancer C Set Run Mode None Set Run Mode Cancel Flash function is activated and program in the program memory is stored to flash memory 6 7 Chapter 6 Memory Module And Built in Flash Memory In case of changing flash operation mode from Set Run Mode to None Set Run Mode Flash Run Mode Setting Flash Run Mode Setting Flash Run Mode Flash Run Mode Within flash run mode setting Source code is Within flash run mode setting Source code is copyed in flash memony when Program download copyed in flash memony when Program download Set Run Mode C None Set Run Mode C Set Run Mode None Set Run Mode Cancel C
4. This flag detects fatal error of external devices ANNUN_ER_M BOOL BIT6 Error Release f mA g Therefore in case of occurring _ANNUN_ER in order to ignore it set itto ON 4 Module Error Mask be GM4C Only In case of occurring error of the base or the module which is mounted to base on operation it can be used in order to ignore it and keep up its operation Set up the location of base which is masked BASE Min aie oo has setting based on wsemn SEP PEE In case of occurring error of the base or the module which is mounted to base on operation it can be used in order to ignore it and keep up its operation Set up the location of slot which is masked 7 6 5 4 3 SLOT M n n O Error Mask setting based on _SLOT_M slot unit _SLOT_M _SLOT_M Keyword In case of excluding the specific expansion base this flag can be used If this flag is set CPU stop the expansion base accessing Module Skip setting based on When changing expansion base power and module on operation this flag can be used _BASE_S n base unit eases e 4 3 2 ft fo In case of excluding the specific expansion module this flag can be used If this flag is set CPU stop the module accessing When changing expansion base power and module on operation this flag can be used 7 6 5 4 3 2 1 0 stots foe fno GATE SSP SSE GERREA Ji SEATS BASE 0 _SLOT_S 1 BASE 1 Enno aA _SLOT_S 6 BASE 6
5. set ar ay SM H global variable DAO3_DATA _CHANGE DA03_DT Specifying the loaded Base No Specifying the loaded Slot No DA02_CH Specifying the used channel No DA02_DT Inputting the digital data to be AD01_RD_0 K The A D conversion writing has normally finisned DA02_WR_0 K REQ DONE 0 BASE STAT F DA02_STAT Indicating the error status during writing function block execution DA02_ACT Indicating the run channels during writing function block execution 2 SLOT DATA HHH Writing the channel data to the moduk D A 03 only when the writing command is applied HHH Using the MOV function at hot restart only fi when the data restore is needed HHH The DAOQ3_OUT which is declared as a resource DA03_WR DA4AWR y The D A conversion writing has normally finished DA03_WR_O K REQ DONE DA03_OUT 0 Specifying the loaded Base No BASE STAT DA0Q3_STAT function block execution 3 DA0Q3_ACT Specifying the loaded Slot No SLOT ACT function block execution DA03_CH Specifying the used channel No DA03_OUT Inputting the digital data to be set 4 28 Indicating the error status during writing Indicating the run channels during writing F The D A conversion writing has normally finished Chapter 4 CPU module 4 5 Operation Modes The CPU module operates in one of the fo
6. 0 e program registration program PO program P1 with the task T SLOW program P2 with the task PROC_1 program P3 with the task E_INT1 If program execution time is equal to external interrupt occurrence time e Execution time for each program PO 17 ms P1 2 ms P2 7 ms P3 2 ms e Interrupt E_INT occurrence time Occurred at the 6 7 20 ms after the operation started e PROC_1 Invoked during execution of scan program Program execution is shown as below Scan start first start Scan program One scan complete complete A new scan start t sewon M N of PO i i Execution of P1 t T_SLOW invoked Execution of P2 PROC_1 detected Execution of invoked Time 0 678 12 30 32 34 mg HE Program execution without stop 7 Temporary stop during prgram execution EJ Program execution delayed e Processing with time ms 0 ms Scan starts and the scan program PO starts its execution 0 to 6 ms The program PO is being executed 6 to 8 ms Execution request for P3 is input and PO is stopped and P3 is executed Execution request for P1 by E_INT1 at the 7 msec is ignored as the P2 is being executed 8 to 10 ms P3 finishes its execution and the PO stopped continues its execution 10 to 12 ms PO is stopped and P1 is executed due to execution request for P1 12 to 20 ms P2 finishes its execution and the PO stopped continues
7. 2 Operation processing contents I O refresh and program operation are executed 1 Task 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 4 29 Chapter 4 CPU module 4 5 2 STOP mode In this mode programs are not operated Program sending through the GMWIN is available only in the remote STOP mode 1 Processing when the operation mode changes The output image area is cleared and output refresh is executed 2 Operation processing contents 1 I O refresh is executed 2 Normal or abnormal operation and mounting conditions of the loaded module are checked 3 Communications service or other internal operations are processed 4 5 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 clear and input image clear are not executed and the operating conditions just before the mode change is maintains 2 Operation processing contents 1 I O refresh is executed 2 Normal or abnormal operation and mounting conditions of the loaded module are checked 3 Communications service or other internal operations are processed 4 5 4 DEBUG mode In this mode errors of a program are searc
8. Common terminal 8 points 1 COM Internal current consumption 70 mA Operating indicator External connections LED turns on at ON state of input 20 point terminal block connector M3 x 6 screws Weight 0 3 kg Circuit configuration External connections Terminal No Chapter 7 7 2 10 Interrupt input module Specifications Number of input points INPUT AND OUTPUT MODULES GM4 G4F INTA 8 points Insulation method Photo coupler Rated input voltage 24 VDC Rated input current 10 mA Input impedance Approx 2 4 KQ Operating voltage range 21 6 to 26 4 VDC Maximum simultaneous input points 100 simultaneously ON ON voltage ON current OFF voltage OFF current 15 VDC or higher 6 5 mA or higher 5 VDC or lower 2 0 mA or lower A OFF gt ON Response time 0 5 msec or less ON OFF 0 5 msec or less Common terminal 1 point 1COM Internal current consumption Ascending or descending edge Setting Dip switch by the channel Internal current consumption 65 mA Operating indicator LED turns on at ON state of input External connections 20 point terminal block connector M3 x 6 screws Weight 0 16 kg Circuit configuration External connections Terminal No Chapter 7 INPUT AND OUTPUT MODULES 7 3 Digital Output Module Specifications 7 3 1 16 point relay output module
9. Operating voltage range 10 2 to 26 4 VDC ripple less than 5 Maximum simultaneous input points 100 8 points COM simultaneously ON ON voltage ON current 9 5 VDC or higher 4 0 mA or higher OFF voltage OFF current 6 VDC or lower 1 0 mA or lower Input impedance Approx 2 2 kQ OFF gt ON 10 msec or less Response time ON OFF 10 msec or less Common terminal 8 points COM Internal current consumption 70 mA Operating indicator LED turns on at ON state of input External connections 20 point terminal block connector M3 x 6 screws 0 25 kg Circuit configuration External connections 7 3 Chapter 7 INPUT AND OUTPUT MODULES 7 2 3 32 points 12 24 VDC input module source sink type Specifications Number of input points GM4 G4I D24A 32 points Insulation method Photo coupler Rated input voltage Rated input current 12 24 VDC 3 7 mA Operating voltage range 10 2 to 26 4 VDC ripple less than 5 Maximum simultaneous input points ON voltage ON current 60 simultaneously ON 19 points COM 9 5 VDC or higher 3 0 mA or higher OFF voltage OFF current 6 VDC or lower 1 5 mA or lower Input impedance Approx 3 3 KQ OFF gt ON 10 msec or less Response time ON OFF 10 msec or less Common terminal 32 points common Internal current co
10. Operation Start e Stage for the start of a scan processing itis executed only one time when Initializat the power is applied or reset is executed It executes the following processing wane gt I O modules reset Execution of self diagnosis gt Data clear gt 1 O module address allocation or type registration e Input module conditions are read and stored into the input image area before Input image area refresh operation processing of a program Program is sequentially executed from the first step to the last step Program operation processing Program start Program end e The contents stored in the output image area is output to output modules when Output image area refresh operation processing of a program is finished e Stage for return processing after the CPU module has finished 1 scan The END processing following processing are executed gt Self diagnosis gt Change of the present values of timer and counter etc gt Processing data communications between computer link module and communications module P Checking the switch for mode setting 4 4 Chapter 4 CPU module 2 Time driven interrupt operation method In time driven interrupt operation method operations are processed not repeatedly but at every pre set interval Interval in the GM4 CPU module can be set to between 0 01 and 4294967 29 sec This operation is used to process operation with a constant cycle 3 Event driven int
11. 12 2 1 Troubleshooting flowchart used when the POWER LED turns OFF The following flowchart explains corrective action procedure used when the power is all lied or the POWER LED turns OFF during operation Power LED is turned OFF Is the power suppi operating Apply the power supply Does the Power LED turn ON See the supply power to within the rated power Does the P ower LED turn ON Is the line voltage 85 to 132VAC or 170 to 264 VAC Is Fuse disconnected Replace the fuse Does the Power LED turn ON Is the power supply module Fixed to the base Fix the power supply module correctly ixed to the base Does the Power LED turn ON 1 Eliminate the excess current 2 Switch the input power OFF then ON Yes Over current protection Device activated Does the Power LED turn ON Write down the troubleshooting questionnaires and contact the nearest service center Complete 12 2 Chapter 12 TROUBLE SHOOTING 12 2 2 Troubleshooting flowchart used when the STOP LED is flickering The following flowchart explains corrective action procedure use when the power is applied starts or the STOP LED is flickering during operation Stop LED goes OFF Read the error code in the system flag S W error Correct the program Set the operation mode to the STOP mode Program error Correct in accordance with the error contents
12. Pnet Rnet Fenet version No FDEnet _CnSTNOH UINT Fnet Cnet Dnet Communications module station e Indicates the number which is seton communications module station switch _CnSTNOL UDINT Pnet Rnet Fenet No Mnet MAC station No marked on the front of communication module FDEnet Fnet Station switch No marked on the front of communications module Cnet Station No set by the frame editor _CnSTNOH Station No seton the side of RS 232C _CnSTNOL Station No seton the side of RS 422 _CnTXECNT UINT Fnet Cnet Dne Communications frame sending Increments by one whenever sending error of communications frame occurs Pnet Rnet Fenet error Connection condition of network is evaluated by this value FDEne e In Cnet this value is the sum of errors occurred during receiving through RS 232 and RS 422 _CnRXECNT UIN Fnet Cnet Dnet Communications frame Increments by one whenever communications service fails Pnet Rnet Fenet receiving error e Connection condition of network is evaluated by this value Overall network FDEne communications quantity and program stability are also evaluated by this value _CnSVCFCNT UINT Fnet Cnet Dne Communications Service e Increments by one whenever communications service fails Pnet Rnet Fenet processing error e Connection condition of network is evaluated by this value Overall network FDEne communications quantity and program stability are also evaluated by this value _CnSCANMX UINT Fnet Cne
13. 0 Module Skip Function 1 Uses and operation introductions I O module skip function is the function which excludes the specific module in the operation I O data revision and error diagnosis are not executed in the specific module It can be useful for temporary operation where erroneous part is excluded 2 Configurations and I O data processing e t can be set up about each of I O modules For details refer to GMWIN User s Manual e Because input refreshing is stopped input image area maintains the previous values when I O module skip function is set up However also in this case I O image area handling by force On Off function is available e Real outputs of output modules are set to Off when setting I O module skip function but output image area is variable by operation of user program After skip function is set outputs of output modules can not be altered by force On Off e When using direct I O operation function the operation of I O skip function is same HINT 1 Even if there are turning on off power changing operation mode and handling reset key the previously set I O skip data operates as it did because the state in the CPU module is maintained Cancellation of 1 0 skip function is available by GMWIN or user program 2 I O skip data can be erased in follow cases 1 In case of re operating after downloading program by GMWIN 2 In case of memory backup is broken up because battery is dead Ch
14. Immediately and all output is off 3 If an exceeding of preset watchdog time is expected in sequence program use WDT_RST function WDT_RST function make elapsed watchdog time as zero 4 In order to clear watchdog error using manual reset switch restarting the PLC and mode change to STOP mode are available Setting range of watchdog 1 to 65 335ms 1ms base Chapter 4 CPU module 4 3 5 Timer Processing The CPU module timer is on incremental timer which increase its present value according to the measuring time Three types of On Delay Timer TON Off Delay Timer TOF and Pulse Timer TP are available Its measuring range is 0 001 to 4 294 967 295 sec 1 193 hours by 1 ms For details refer to GLOFA GM Programming NE Txx BOOL IN Q BOOL TIME PT ET f TIME 1 On Delay Timer Process Time Change and Contact On Off Timer Process time is newly changed when the timer function block is executed When the process time reaches the setting time process time setting time the Timer output contact turns on On Delay Timer Timing Diagram is shown as below 2 Off Delay Timer Process Time Change and Contact On Off e f input condition turns on timer output contact Q turns on If input condition turns off timer process time change starts e The process time is newly changed when the timer function block is executed When the process time reaches the setting time process time setting time the cont
15. Models Specifications GM4 G4Q RY2A Number of output points 16 points Insulation method Photo coupler Rated load voltage current 24 VDC 2A load resistance 1 point 4A 1 COM 220 VAC 2A COSW 1 Minimum load voltage current SVDC 1mA Maximum load voltage current 250 VAC 125 VDC Off leakage current 0 1 mA 220 VAC 60 Hz Maximum switching frequency 3600 times per hour Surge absorber Mechanical Service life Electrical Off On Response time On Off None 20 million times or more Rated load voltage current 100000 times or more 200 VAC 1 5 A 240 VAC 1A COS 0 7 100000 times or more 200 VAC 1A 240 VAC 0 5A COS 0 35 100000 times or more 24 VAC 1 5A 100 VDC 0 1A L R 7 msec 100000 times or more 10 msec or less 12 msec or less Common terminal arrangement Internal current consumption External power Voltage supply Current Operation indicator 8 points common 100 mA 24 VDC all points ON 24 VDC 10 ripple voltage 4VP P or less 150 mA 24 VDC all points ON LED turns on at ON state of output External connections 20 point terminal block connector M3 x 6 screws Circuit configuration 0 31 kg Terminal No Chapter 7 INPUT AND OUTPUT MODULES 7 3 2 16 point transistor output module sink type Models GM4 Specifications G4Q TR2A Number of output points 16 points Insulation method Photo coup
16. The faing projector of each module wil be inserted lo fix Connector for sending and receiving trait b and tom he basivincenson base unt The foirg projector af each module will be inceried lo fart 9 3 Chapter 10 INSTALLATION AND WIRING Chapter 10 INSTALLATION AND WIRING 10 1 Installation 10 1 1 Installation Environment This unit has high reliability regardless of its installation environment but be sure to check the following for system reliability and stability 1 Environment requirements Avoid installing this unit in locations which are subjected or exposed to 1 Water leakage and dust 2 Continuous shocks or vibrations 3 Direct sunlight 4 Dew condensation due to rapid temperature change 5 Higher or lower temperatures outside the range of 0 to 55 C 6 Relative humidity outside the range of 5 to 95 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 50 mm 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 b
17. Write the program newly Yes Set the operation mode to the RUN Program error mode Write down the troubleshooting questionnaires and contact the nearest Complete service center Chapter 12 TROUBLE SHOOTING 12 2 3 Troubleshooting flowchart used when the RUN and STOP LEDs turn off The following flowchart explains corrective action procedure use when the power is applied starts or the RUN and STOP LED is turned OFF is flickering during operation RUN and STOP LED is turned OFF No Is the expansion base Connected Check the power supply module of the main base unit Is the expansion power Supply LED turned ON Separate the expansion connector No Turn the power supply module of the main base unit from OFF to ON Check the power supply module of the expansion base board Is RUN and STOP LED Turned OFF No Turn the power supply modules of the main base and expansion base board from OFF to ON contact the nearest service center Complete Chapter 12 TROUBLE SHOOTING 12 2 4 Troubleshooting flowchart used when the output load of the output module does not turn on The following flowchart explains corrective action procedure used when the output load of the output module does not turn ON during operation Output load does not turn ON No Check the output status in monitor Measure the voltage mode of the peripheral devices across modul
18. it will be stored to the following flags and the STOP LED flickers e Representative system error flag CNT_ER e Representative system warning flag _CNF_WAR HINT 1 Refer to 12 5 Error Code List of Chapter 12 Troubleshooting for details of contents of self diagnosis and corrective actions 4 6 3 Clock function Aclock device RTC is basically included in the CPU module The RTC continues its operation by the backup battery when the power turns off or at the 20msec or more momentary power failure The clock data of the RTC can be used for time control of system or of error history The system operation status information flag is updated with the RTC present time every scan 1 Clock Data 2 digit solar calendar 1 to 12 1 to 31 Oto 23 the twenty four hour system 0 to 59 0 to 59 1 100 sec 0 to 99 Day of the week 0 to 6 Monday to Sunday 2 Timer error 5 sec per month 3 Clock data Read Write Clock data can be read from written to the PLC information in the GMWIN on line mode For details refer to the GMWIN User s Guide Section 7 10 PLC information 1 The RTC at first has no written clock data When using the CPU module be sure to set exactly the RTC with a clock data 2 Battery error can cause the RTC to stop or error in it In this case writing a new clock data to the RTC removes the error 3 Ifa RTC error occurs the flag RTC_ERR of the system warning flag _CNF_WAR turns on If the RT
19. 11 MAINTENACE Chapter 11 MAINTENANCE Be sure to perform daily and periodic maintenance and inspection in order to maintain the PLC in the best conditions 11 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 J udgment Corrective Actions Ambient Temperature 0 to 55 C Adjust the operating temperature and environment Humidity 5 to 95 RH humidity with the defined range Vibration No vibration Use vibration resisting rubber or the vibration prevention method Play of modules No play allowed Securely enrage the hook Connecting conditions of No loose allowed Retighten terminal screws terminal screws Change rate of input voltage 15 to 15 Hold it with the allowable range Spare parts Check the number of spare parts Cover the shortage and improve the storage and their storage conditions condition 11 2 Daily Inspection The following table shows the inspection and items which are to be checked daily Corrective Actions Check for loose mounting screws The base unit should be securely mounted Retighten Screws Check Items Check points J udgment Base unit mounting conditions Mounting conditions of e Check if the hook is secur
20. 41 in the user program Re load the program and re start it STOP 0 4 sec program cold Refer to the external device fatal error 50 External device fatal fags ANNUN ER ANC_ERRIn and correct the STOP 0 4sec When scan completes cold error fault devices and then re start the system Correct the program so that the error elements that 60 Hd oe invoked the E_STOP function can be eliminated in the STOP During execution of cold program and re start the system Cold re start program Communications anti If the number of computer 4communications module is z 100 Pare configuration included then adjust the maximum number with in 8 STOP 0 4 sec When power is applied cold Special Communications Adjust the number of high speed communications m 101 module initialization modules loaded STOP 0 4 sec When power is applied cold failure 500 H memory backup iF the battery has no error RUN When power is applied cold If the battery has no error re set the time using the When power is applied RTC data 501 ata error GMWIN RUN 2 sec When scan completes 502 Lower battery voltage Replace the battery which the power is being applied RUN 4 sec ti cance 12 11 Appendix 1 System Definitions Appendix 1 System Definitions 1 Option 1 Communication port configuration In order to communicate with PLC set up communication port COM 1 8 in GMWIN The follow shows the method to set up the configuration e In the menu
21. 6A REME SUNCU in E E EE aa a Keay 4 37 AG UO Force On OTT TUPLE senses i a e Gaeta Ta Moat e eS a 4 38 4 6 6 Direct I O Operation function e225 centr teeta ieee rsh escent ieee os seni Ci cis intranet cette 4 39 4 6 7 History al 6002 eae se a i eee aL 4 39 4 6 8 External Device Error Diagnosis function vecereresesecerenenerereeecnees 4 40 4 7 GM4 CPUC Dedicated Functions Heer er igtesmenet nner artrziaiiges nenstirks taginiiet otituelstatniatpranets 4 42 AT LEmorMask funciones s ariin tati nieder Tea Lena RIO 4 42 ATAO Module Skip Ucho A e aeit iiei eninin etiain nais 4 43 4 7 3 Online Module Changing Function eeeeeeteeeneneneeereneerirntee 4 44 4 7 4 O Reservation Function sess etenn sisi enter neiestel seer gren ert ian ye paar nese an aretainihe 4 46 ARIF EnetResetFunchone ienesis eneee sik aa clo MEE Cen SEO RRS HR 4 47 4 1 Memory Configuratie niee reaa iene iaee ta tein Cie ein ava tinker 4 48 4 8 I O No Allocation Methodeeeeeeeeeeeeeeeeeettrttiritieetitiereieeieetititinieietetenene 4 50 SL Sp cifications eiin teei iAeti meets Enae eaaa aa getinte 5 1 Ded Precautions TORU SER ares iei E aee ae aia aa aage Taea e aiea aaka 5 1 5 3 Battery Replacement ipoe eeni needa taney aaeem ces mireniengnca Manta reap iii eniti 5 1 Chapter 6 MEMORY MODULE AND BUILT IN FLASH MEMORY 6 1 GM4 CPUA Using Memory Module eesesereresererereneneerinenereneniumunn 6 1 ODL Memory Moduleres ari aa ana eina eeta atat ai 6 1 6 1 2 Method of Writing
22. 9 USB Connector Connector for communication with GMWIN GM4 CPUC only 4 2 Chapter 4 CPU module Handling Reset Switch of GM4 CPUC Handling Manual Reset Switch Operations Pushing within 5 seconds Restart in cold or warm mode according to parameters setting Pushing over 5 seconds Restart in cold mode unconditionally after turned on STOP LED REMARK The follows show LED features and operation modes according to handling Key Switch 1 LED features according to operation modes LED feat Operation mode ealures Local Run Local Stop Local Pause Remote Run Remote Stop Remote Pause Remote Debug 2 Operation mode according to handing Key Switch Handling Key Switch Operation Mode STOP gt PAU REM Remote Stop PAU REM gt RUN Local Run RUN gt PAU REM Local Pause PAU REM gt STOP Local Stop Possible to use remote mode operations after operation mode is remote stop mode 4 3 Chapter 4 CPU module 4 3 Operation Processing 4 3 1 Operation Processing Methods 1 Cyclic operation A PLC program is sequentially executed from the first step to the last step which is called scan This sequential processing is called cyclic operation Cyclic operation of the PLC continues as long as conditions do not change for interrupt processing during program execution This processing is classified into the following stages
23. 9 12 Expansion Base DOAN Setzer iseit inie iinne i ngeri centeie Eaei ra nerit 9 2 9 1 3 Expansion ahl i ienet ra ie Ene aii en eerte ieaie 9 2 9 2 Names OTP asi iiaeia een Makat taut me ioe dat ana Tiaa dedat danai i 9 3 9 21 Main Base BOA spares ssp mag a iaeeh ten EAE EAE T ETE cept a3 9 2 2 Expansion Base Board xastes kseeneteatarespeitent swtoetevonsrenes nates enia PHS O23 Chapter 10 INSTALLATIONAND WRING Ta lias te llaB erasers Gest wens pthc eet thie res eeen Naa eta eae reen iein 10 1 10 1 1 Installation Environment sa ericeer eons sine eeeeatat ene ageipterireerstetmevorertetin gen sen rare e 10 1 10 14 27 Handling Instructions etereoa Aai eien aeinn e riers 10 4 10 1 3 Mounting And Dismounting of Modylereeseeeereereenrereereeerennemtrenee 10 7 NPA e E E 10 9 10 2 LP owerS upply Winngi is eiieeii tinei e aiaa aa aata 10 9 10 2 2 Inp tand Output Devices WV TMI Gee sires Sai neeo eea ae 10 11 10 2 3 Grounding senga aa aeaa o E E AEE E A 10 11 102 4 Cable Specification for Wiring ea ociera inania attici ake 10 12 Chapter 1 MAINTENANCE 11 1 M intena ce and Inspection espe cineca site unea ieiet ui tiee 11 1 12 Dally INGPOCHON n neesate ne e ia n o oona a eE eoa 11 1 113 PERO CIC INS ECUON nites dtinte datto Rea iiaeia ee Tant aiies 11 2 Chapter 12 TROUBLESHOOTING 12 1 Basic Procedures of Troubleshooting vesesececererenenenerereeceriennre 12 1 12 2 Troubleshooting ete iep ennaa ee aea paee EREE Neuse EE a 12 1 1
24. A User Program to the Memory Module seeeeseeeeertrerererreerrreeerrenees 6 2 eles Operation Method airen anaiak aaaea ATE RE EEEE EE ET atone 6 3 6 2 GM4 CPUB Using Built in Flash Memoy eveveseenecereeeeereernereieeeerir 6 4 6 2 1 Operation Mode Se ing vesvesesererecececenererenerennneriinenriin 6 4 6 2 2 Starting Program in the Built in Flash Memory And Operation Method rss 6 4 6 3 GM4 CPUC Using Built in Flash Memoy evecererenecenenerereccnerererrennu 6 6 6 3 1 Program Storing Method by Using Built in Flash Memoyeeeserenvenencccccrees 6 6 6 3 2 Setting Operdton Mode ene tenorist ie ae ieii phone 6 9 6 3 3 Upload Program Storing Method by Using Built in Flash Memory rrr 6 9 7 1 Notes on Selecting Input and Output Modules teeeeecerenececenereenerennerii 7 1 7 2 Digital Input Module Specifications e eeeeeeeeerenenennenereneneneeeneeni 7 2 7 2 1 16 point 12 24VDC input module Source Sink type eeeeeererererenrreeereees 7 2 7 2 2 16 point 12 24VDC input module source type jeeesenenenecnceenrrermerennn 7 3 7 2 3 32 point 12 24VDC input module Source Sink type eeeeeetererennnnnenerenu 7 4 7 2 4 32 point 12 24VDC input module Source type jeeesvenenececncnereremenennnu 7 5 7 2 5 16 point 24VDC input module source sink type jesenenecenenenenerererennu 7 6 7 2 6 32 point 24VDC input module source sink type jevereneeeneneneneremeernnn 7 7 7 2 7 64 point 12 24VDC input module Source Sink type strstr ttre 7 8 7 2 8 16 point ILOVAC input module
25. Com No 17 18 36 Chapter 7 INPUT AND OUTPUT MODULES 7 3 6 64 point transistor output module sink type GM4 Specifications G4Q TR8A Number of output points 64 points Insulation method Photo coupler Rated load voltage current 12 24 VDC Operating load voltage range 10 2 to 26 4 VDC Maximum load current 0 1A 1 point 2A 1COM Off leakage current 0 1mA_ orless Maximum inrush current 0 4A 10 msec or less Maximum voltage drop at ON circuit 1 0 VDC Surge absorber None Response Off On 2 msec or less time On gt Off 2 msec or less Common terminal arrangement 32 points 1 COM Internal current consumption 300 mA all points ON External Voltage 10 2 to 26 4 VDC power supply Current 100 mA 24 VDC per COM Operation indicator LED turns on at ON state of output External connections Two 40 point connectors Circuit configuration 17 18 37 38 External load DC12 24V Chapter 7 INPUT AND OUTPUT MODULES 7 3 7 16 point triac output module Models Specifications G4Q SS2A G4Q SS2B Number of output points 16 points Insulation method Photo coupler Rated load voltage 100 to 240 VAC 50 to 60 Hz Minimum load voltage 264 VAC Maximum load current 1A 1 point 5A 1COM 0 6A 1 point 2 4A 1 COM Minimum load current 20 mA 10 mA Off leakage cu
26. D conversion module Voltage eE e Voltage current input 8 channels ae eDC1to5V 0to10V DC 4 20mA G4F pAa Voltage current output 2 channels La e DC 10 to 10V DC 4 to 20 mA G4F pa2v Voltage current output 4 channels e DC 10 to 10V D A conversion module G4F DA2I Current output 4 channels DC 4 to 20 mA G4F DA3V Voltage output 8 channels e DC 10 to 10V G4F DA3 Current output 8 channels e DC 4 to 20 mA e Counting range 0 to 16 777 215 24 bit binary ae G4F HSCA 0 KHE Lchaniel 24 bit binary High speed counter e Counting range 2 147 483 648 to 2 147 483 647 er nodule G4F HO1A e 200 KHz 2 channels 32 bit binary e Counting range 2 147 483 648 to 2 147 483 647 mer G4F HD1A 500 KHz 2 channels 32 bit binary G4F POPA e Pulse output 1 axis control S pecial G4F POPB e Pulse output 2 axis control modules G4F PP10 e Pulse output Open Collector 1 axis control G4F PP20 e Pulse output Open Collector 2 axis control Positioning module G4F PP20 2 G4F PP30 e Pulse output Open Collector 3 axis control G4F PP1D e Pulse output Line Driver 1 axis control G4F PP2D e Pulse output Line Driver 2 axis control G4F PP3D e Pulse output Line Driver 3 axis control Thermocouple input G4F TC2A Temperature sensor seven types K J E T B R or S module e Input point 4 channels Temperature measuring G4F RD2A Temperature sensor Pt 100 J pt 100 resistor input module e Input poi
27. GM4 series 2 2 1 GM4 series Configuration GM4 CPUA e Maximum I O points 2 048 CPU module GM4 CPUB Je Maximum 1 0 points 2 048 GM4 CPUC e Maximum I O points 3 584 G4l D22A e 16 point 12 24 VDC input module current source sink input G4l D22B e 16 point 12 24 VDC input module current source input G4l D22C Digital input eii module G4l D24B G4l D24C e 32 point24 VDC input module current source sink input G4l D28A e 64 point 12 24 VDC input module current source sink input G4l A12A e 16 point 110 VAC input module G4I A22A e 16 point 220 VAC input module G4Q RY2A Je 16 point relay contact output module 2 A G4Q TR2A e 16 point transistor output module 0 5 A sink output e 16 point 24 VDC input module current source sink input e 32 point 12 24 VDC input module current source sink input e 32 point 12 24 VDC input module current source input G4Q TR2B e 16 point transistor output module 0 5 A source output Digital output G4Q TR4A e 32 point transistor output module 0 1 A sink output module G4Q TR4B e 32 point transistor output module 0 1 A source output G4Q TR8A e 64 point transistor output module 0 1 A sink output G4Q SS2A G4Q SS4A e 16 point triac output module 1 A e 16 point triac output module 0 6 A e 8 point 12 24 VDC input module current source sink input e 8 point relay contact output module 2 A G4H DT2A 8 point 12 24 VDC input module current source sink input e 8 point
28. This representative flag indicates that one of fuses of slots including them disconnection has disconnection Refer to_FUSE_ER_N and _FUSE_ER n error _10 _RWER BOOL Bit4 1 0 module This representative flag indicates that a I O module does normally read write error executes read write Refer to_IP_RWER_N and _IP_IFER n _SP_IFER BOOL Bit5 Special communic This representative flag indicates that special or communications module ations module has failed in initialization or normal interface is impossible due to module interface error malfunction Refer to _IP_IFER_N and_IP_IFER n _ANNUN_ER BOOL Bit 6 External device This representative flag indicates that an external device has fatal error fatal fault detection The error code has been written to ANC_ERRIn error Bit7 _WD_ER BOOL Bit8 Scan watch dog This flag indicates that the scan time of a program has overrun the scan error watchdog time specified by the parameter _CODE_ER BOOL Bit9 Program code This flag indicates that an unreadable instruction has been met while error executing an user program _P_BCK_ER BOOL Bit 11 Program error This flag indicates that program execution is impossible due to destroyed memory or program error APP2 1 Appendix 2 Flag List 3 Error Mask Flag GM4C Only Represent System Error Release CNF ER M BYTE This flag processes operation stop error release flag collectively ia jere ies fatal error gp p raton stp g colectvely
29. Upload Program menu is activated Using this menu the upload program can be written separately This function is supplied for the user who does not need to write upload program in the stop mode but need to write the upload program without stopping PLC when itis running Area C Basic Parameter C VO Parameter C HS Link Parameter C Redundancy Petameter C Communication Parameter C Program 4 Upload Proorarn C Parameter and Program 4 In case of online editing when an upload program has been already written Write upload program Programs were changed Would you like to write upload program to the PLC I Not show this dialog box next time Ifyou check this upload program will be written to the PLC during disconnecting to the PLC Write during Disconnecting Write Now Write during Disconnecting Choose one of them In case of using online editing very often if Write during Disconnecting is selected the upload program is copied to flash memory in case of disconnecting only In case of writing the upload program during running the operation time is variable according to the scan time 6 10 Chapter 7 INPUT AND OUTPUT MODULES Chapter 7 INPUT AND OUTPUT MODULES 7 1 Notes on Selecting Input and Output Modules The followings describe instructions for selection of digital I O modules that will be used in the GLOFA GM4 Series 1 The types of digital input are c
30. User s Manual is given below Chapter 1 Introduction Describes configuration of this manual units features and terminology Describes available units and system configurations in the GLOFA GM4 series Describes general specifications of various units used in the GLOFA GM4 series Describes the performance specifications and functions of the CPU module Chapter2 System Configuration Chapter3 General Specifications Chapter 4 CPU Module Chapter 5 Battery Chapter 6 Memory Module Describes the specifications and handling instructions for other modules Chapter Digital I O Module aycept for the CPU module Chapter8 Power Supply Module Base Unit and Chapter 9 Extension Cable Describes installation wiring and handling instructions for reliability of the PLC system Describes the check items and method for long term normal operation of the PLC system Chapter 12 Troubleshooting Describes various operation errors and corrective actions Chapter 10 Installation and Wiring Chapter 11 Maintenance Describes parameter setting for basic I O module and communications module Appendi System Definitions Function Function Block List Describes the types and processing time of function function block Appendi Appendi Flag List Describes the types and content of various flags Appendi Outer Dimensions Shows outer dimensions of the CPU I O module
31. a same task had been repeatedly invoked Refer to the flag external tasks TC_BMAP n and_TC_CNT n This flag detects and indicates that the voltage of the battery which is _BAT_ERR BOOL Bit5 Battery fault used to backup user programs and data memory is lower than the defined value External davies This representative flag indicates that the user program has detected an ANNUN_WR BOOL Bit6 A ordinary fault of external devices and has written it to the flag ANC_WB z warming detection in STS Bit7 2 HSPMTLER BOOL Bits High speed link parameter 1 error High speed link _HSPMT2_ER BOOL Bit9 parameter 2 error HSPMT3 ER BOOL Bit10 High speed Imk parameter 3 error E z High speed link This representative flag detects error of each high speed link parameter HSPMT4 ER BOOL Bit11 when the high link has been enabled and indicates that high speed link parameter 4 error l A fe a High dJ link cannot be executed It will be reset when the high speed link is disabled _HSPMT5_ER BOOL Bit12 g cae n According to the CPU type the flag is different as follow paame ETE GM4A 1 2 GM4B 1 4 GM4C 1 8 HSPMT6_ER BOOL Bit13 ga Speec an gt parameter 6 error nla High speed link _HSPMT7_ER BOOL Bit 14 parameter 7 error HSPMT8 ER BOOL Biti5 High speed link parameter 8 error APP2 3
32. and base unit REMARK 1 This manual does not describes the special communications module and programming for them For their own functions refer to the related User s Manual 1 1 Chapter 1 INTRODUCION 1 GLOFA GM series features 1 Design on the basis of international standard specifications IEC 1131 3 e Easy programming device support e Languages in compliance with IEC 1131 3 are given IL LD SFC 2 Open network by use of communications protocol in compliance with international standard specifications 3 High speed processing with an operation dedicated processor included 4 Various special modules that enlarge the range of application of the PLC 2 GM4 CPUA features 1 High speed operation processing High speed processing of 0 2 us step with an operation dedicated processor included 2 Heightened Self diagnosis Cause of errors is easily found as error codes has been more divided in accordance with their contents 3 Restart mode setting The User can set Cold Warm Hot restart mode in accordance with the environment Especially the User can set a allowed time in the Hot restart mode for exact control of the process Allowed Time of Power failure Maximum 23h 59m 59s 4 Debug operation On line debugging is available if the PLC operation mode is set to debug operation mode Debugging functions e Executed by one instruction e Executed by the break point settings e Executed by the device status e Execute
33. current of external device such as a drive by non contact switch Leakage current external device Input signal does not turn OFF Input signal does not turn OFF Leakage current of external device Drive by a limit switch with neon lamp Leakage current External device Leakage current due to line capacity of wiring cable Leakage current external device e Connect an appropriate register and capacity which will make the voltage across the terminals of the input module lower than AC input e C and R values are determined by the leakage current value Reminded value C 0 1 0 47 uF R 47 120Q 1 2W Or make up another independent display circuit e Power supply is located on the external device side as shown below exteran device Input signal does not turn OFF Leakage current of external device Drive by switch with LED indicator DC input Leakage current External device e Connect an appropriate register which will make the voltage across input module terminal and common higher than the OFF voltage as shown below DC input Input signal does not turn OFF e Sneak current due to the use of two different power supplies e E1 gt E2 Sneaked 12 8 e Use only one power supply e Connect a sneak current prevention diode as shown below DC input Ef E2 l Chapter 12 TROUBLE SHOOTING 12 4 2 Output circuit troubles and corrective actio
34. et P net R nei communications state _HSmSTATE k _HSmMOD k amp HSmTRX k amp _HSmERR k k Station No Fenet FDEnet information HSmMOD k Bi Fnet Cnet Dn K Data Block setting stations Indicates the operation modes of stations set the K data block of parameters 0 to 63 Array et Pnet Rne mode information RUN 1 k Station No Fenet FDEnet others 0 HSmTRXIk Bi FnetCnet Dn K Data Block communications e Indicates that communications of the K data block of parameters are normally 0 to 63 Array et Pnet Rne state information Normal 1 operating as setor not k Station No Fenet FDEnet abnormal 0 _HSmERRIk Bi Fnet Cnet Dn K Data Block setting stations e Indicates that the stations set in the K data block of parameters have an error k 0 to 63 Array et Pnet Rne state information Normal ornot k Station No Fenet FDEnet 1 abnormal 0 APP2 8 Appendix 2 Flag List 3 FEnet Reset Flag List GM4 CPUC Keyword Type Applicable Net Name Description _FENET_RESET_Mx BIT FEne To reset FEnet module in the slot e Using the variable monitor or using coil in the scan program F Enet reset function ARRAY No x of main base is available by setting the flags to 1 _FENET_RESET_Ex BIT FEne To reset FEnet module in the slot e If the flags is set to 1 in order to reset FEnet they are cleared to 0 again after the ARRAY No x of
35. for debugging of the program 4 Remote reset 1 This function permits remote operations to reset the CPU module which locates in the place where direct operations cannot be applied when an error has occurred 1 For remote function operations refer to the GMWIN User s Manual Chapter 7 On line Chapter 4 CPU module 4 6 5 I O Force On Off function 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 I O modules are not really loaded 2 Force on off Processing timing and method 1 Force Input e 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 e 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 o
36. for use 1 Do not heat or solder its terminals 2 Do not measure its voltage with a tester or short circuit 3 Do not disassemble 5 3 Battery Replacement Backup battery needs periodic replacement Programs and power failure retain data remains for about 30 minutes by the super capacitor though the battery is removed at a power failure but the battery has to be replaced as soon as possible The following shows the battery replacement procedure 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 in the exact direction and connect the connector Stop LED flickering Yes Chapter 6 Memory Module And Built in Flash Memory Chapter 6 Memory Module And Built in Flash Memory This chapter describes user programs storage method and operation method of the PLC mounted with the memory module Flash memory is being used for the memory module in this PLC Operation methods are different according to types of CPU module 6 1 GM4 CPUA Using Memory Module 6 1 1 Memory module Connector Models ene G4M M032 Memory type Flash memory Memory capacity 128K bytes 32K steps Weight Kg 0 01 Chapter 6 Memory Module And Built in Flash Memory 6 1 2 Method of writing a user program to the memory module Be sure to turn the power off when mounting the memory module onto the CPU modul
37. l O Parameters Setting List gt continued Keyword Description Applicable Module G4l D22A 16 points G4I D22B 16 points G4I D22C 16 points DEF All input modules G4l D24A 32 points G4I D24B 32 points G4I D24C 32 points G4I D28A 64 points G4I A12B 16 points G4l A22A 16 points G4Q RY 2A 16 points G4Q SS2A 16 points G4Q SS2B 16 points DEF_O All output modules G4Q TR2A 16 points G4Q TR2B 16 points G4Q TR4A 32 points G4Q TR4B 32 points G4Q TR8A 16 points DEF 10 All mixed I O modules G4H DR2A 16 points G4H DT 2A 16 points DEF SP A communications e All special modules Special modules e All communications modules e All input modules e All output modules pre All modules e All mixed I O modules e All special modules e All communications modules DEF EMPTY Empty slot APP1 10 Appendix 1 System Definitions 3 Communications Parameters These high speed link parameters are used to set the opposite station for data communications data and communications cycle when communicating a defined data repeatedly through communication modules For detailed descriptions refer to the User s Manual relating to data communications High Speed Linki Remote1 Send0 0 1 2 3 4 5 6 7 8 9 1 0 1 Network type Used to set the type of the communications module 2 Base No Base number of slot where the communications module has been m
38. solution Leader in Electrics amp Automation User Manual GLOFA GM4 Programmable Logic Controllers AN Safety Instructions e Read this manual carefully before installing wiring operating servicing or inspecting this equipment e Keep this manual within easy reach for quick reference LS www lsis biz SAFETY INSTRUCTIONS To Prevent injury and property damage follow these instructions Incorrect operation due to ignoring instructions will cause harm or damage the seriousness of which is indicated by the following symbols D ANG E R This symbol indicates the instant death or serious injury if you don t follow instructions A N WARNING This symbol indicates the possibility of death or serious injury CAUTIO N This symbol indicates the possibility of injury or damage to property Mi The meaning of each symbol on equipment is as followed This is the safety alert symbol Read and follow instructions carefully to avoid dangerous situation This Symbol alerts the user to the presence of dangerous voltage Inside the product that might cause harm or electric shock SAFETY INSTRUCTIONS Design Precautions gt Install a safety circuit external to the PLC that keeps the entire system safe even when there are problems with the external power supply or the PLC module Otherwise serious trouble could result from erroneous output or erroneous operation Outside the PLC construct mechanical d
39. that will be mounted and operated onto their own slot in the base unit If a parameter that has been set and the real mounted module are different the operation will not be executed When writing a new project I O configuration parameters will be all set to default DEF MODULE If I O configuration parameters are set to default the operation starts on the basis of the configuration of the real mounted module when the power is applied Therefore though a power failure had occurred during normal operation or the system configuration had been changed due to slip out of a mounted module operation starts and continues when the power has been re applied because the system considers that it is a normal operation state To prevent this error be sure to set correctly the I O configuration parameters complying with the real modules that shall be mounted and operated Base OIO Parameter r Select base Close o Reset All Help mlO configuration GLOFA Cnet Slot 1 GLOFA Cnet Slot 2 SSR Output 1Gpoint Slot 3 TR Output 32point Slot 4 DC Input Relay Output 1 6point Slot 4 AC 2204 Input 16point Slot 6 Relay Output 1 6point Slot 7 Relay Output 1 6point Reset APP1 8 Appendix 1 Keywords System Definitions Base 15lot Select type Relay Output cancer Heo 7 0 Parameter lt l O Parameters Setting List gt Description Applicable Modules DC in
40. to Run mode it operates like the follows according to flash operating mode setti ng Flash operating mode setting Operation The program which is stored in the flash memory operates after downloading it to program memory a In case of that programs in the flash memory and program memory are equal downloading operation is not executed OFF CPU recognizes that there is not a program in the flash memory and it is operated by the program which is stored in the program memory 6 3 3 Upload program storing method by using built in flash memory Basically the upload program is stored to the flash memory in the GM4 CPUC and there are 4 kinds of methods to store upload program to the flash memory When to write upload program flash operation mode setting has no effect on it 1 In case of choosing Upload Program together when to download program Area C Basic Parameter C VO Parameter C HS Link Parameter sedundancy Rararmiete ad Program C Parameter and Program M Upload Frogram Area C Basic Parameter C VO Parameter C HS Link Parameter C Redundancy Parameter C Communication Parameter C Program F UJ cP M Upload Program Upload Procrany 6 9 Chapter 6 Memory Module And Built in Flash Memory 3 In case of choosing Upload Program when PLC is running If Online gt Write menu is chosen when PLC is running
41. type into LREAL type 36 50 ULINT_TO_REAL Conversion of ULINT type into REAL type 36 55 USINT_TO_LREAL Conversion of USINT type into LREAL type 36 5 USINT_TO_REAL Conversion of USINT type into REAL type 36 3 5 HINT 1 The items marked with has following meaning 1 The size of the program memory which a program occupies when it uses the function once 2 The size of the program memory which a program occupies only one time though it uses the function many times 3 of IL programs 2 input variables 10 strings 2 The above shows the function list when programs are written with LD Ladder Diagram Expansion available functions ADD MUL MAX MIN MUX EQ etc are standardized to 2 input variables String operation functions are standardized to 10 characters Input variables of trigonometric functions are standardized to average values which are MAX a 2 Function Block List Name Function Ta te Size b ae ae instance GM RNE mee ae ize byte memory 3 i j CTU Addition counter 72 110 6 12 8 6 4 CTUD Addition subtraction counter 112 186 6 18 4 10 4 F_TRIG Descending edge detection 40 38 1 6 6 2 6 RS Preference reset table 48 72 2 8 7 2 9 TON ON delay timer 56 200 20 11 1 6 2 1 The items marked with has following meaning 1 The size of the program memory which a program occupies when it uses the function once 2 The size of the program memory which a program occupies on
42. voltage 24 VDC Rated input current 7mA Operating voltage range 20 4 to 28 8 VDC ripple less than 5 Maximum simultaneous input points 100 simultaneously ON ON voltage ON current 17 VDC or higher 5 2 mA or higher OFF voltage OFF current 8 VDC or lower 2 4 mA or lower Input impedance Approx 3 3 KQ OFF gt ON 10 msec or less ON OFF 10 msec or less Common terminal 8 points 1 COM common Internal current consumption 70 mA Operating indicator LED turns on at ON state of input External connections 20 point terminal block connector M3 x 6 screws Weight 0 25 kg Response time Circuit configuration External connections Internal circuit Terminal No i Terminal No 7 6 Chapter 7 INPUT AND OUTPUT MODULES 7 2 6 32 points 24 VDC input module source sink type GM4 Specifications G4l D24C Number of input points 32 points Insulation method Photo coupler Rated input voltage 24 VDC Rated input current 7 mA Operating voltage range 20 4 to 28 8 VDC ripple less than 5 Maximum simultaneous input points 60 19 points 1 COM simultaneously ON ON voltage ON current 17 VDC or higher 5 2 mA or higher OFF voltage OFF current 8 VDC or lower 2 4 mA or lower Input impedance Approx 3 3 KQ OFF gt ON 10 msec or less ON OFF 10 msec or less Common terminal 32 points 1 COM common Internal current consumption 75 mA Operating indicator 16 points indicatio
43. without stop Chapter 4 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 key position is in the STOP PAU REM Mode key position Mode change by Mode change using FAM the GMWIN or computer link etc Mode Change Remote STOP Remote RUN Remote STOP Remote PAUSE Remote STOP DEBUG Remote RUN Remote PAUSE Remote RUN Remote STOP Remote RUN DEBUG Remote PAUSE Remote RUN Remote PAUSE Remote STOP Remote PAUSE Remote DEBUG DEBUG Remote STOP DEBUG Remote RUN DEBUG Remote PAUSE O O PAU REM xixi ol lxilo lo lxlio lo olx xixilol lxlio lo lxlio lo olx 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 key and GMWIN 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 4 5 6 System Starting Method 1 Starting Method The follows show the methods to start PLC systems stably In order to improve system reliability observe the starting rules 1 Start
44. 2 2 1 Troubleshooting flowchart used when the POWER LED turns OFF eeeecerereee 12 2 12 2 2 Troubleshooting flowchart used when the STOP LED is flickering vevenenenenes 12 3 12 2 3 Troubleshooting flowchart used when the RUN and STOP LEDs turn off sree 12 4 12 2 4 Troubleshooting flowchart used when the output load of the Output module does not turn Onis srceri trier nnitneh eetssimbreinesstyostir neghunsenrinon do 12 5 12 2 5 Troubleshooting flowchart used when a program cannot be written to the CPU module eesecereeecereecnecereeecrierenree 12 6 12 3 Tr ubl shooting Quest nNa rE ates enori ones o Sets E anei iop 12 7 12 4 Troubleshooting Examples evevesenereeeneecrennnnerennnecrinnreene 12 8 12 4 1 Input circuit troubles and corrective actions eveveseneneneenneecreeerren 12 8 12 4 2 Output circuit troubles and corrective actions eeeevenevenennnecereenereen 12 9 12 5 Error d Ms a aR niet bania i taia eee in oaa 12 11 Appendix 1 System Definitions ein egini e ratei ai e APP 1 1 Appendix 2 Flag Listes netti ec ieaie ane aa eent APP 2 1 Appendix 3 Function Function Block Listeseseserececererecccccererereenenn APP 3 1 Appendix 4 Dimensions oriei senei oE a iat ai pate G APP 4 1 Chapter 1 INTRODUCION Chapter 1 INTRODUCTION 1 1 Guide to User s Manual This User s Manual gives the specifications performance and handling instructions for each of the necessary units of the GLOFA GM4 series PLC system The configuration of the
45. 2 5 Error code list Error opari a no Cause Corrective Action on TEAS Diagnosis time start code G Flickerin mie g cycle Contact the service center if it reactively occurs when 2 OS ROM error the power is re applied Defect 0 4sec When power is applied 3 0S ROM error Defect 0 4sec When power is applied 4 RTC fault i Defect 0 4sec When power is applied 5 rai ag PESO i Defect 04sec When power is applied 6 Program memory fault i Defect 0 4sec When power is applied 7 Data memory fault Defect 0 4sec When power is applied Watch dog error due to 10 gs program congestion RE apply the power Reset 0 4sec During run Cold Replace the battery if it has error check the program 20 Program memory after cc loading it and if an error is detected replace STOP 0 4 sec When power is applied Cold backup error the CPU module Check and correct the memory module mounting 21 Memory module defect condition Re apply the power and if an error occurs STOP 0 4 sec When power is applied Cold replace the memory module Memory module Correct the memory module program and re operate a Change into the RUN 22 program fault he system STOP 0 4 sec mode on 23 An nomal program Re load the program and start it STOP 0 4 sec a into Te RUN Cold Inconsistency between odule type inc
46. 2 Hot restart _INIT_RUN BOOL Bit3 During An initialization program written by the user is being executed initialization _SCAN_MAX UINT a Maximum scan Maximum scan time is written during operation time msec _SCAN_MIN UINT Minimum scan Minimum scan time is written during operation time msec _SCAN_CUR UINT 2 Present scan Present scan time is continuously updated during operation time msec _RTC_TIME n BYTE N 0to7 Present time BCD data of present time of RTC Example 96 01 12 00 00 00 XX _RTC _TIME 0 year RTC _TIME 1 month RTC _TIME 2 day _RTC _TIME 3 hour RTC _TIME 4 minute RTC _TIME 5 second _RTC _TIME 6 day of the week RTC _TIME 7 unused Day of the week 0 Mon 1 Tue 2 Wed 3 Thur 4 Fri 5 Sat 6 Sun _SYS_ERR UINT Error code Error type See the Section 12 5 Error Code List APP2 5 Appendix 2 Flag List 9 System Configuration status Information Flag 1 User Program Status Information Keyword Type sti Name Description _DOMAIN_ST BYTE Representative System S W Indicates the status of system parameter and user program keyword configuration configuration information Bit0 Basic parameter error Checks and indicates Basic parameter error Bit1 1 0 configuration Checks and indicates I O configuration parameter error parameter error Bit2 Program error Checks and indicates Program error Bit3 Access variable error Checks and indicates Access
47. 3 1 Basic System 1 Existing Systems The following describes basic system which is configured with a cable connection of only basic base units and expansion base units GM4 Series can be used CPU GM4 CPUA GM4 CPUB GM4 CPUC and Base together Slots No Main Base Base No 0 Expansion Example of System Cable Configuration Expansion Base Base No 1 Expansion Base Base No 2 Expansion Base Base No 3 The above figure shows the configuration where 16 input output modules are loaded 2 6 Chapter 2 SYSTEM CONFIGURATION Maximum Number of Expansion Three Stages Stages Maximum number of Input Output 32 modules modules le 16 point module loaded 512 points Mainu nner OL RUN e 32 point module loaded 1 024 points points e 64 point module loaded 2 048 points CPU module GM4 CPUA GM4 CPUB GM4 CPUC Power Supply module GM4 PA1 2A GM4 P A1 2B GM4 PD3A GM4 P A2C Basic Base Unit GM4 B04 06 08 12M GM4 B4MH B6MH B8MH Configuration Expansion Base Unit GM4 B04 06 08E GM4 B4E H B6E H B8EH an Expansion Cable G4C 041 E121 E 301 G4l 0000 1 0 module G4Q 0000 G4F 0000 e 64 1 0 points have been fixedly allocated for every slot in the base unit e 64 points are allocated to each slot in a base unit whatever it is empty or not le There s no limitation in the loading location and loading number of special modules e Special modules do not have fixed I O numbers while a fixed I O number
48. 3 9 EQ Equality comparison 20 788 38 3 FIND To find a string 40 222 73 9 INSERT To insert a string 68 524 418 9 LEFT To obtain the left part of a string 56 158 33 4 LEN To obtain the length of a string 16 48 17 5 LIMIT str To output upper or lower limits 80 794 80 9 MAX str To output the maximum input value 76 738 68 4 MID To obtain the middle part of a string 64 236 47 1 REPLACE To replace a string with another 73 584 97 9 RIGHT To obtain the right part of a string 56 226 53 9 ADD_TIME time Time addition 40 280 11 6 DIV_TIME i1 time Time division 40 266 67 9 1 The items marked with has following meaning 1 The size of the program memory which a program occupies when it uses the function once 2 The size of the program memory which a program occupies only one time though it uses the function many times 3 of IL programs 2 input variables 10 strings 2 The above shows the function list when programs are written with IL Instruction List language If programs are written with LD Ladder diagram the following differences occur 1 16 byte will be added to the size of the PB 2 In non execution 0 4 will be added to the processing speed In execution 0 8 usec will be added APP3 1 Appendix 3 Function Function Block List Function List GM4 CPUC Size of library Processing speed Function O Size OL Pe oye T usec 3 ABS int Absolute value operation ADD _ intdint Addition ADD l
49. 4 4 3 2 Operation processing at momentary power failure occurrence Visti ttt ites 4 5 ASS Scan TIME SSN R Ape NE CARS ENE a a REG Cae AS EN a Re Oa 4 6 AS AS CaN Watchdog TimMer iarria a a e ete 4 7 4 33 PMET PLO CSS SING u a na gti Dag Care a Op e ag 4 8 43 6 COUNTER DIOCESE ING A norne a eie iaie a a Ree oia TIE 4 10 AA Programeri re senses ker giure aie nee iina Yourish a a an raia one iada deat 4 12 Atel Program Configuration esi creis ioei ee enie oeiia unii 4 12 4 4 2 Program Execution Procedures tip seit ecarrt en mnciap risa ea recat eiei n 4 13 NOS 51 Cota ae ea ea ga ne ee oa aaa 4 16 AAA Enor Handing ereite niaan aei cea eis Con ter ee ates eie 4 22 4 4 5 Precautions when using special modules 1 tt etter 4 23 A SOperaton Modes ete tos Soe iit aurea ET Ta E a a a DEAE AGE ra KOE aa 4 29 AS cle PUN Modenie ueiaire ta as a cll aR ea mt RT end eTR Na pin 4 29 ES 2 SOLE TIN E E E HEY 4 30 Haid PAUS EMOJE yeti rnc ce vant T R E oes mene ey E A OIRO 4 30 45A DEBUG MOJE i creer o eamenn teas a S ER meaner em a STE EE R E 4 30 45 5 Operation Mode Change sect iiion itisid itiiti nateli bieria 4 31 45 6 System Staring Method testes ieat ti eed aiia iiie onid 4 32 A O FUNCIONS i eer eterne nrtnr fke rient eener tion uriinnenyenineei ieee inina tenia a rinnete 4 34 40l Restat modesti ea spienp eang ne a e an 4 34 46 2 Self diagnoSiS it nnee aeai Tis ne etate Teie aaas iian 4 36 463C locKTunction saa ai aE E Ea E 4 36 A
50. C is restored to normal state the flag RTC _ERR turns off Chapter 4 CPU module 4 6 4 Remote function The CPU module can be controlled by external operations from GMWIN and computer link module etc For remote operation set the SPU module mode setting key to remote position 1 Remote RUN STOP 1 The remote RUN STOP permits external operations to RUN STOP the CPU module under the condition that the CPU module key switch is in the remote position 2 This function is convenient when the CPU module is located on the place where it is difficult to control the CPU module or the user want to control the CPU module in the control panel from outside 2 Remote PAUSE 1 The remote PAUSE permits external operations to execute PAUSE operations under the condition that the CPU module key switch is in the remote position The PAUSE operations stop the CPU module operation processing while maintaining the On Off state of the output module 2 This function is convenient when the user wants to maintain the ON state of the output module under the condition the CPU module has been stopped 3 Remote DEBUG 1 This function permits external operations to execute DEBUG operations under the condition that the CPU module key switch is in the remote position The DEBUG operations execute programs complying with the specified operation conditions 2 This function is convenient when program execution or contents of any data are checked
51. E 0to3 Special link module link module of a slot or normal interface is impossible due to module Se GM4C interface error location malfunction and indicates the slot locations in the bit map of base 0 to 6 units This flag detects fatal error of external devices and its content is _ANC_ERR n UINT n 0to15 ee geviee tala written to this flag A number that identifies error type will be written to each of the sixteen locations The number 0 is not allowed Externa device If the user program indicates a warning on the flag_ANC_WBh n the _ANC_WAR n UINT n 0to7 ordinary error bit locations are sequentially written to _ANC_WAR n from ANC_WAR 0 complying with their occurrence sequence Externa device The user program detects ordinary error of external device and the SANC WBIn BIT n 0 to 255 ordinary error bitmap errors are indicated on a bitmap The number 0 is not allowed Fane The flag detects that task collision has occurred because while a TC BMAPIn BIT n 0to 47 Piece ve task was being executed or ready for execution an execution FORS External n 32 to 47 request has occurred for the same task indicates the errors on a bitmap This flag detects task collision occurrence time for each task when _TC_CNT n UINT n 0 to 47 Task collision counter executing a user program indicates the task collision occurrence time DATE amp The first detection date and time of battery voltage drop are written BATE RIM TIME 7 Batter voltage drop
52. I O modules 4 modules 6 modules 8 modules 12 modules Outer dimensions mm 289 x 135 x 17 367 x 135 x 17 437 x 135 x 17 540 x 135 x 17 Panel installation hole size FG terminal connection Screws specifications 04 5 for M4 screw BHM x 6 washer Weight kg 1 1 0 73 Accessory Connector cover 1 Expansion cable cannot be connected in the GM4 B12M l 9 1 2 Expansion Base board Item Chapter 9 BASE BOARD AND EXPANSION CABLE GM4 B04E GM4 B4EH GM4 B 06E GM4 B6EH GM4 B 08E GM4 B8EH Loaded I O modules 4 modules 6 modules 8 modules Outer dimensions mm 297 x 135 x17 367 x 135 x 17 437 x 135 x17 Panel installation hole size 4 5 for M4 screw FG terminal connection screws specifications BHM 3x6 washer Weight kg 1 15 Accessory 9 1 3 Expansion Cable G4C E041 G4C E061 G4C E121 G4C E301 Dust Cover Connector cover G4C E601 G4C E102 G4C E152 Length m 0 4 3 0 6 0 10 0 15 0 0 21 Weight kg 9 2 1 09 1 86 2 98 4 39 Chapter 9 BASE BOARD AND EXPANSION CABLE 9 2 Names of Parts 9 2 1 Main base board Guide hole for tere unit inelaision r Connector tor extension cable Used to mounl thie tees unit lo Pa panel of control bax Connector for sending and reseiang agrais to and from he extension
53. M4 CPUA B 128k byte 3 Communication module Up to 4 communication modules 8 modules of Cnet can be mounted Refer to 2 3 3 Network System for details 4 Flexible Application of Cnet Module GM4 CPUA B do not support Cneet Module in expanded base module however Cnet Module can be mounted on expanded base module in GM4 CPUC Refer to 2 3 2 Cnet I F System for details 5 Flash Memory Writing is available in On line Editing 6 High Speed Communication with GMWIN using USB GM4 CPUC can support Maximum 115 2kbps using RS 232C and also itcan support 12Mbps using USB User can decrease Program Writing Reading and Monitoring Time using USB Downloading Time of 100k Byte Program USB GM4 CPUC RS 232C GM4 CPUC 7 Maximum 6 expanded base modules are available GM4 CPUC supports Maximum 6 expanded base modules using high performance base modules Therefore Maximum 56 I O modules can be mounted Expanding distance is maximum 15 m 8 GM4 CPUC can be supported in GMWIN Ver 4 0 or over 1 3 Chapter 1 INTRODUCION 1 3 Terminology The following table gives definition of terms used in this manual Definition Remarks 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 Example CPU module Power Supply module 1 0 module A module or a module group which is a minimum element to operate
54. ON Definition Remarks Source Output Current flows in from the output terminal to the load if the PLC output junction A power source Fieldbus Network Computer Network Ethernet Network Mini MAP Network Dnet DeviceNet Network Pnet Profibus Network ISA Instrument Society of America System which is combined by GM4 CPUC and high performance bases GM4C System GM4 B4MH GM4 B6MH GM4 B8MH GM4 B4EH GM4 B6EH GM4 B8EH Refer to Chapter 2 for details 1 6 Chapter 2 SYSTEM CONFIGURATION Chapter 2 SYSTEM CONFIGURATION The GLOFA GM4 series have various units 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 The following shows the overall configuration of the GLOFA GM4 series Al RS 232C Or USB Cable CPU Module Power Module GM4 P Main Base GM4 BOLIM GM4 BLJMH 1 0 Module Expansion Cable G4C E G4F Expansion Base GM4 BOLJE GM4 BLJEH Communication Module G4L Chapter 2 SYSTEM CONFIGURATION 2 2 System Configuration Component Units List The following table shows components units configuration of GLOFA
55. OOL BOOL INT INT e f the counting value CV increments and reaches the setting value PV the output contact Q turns on When the reset signal is turned on the counting value is set to 0 and the output contact Q turns off 2 Decrement Counter e t should have input condition CU load LD and setting value PV NAME CTD BOOL BOOL BOOL INT INT e f the counting value CV decrements and reaches 0 the output contact Q turns on If the reset signal is turned on the counting value is set to the setting value and the output contact Q turns off Chapter 4 CPU module 3 Increment Decrement Counter e t should have Increment input condition CU Decrement input condition CD load LD and setting value PV BOOL BOOL INT e f reset signal R turns on counting value CV is set to 0 e f load signal LD turns on counting value is set to setting value PV e t is increased by tat the rising edge of increment input CU and decreased by 1 at the edge of decrement input CD If counting value CV is equal or larger than setting value PV QU will be on and if counting value CV is equal or less than setting value PV QD will be on 2 Counting speed e The counting speed is decided by scan time and it will be counted when on time or off time of input condition is larger than each scan time Max Counting speed Cmax n 100 Xx 1 ts s n Duty ts scan time s e Du
56. Off Change the operation mode into the STOP mode and then turn the power off l Load correctly a memory module where a user program has been written onto the connector for memory module in the CPU module as described above Mounting the memory module If a memory module where no program has been written is mounted onto the CPU module Write to memory module will be executed Changing the operation mode Change the operation mode into the RUN mode Execution Check Check if the changed program is executed or not Check the information of the memory module by using GMWIN Complete 1 If the operation mode was the RUN mode when the power has been turned on then mounting a memory module makes the contents in the memory module will be written to the program area of the CPU module Be cautious when mounting a memory module to write a user program to the memory module It will be convenient to operate the PLC without memory module during debugging and to mount a memory module after the debugging 6 3 Chapter 6 Memory Module And Built in Flash Memory 6 2 GM4 CPUB Using Built in Flash Memory 6 2 1 Operation mode setting GM4 CPUB does not use separate memory module in order to operate the ROM operation function of GM4 CPUA Using Built in flash memory of GM4 CPUB instead of memory module it can execute the function which stores user program or corresponds
57. U module 4 2 Parts Name and Descriptions lt GM4 CPUA gt lt GM4 CPUB gt lt GM4 CPUC gt No Name Details Indicator of CPU Operation Mode e On In case of Key Switch is Local or Remote RUN Mode e Off In below case RUN LED is OFF gt Incase of Power is supplied abnormally gt Incase of Key Switch is STOP or PAU REM Mode gt Incase of occurrence of Error which stops operation 1 RUN LED e On In case of Key Switch is Local or Remote STOP Mode e Off In below case STOP LED is OFF 2 STOPLED gt Incase of Key Switch is Local RUN or Local Pause Mode gt In case of operation mode is Remote RUN PAUSE DEBUG e Flickering In case of detection of Error by Self Testing Function To set CPU operating mode e RUN Execution of Program e STOP Stop of Program 9 Key Switch e PAU REM Mode is as follow gt PAUSE Temporary Stop of program operation gt REMOTE Set when to operate Remote Mode 4 Manual PLC System Reset and Initialization when to occur Error on operation GM4 CPUC only Reset Switch 5 RS 232C Connector Connector for communication with GMWIN or other equipments 6 Memory Module Connector Connector to mount Memory Module in the CPU Module GM4 CPUA only 7 Backup Battery Connector Connector for Backup Battery Flash Memory Run Mode Setup Switch Flash Memory Run Mode Setup Switch GM4 CPUB only Refer to 6 4 for details
58. _AC_F_CNT _CPU_TYPE VER_NUM MEM_TYPE SYS STATE PADT_CNF ea ape ee SEAN iN RST TY _INIT_RUN SCAN MAX SCAN MIN SCAN CUR SCANTCUR SENIN STSK_NUM STSK MAX STSK MIN STSK_CUR oe STSK MAX STSK_MIN RTC_TIME n SYS ERR eta arr Configuration Status information DOMAIN st KEY STATE CPU_CNF _I0_INSTALL n Unavailable Communication Flag FSMn RESET FSMn IO RESET FSMn HS RESET FSMn ST NO Available System Operation Status Information Flag 2 Method of access array variables Method of access BOOL array variables example ANC_WB n In case of requiring overall data ANC_WB In case of requiring an individual unit ANC_WB 1 Method of access BYTE array variables example SLOT Sj n In case of requiring overall data SLOT S In case of requiring an individual unit SLOT S 1 In case of requiring to read 1 Bit in the individual unit SLOT 1 0 APP2 9 Appendix 3 Appendix 3 Function Function Block List Function Function Block List 1 Function List GM4 CPUA B Size of PB Size of library Processing speed Name Function byte 1 byte 2 usec 3 ABS int Absolute value operation 24 1 2 ADD int Addition 24 1 7 AND word Logical multiplication 16 4 3 DIV int Division 32 32 9 DIV d
59. a method other than the original intended method 5 Problems caused by unexpected reasons due to the level of the science technology at the time of the project release 6 In the cases that LGIS is not responsible for such as natural disaster fire etc 3 This warranty means only for the PLC unit body When using the product consider the safety precautions for the system configuration or product application
60. act Q turns off The following diagram shows Off Delay Timer Timing 4 8 Chapter 4 CPU module 3 Pulse Timer Process Time Change and Contact On Off If input condition turns on output contact Q turns on The process time is newly changed when the timer function block is executed When the process time reaches the setting time process time setting time the contact Q turns off The contact turns off after the setting time regardless of input condition off status The following diagram shows pulse timer timing 4 Timer error The maximum timer error is 4 scan time time from the start of scan to execution of the timer function block Chapter 4 CPU module 4 3 6 Counter Processing The CPU module counter increment decrement the present counting value by the detection of rising edge off gt on of input signal Three types of counter are increment counter Decrement counter and Increment Decrement Counter For details refer to GLOFA GM Programming e The Increment counter is a counter which increment the present counting value e The Decrement counter is a counter which decrement the present counting value e The Increment Decrement counter is a counter which compares the counting values of two input conditions 1 Counter Present Value Change and Contact On Off 1 Increment Counter e t should have Input condition CU reset condition R and setting value PV NAME CTU BOOL B
61. al expansion base must be set to group 1 In this case those expansion bases are assigned to 4 5 6 as sequence 2 9 Chapter 2 SYSTEM CONFIGURATION 2 3 2 Computer Link System Computer Link System communicates data between the CPU module and peripheral devices like a computer or a printer by use of RS 232C and RS 422 or RS 485 interface of the computer link module The G4L CUEA is the computer link module for GM4 series For details of computer link module refer to related User s Manual REMARK 1 The follow shows the possible mounting number of computer link module and possibility of mounting on expansion base as CPU models The Possible mounting number Possibility of mounting on Items GM4 CPUA GM4 CPUB GM4 CPUC of Computer Link Module expansion base Chapter 2 SYSTEM CONFIGURATION 2 3 3 Network System The Network system adapted in the GLOFA series is a Fnet system that satisfies the IEC ISA field bus specifications Fnet system as a network system is used for data communications between CPU modules and control of remote I O modules so that distribution of control and concentration of supervision could be easy And also as user s needs Ethernet I F system DeviceNet I F system or Profibus I F system could be built For details refer to Fnet system user s manual 1 System Configuration e Maximum 3 stages of expansion bases could be used in each of remote systems F
62. always generated e Set M area size Setup M area size which is available to use in the program e Method of data type check If Only Warning if Size is Equal is selected if variable size is equal even though variable type is different error is not generated and warning is generated APP1 5 Appendix 1 System Definitions 2 Basic Parameters The basic parameters are necessary for operation of the PLC and used to allocate memory set the restart mode and set the scan watch dog time etc Basic Parameter Configuration PLC name UNNAMED PLC version v1 0 V Remote Access Right Restart mode I Hot Restart C Cold Restart a hr T min a sec Warm Restart Resource CPU property Name Type Scan W D timer Resource 0 RESO 200 ms ome een 1 Configuration PLC Name e Itis a representative name for the PLC system Itis used to designate this PLC system when a network system is configured using communication modules 2 Enabling Disabling the control of the PLC via communications e This parameter is used to enable or disable the remote control of this PLC system through the FAM or computer link module etc except for the GMWIN If this parameter has been set to enable change of the operation mode and download of programs are available via communications 3 M area This parameter is used to set the size of the direct variable area of the CPU module s data buffer T
63. amage preventing interlock circuits such as emergency stop protective circuits positioning upper and lower limits switches and interlocking forward reverse operation When the PLC detects the following problems it will stop calculation and turn off all output in the case of watchdog timer error module interface error or other hardware errors However one or more outputs could be turned on when there are problems that the PLC CPU cannot detect such as malfunction of output device relay transistor etc itself or I O controller Build a fail safe circuit exterior to the PLC that will make sure the equipment operates safely at such times Also build an external monitoring circuit that will monitor any single outputs that could cause serious trouble gt Make sure all external load connected to output does NOT exceed the rating of output module Overcurrent exceeding the rating of output module could cause fire damage or erroneous operation Build a circuit that turns on the external power supply when the PLC main module power is turned on If the external power supply is turned on first it could result in erroneous output or erroneous operation SAFETY INSTRUCTIONS Design Precautions gt Do not bunch the control wires or communication cables with the main circuit or power wires or install them close to each other They should be installed 100mm 3 94inch or more from each other Not doing so could result in noise that
64. an and task programs e The initialization can be executed with the restart mode which has been specified for program 2 Restart mode execution conditions e The initialization tasks can be specified as below complying with the purpose of the initialization task gt Program for Cold Worm restart started by the _INIT task gt Program for Hot Restart started by the _H_INIT task 3 Cold Warm Restart program e The initialization program specified to _INIT task is executed with cold or warm restart mode when the operation starts e This initialization program executes the operations repeatedly until the setting conditions are satisfied that is until the Flag_INIT_DONE in the initialization program turns on However the I O refresh is still executed 4 Hot restart mode program e Task programs specified to the _H_INIT task executes initialization with the hot restart mode when momentary power failure has been occurred e This initialization program executes the operations repeatedly until the setting conditions are satisfied that is until the flag _INIT_DONE in the initialization program turns on In this case I O refresh will not be executed Therefore the operation is executed with the data that has been stored into the input image area before a momentary power failure had occurred 2 Scan program 1 Function e In order to process signals which repeats constantly the program executes its sequential operation repeatedly fr
65. ancel Flash function is inactivated and program in the flash memory is erased 2 3 In case of online editing GM4 CPUC supports writing flash memory during online editing If write in online editing is clicked after online editing in case of setting flash operation mode the follow message is displayed Write program Programs were changed Programs are copied to flash memory Would you like to write programs to flash memory M Not show this dialog box next time if you check this program will be written to the PLC during disconnecting to the PLC Write during Disconnecting Write Now Write during Disconnecting Choose one of them In case of using online editing very often if Write during Disconnecting is selected the program is copied to flash memory in case of disconnecting changing operation mode only in case of writing program to flash memory during online editing flash service is executed for 1 8 of the scan time in order NOT to have an effect on executing time of scan program Therefore the execution requires much time and itis variable according to the scan program In case of online editing in the remote mode it can cause losing data Therefore Use online editing in the local connecting as possible 6 8 Chapter 6 Memory Module And Built in Flash Memory 6 3 2 Setting operation mode In case of re operating PLC systems or changing operation mode
66. and organizes PLC system and is connected with other modules or other module groups Example Main Unit Expansion Unit PLC system Cold Restart A system which consists of the PLC and peripheral devices A user program can control the system To restart the PLC system and user programs after all of the data Variables and programs of I O image area of internal register of timer of counter were set to the specified conditions automatically or manually Warm Restart In the warm restart mode The power supply Off occurrence will be informed to the user program and the PLC system restarts with the previous user defined data and user program after the power supply Off Hot Restart After a power supply Off the PLC system return all of the data to the previous status within maximum allowed time and restarts 1 0 Image Area Internal memory area of the CPU module which used to hold 1 0 Statuses Watch Dog Timer Supervisors the pre set execution times of programs and warns if a program is not completed within the pre set time Function Operation Unit which outputs immediately its operation result of an input while four arithmetic operations comparison operation store their results in the inside of instructions Function Block Operation Units which store operation result in the inside of instruction such as timer and counter and use the operation results which have been stored through many scan
67. aps should not enter into the upper side of the PLC If any foreign matter has entered into it always eliminate it e Do not load or unload the module while the power supply is being connected 1 1 0 module handling instructions The followings explain instructions for handling or installing the input module 1 1 0 module specifications re check Re check the input voltage for the input module 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 AWG 22 0 3 mm or more 3 Environment When wiring the I O module if it locates near a device generating an cause short circuit destruction or malfunction 4 Polarity Before applying the power to a module that has polarities be sure to check its polarities 5 Wiring e Wiring I O wires with high voltage cable or power supply line can cause malfunction or disorder e Be sure that any wire does not pass across during input LED I O status will not be clearly identified e f an inductive load has been connected to output module connect parallel surge killer or diode to a load Connect the cathode part of diode to the part of the power supply Chapter 10 INSTALLATION AND WIRING 6 Terminal block Check its fixing During drilling or wiring do not allow any wire scraps to enter into the PLC It can cause malfunc
68. apter 4 CPU module 4 7 3 Online Module Changing Function Online module changing function is available in the GM4C system However because online module changing can be the reason of the system error extra attentions are required Be sure to follow the steps of the User s manual 1 Precautions for use e The modules in the main base can not be changed e Base power and communication module can not be changed e When changing module be sure to insert the module correctly e All of I O modules can be changed and the follow special modules can be changed gt G4F AD2A G4F AD3A G4F DA1A G4F TC2A G4F RD2A gt G4F DA2V G4F DA2I G4F DA3V G4F DA3I G4F AD3A 2 Module changing method The method of changing module is as follow 1 2 3 4 5 6 Using GMWIN set I O skip function about the slot of the base where the changing module is mounted Using GMWIN set error mask function about the slot of the base where the changing module is mounted Change the module In case of special module Initialize by GMWIN Using GMWIN release the slot from I O skip function eet tos ee Be ee re TFS TOSS Elf After checking the normal operation and also the error flag release error mask function 1 In case of using I O skip function in order to change module cut off the loaded power and in case of using I O force On Off function deliberate to set input image In order to prevent the overall system error caused by changing modul
69. ardized to 10 characters Input variables of trigonometric functions are standardized to average values which are MAX m 031 KOL KOA ES Kea Ds Njo EID aD NPR roProf nro amp ro NINA AI EID EID col S gt DD BIR olos o APP3 2 Appendix 3 Function Function Block List Floating point Arithmetic Function List GM4 CPUC ee ee ABS real Ireal Absolute value operation 36 7 pO eaves _ aaiton CTS TCT SW eae e CSCC TaN eaves ___ areTengertopewton YC COC COS real Ireal Cosine operation 36 75 100 A E sd WT_TO_REAL__ ConersonofoNTypeinmReALpe CT a w eae s S o e o o S EQ real Ireal Equality comparison EXP real Ireal Natural exponential operation EXPT real lreal Exponential operation 230 260 110 5 50 0 LOG real Ireal Logarithm operation LREAL_TO_INT Conversion of LREAL type into INT type LREAL_TO_LINT Conversion of LREAL type into LINT type LREAL_TO_REAL Conversion of LREAL type into REAL type ae ee o ee a ee ee a E ee DO ie ee eee INT_TOLREAL Conversion of NT ype to REALpe o a Ooa a e le E a E ae a a 2 6 32 4 4 4 4 36 36 36 LINT_TO_LREAL Conversion of LINT type into LREAL type LREAL_TO_SINT Conversion of LREAL into SINT type LREAL_TO_UDINT Conversion of LREAL in
70. ated input current 11 mA 110 VAC 60 Hz Operating voltage range 85 to 132 VAC 50 60 Hz 3 Hz Maximum simultaneous input points 100 simultaneously ON Inrush current 600 mA 0 12 msec or lower 264 VAC ON voltage ON current 80 VAC or higher 6 mA or higher OFF voltage OFF current 30 VAC or lower 3 mA or lower Input impedance Approx 10 kQ OFF gt ON 15 msec or less Response time ON OFF 25 msec or less Common terminal 8 points 1 COM Internal current consumption 70 mA Operating indicator LED turns on at ON state of input External connections 20 point terminal block connector M3 x 6 screws Weight 0 29 kg Circuit configuration External connections Internal circuit Terminal No 7 9 Chapter 7 INPUT AND OUTPUT MODULES 7 2 9 16 points 220 VAC input module Model Specifications Number of input points Insulation method GM4 G4l A22A 16 points Photo coupler Rated input voltage 200 to 240 VAC 50 60 Hz Rated input current 11 mA 220 VAC 60 Hz Operating voltage range Maximum simultaneous input points 170 to 264 VAC 50 60 Hz 3 Hz 100 simultaneously ON 8 points 1 COM Inrush current 600 mA 0 12 msec or lower 264 VAC ON voltage ON current 150 VAC or higher 4 5 mA or higher OFF voltage OFF current 50 VAC or lower 3 mA or lower Input impedance OFF ON Approx 10 kQ 15 msec or less Response time ON OFF 25 msec or less
71. ator 16 points indication by selection switch External connections 37 pin D Sub connector Weight 0 18 kg Circuit configuration External connections G40 TR4A G4Q TR4A cupan J a F sit trbeeisasedyyes I r EE H aj 3 AHA a keb 3 os a LI Chapter 7 INPUT AND OUTPUT MODULES 7 3 5 32 point transistor output module source type Models GM4 Specifications G4Q TR4B Number of output points 32 points Insulation method Photo coupler Rated load voltage current 12 24 VDC Operating load voltage range 10 2 to 26 4 VDC Maximum load current 0 1A 1point 2A 1 COM Off leakage current 0 1mA orless Maximum inrush current 4A 10 msec or less Maximum voltage drop at ON circuit 1 0 VDC Surge absorber None Response Off On 2 msec or less time On gt Off 2 msec or less Common terminal arrangement 32 points 1 COM Internal current consumption 160 mA all points ON External Voltage 24 VDC 10 ripple voltage 4VP P or less power supply Current 100 mA or less 24 VDC per COM Operation indicator 16 points indication by selection switch External connections 37 pin D Sub connector Weight 0 18 kg Te DC12 24Ve 7 Connector Pin No 0 s0 O 0 0 070 0 0 0 0 2030302020202080 ORON OBO HONOR ONO NOSO 0204083 O80 s080K0
72. ce and high performance in using special modules compared with the existing methods Therefore take some precautions when composing the system Check the system after the following items have been thoroughly understood 1 Special module programming 1 Special function block is offered for each special module to make programs concise and to prevent errors in writing down the user program 2 Function blocks are largely of two types Initialization function block for initializing special modules and control function block for control of the operations of special modules Function block functions as an interface between the user program data and the special modules As it includes the function that watches the operation status of special modules and indicates the error status other separate error diagnosis program does not have to be written For detailed description of function block refer to the User s Manuals of special modules and GLOFA GM instructions 2 Special Module Initialization This means to define the operations of a special module It is done with initialization function block Generally it specifies the data range to used channel resolution or filtering method etc It defines the hardware characteristics and only one time execution at system start is sufficient 1 As the initialization should be finished before the scan program starts its execution its program should be written in the restart progra
73. cking the product s rated voltage and the terminal layout Incorrect wiring could result in fire damage or erroneous operation gt Tighten the terminal screws with the specified torque If the terminal screws are loose it could result in short circuits fire or erroneous operation gt Be sure to ground the FG or LG terminal to the protective ground conductor Not doing so could result in erroneous operation gt Be sure there are no foreign substances such as sawdust or wiring debris inside the module Such debris could cause fire damage or erroneous operation SAFETY INSTRUCTIONS Startup and Maintenance Precautions gt Do not touch the terminals while power is on Doing so could cause electric shock or erroneous operation gt Switch all phases of the external power supply off when cleaning the module or retightening the terminal or module mounting screws Not doing so could result in electric shock or erroneous operation gt Do not charge disassemble heat place in fire short circuit or solder the battery Mishandling of battery can cause overheating or cracks which could result in injury and fires gt Do not disassemble or modify the modules Doing so could cause trouble erroneous operation injury or fire gt Switch all phases of the external power supply off before mounting or removing the module Not doing so could cause failure or malfunction of the module gt Use a cellular phone or wa
74. ct signal 1 Settings that have to be set for the interrupt module e Set the dip switch to rising edge or falling edge at each contact of the interrupt module complying with the requested conditions 2 Settings that have to be set in the task e Set the contact No of interrupt module and priority module in the task that will be used as start up conditions of the task programs to be executed Check the task No for task control 3 External contact task processing e If an interrupt occurs in the interrupt module by a signal which is applied from the external the CPU module recognize this signal and executes the task program which are invoked by the contact at which the signal has been occurred 4 Precautions for using an external contact task e While a task program which are invoked by an interrupt module contact is being executed or ready for its execution if an execution request of a task program has been occurred to the same input contact then the newly invoked task will be ignored the representative task collision warning flag _TASK_ERR will be set to ON the detailed system error flag _TC_BAMPIn will be set to ON at its corresponding location and the occurrence time of the external task whose execution request has been congested e Execution request for a task program can be accepted only when the operation mode is in the RUN mode That is if the RUN mode has been changed into the PAUSE mode while operating with the RUN mode and t
75. d 2 When I O module skip function is set up e In case of I O module which is set up I O module skip function it is excluded in operation on running and error diagnosis function is not executed If skip function is released on running the I O module is included to normal operation For details refer to 4 6 10 I O module skip function and 4 6 11 module changing function on operation 3 When error mask function is set up e The module which is set up error mask is included on operation and executed error diagnosis function However when system starts if module type disagreement error is occurred operation is continued For details refer to 4 6 9 error mask function Chapter 4 CPU module 4 6 Functions 4 6 1 Restart mode The restart mode defines how to initialize variables and the system and how to operate in the RUN mode when the system starts its operation with the RUN mode by re application of the power or mode change Three restart modes cold warm and hot restart are available and the execution condition for each restart mode is given below For details refer to the 4 5 1 Basic Parameters Edit of the GMWIN User s Manual Section 4 5 Parameters Edit 1 Cold Restart 1 It is executed when the restart mode parameter has been set to the cold restart mode 2 All data are cleared with 0 and only the variables to which their initial value has been defined will be set to their initial valu
76. d by the specified scan times 5 Various Program Executions Time driven task external and internal contact task programs as well as scan program can be executed by setting the execution condition The user can set variously the program execution mode 6 On line Program Editing On line Program Editing is available therefore the user can test systems easily after itis set up 7 Various instruction support GLOFA PLC can support additional instructions steadily without changing CPU module e Various Functions and Function Blocks are supported for various applications e User can make great instruction groups through making out user s own functions and function blocks 1 2 Chapter 1 INTRODUCION 3 GM4 CPUB features GM4 CPUB has the same features with GM4 CPUA and also it has its own features as follow 1 Built in flash memory GM4 CPUB has a 512kb built in flash memory for upload program 2 Communication module Up to 4 communication modules GM4 CPUA 2 modules can be mounted 3 Communication modules on expansion base board Communication module can be mounted on an expansion base board 4 GM4 CPUC features GM4 CPUC has the same features with GM4 CPUA and also it has its own features as follow 1 High speed processing Operation processing of GM4 CPUC is faster than GM4 CPUA B e GM4 CPUA B 0 2 ws step e GM4 CPUC 0 12 ys step 2 Expanded User Program Capacity GM4 CPUC has 1M byte program capacity which is bigger than G
77. e 3 Though the parameter has been set to the warm restart mode cold restart will be executed at the first execution of a program after it has been changed 4 Pressing the manual reset switch the reset command in the GMWIN performs same function makes the system operate with the cold restart mode regardless of the restart mode set by the parameter 2 Warm Restart 1 It is executed when the restart mode parameter has been set to the warm restart mode 2 If a data is specified so that it can retain its previous value the value remains during the warm restart If a data has been set to an initial value the value will be set during the warm restart All other data will be cleared with 0 3 Though the parameter has been set to the warm restart mode cold restart will be executed at the first execution of a program after it has been stopped due to its down load and error 4 Though the parameter has been set to the warm restart mode cold restart will be executed if data contents are abnormal i e the data does not remain at a power failure 3 Hot Restart 1 If the operation mode is in the RUN mode when the power is re applied after a power failure and the time from power failure to re application of the power falls into within the allowable hot restart time the operation starts with the hot restart mode 2 All data and program execution elements will be restored to their state before the power failure As the program is
78. e It means to store the user program in the program memory of the CPU module to the memory module That is only available when the operation mode is the STOP mode e The following shows the method of writing a user program to the memory module Start Power On Change the operation mode to the STOP mode and turn the power off Mounting the memory module Mount correctly the memory module onto the connector for memory module in the CPU module Turn the power on Check the memory module information Use the GMWIN to check the memory module just mounted Execution Select the Flash Memory Write in the GMWIN This instruction makes the contents of the program memory of the PLC written to the memory module A program to be stored into the memory module has to exist in the program memory Complete HINT 1 For detailed handling instructions refer to the chapter 7 Flash Memory of the GMWIN User s Manual 6 2 Chapter 6 Memory Module And Built in Flash Memory 6 1 3 Operation method e Be sure to turn the power off when mounting the memory module onto the CPU module e f the operation mode is the RUN mode when the power is turned on or the operation mode changes from other mode into the RUN mode after the power has turned on a user program in the memory module starts its operation after it has been written to the program memory of the CPU module Start Power
79. e GOL AD3A DC 1 to 5V DC Oto 10V DC 4 to 20 mA moaules GOL DA3I l Current output 8 channels e DC 4 to 20 mA Repeater GOLFREA Optic converter GOL FOEA e Optic Electric converter GOL FAPA e Power supply board for active coupler Po Active coupler LGOL FABA e Base unit for active coupler a GOL FACA e Card for active coupler fF GOL FADA e Dummy card for active coupler PY Computer link module G4L CUEA e RD 232C RS 422 1 channel for each 5 e Comply with IEEE 802 3 Enet I F module G4L EUEA e 10 Base 5 10 Base T G4L DUEA Je DeviceNet I F module e Dnet slave module GOL DSIA e 16 point DC12 24V input DeviceNet I F module e Comply with ODVA 2 0 e Dnet slave module GOL DSQA e 16 point relay input e Comply with ODVA 2 0 LPUER Profibus DP I F module G4L PUEA e Profibus DP master module I O 1K G4L PUEB e Profibus DP master module I O 7K Others Pseudo input switch G4S SW16 e 16 point pseduo switch for GM4 input Dust protection module GM4 DMMA e Keeps unused slots from dust ee 2 5 Chapter 2 SYSTEM CONFIGURATION 2 3 System Configuration Types System configuration is classified into 3 types First Basic system that is configured with only basic and expansion base units Second Computer link system that executes data communications between the CPU module and a computer by use of a computer link module G4L CUEA Third Network system which is used to control the PLC and remote I O modules 2
80. e Select Project Option Auto Save in the menu e Setup the Auto save time cycle Setting 0 to 60 minutes is available In case of set 0 auto save function is not executed e Click OK button APP1 3 Appendix 1 System Definitions 4 Monitor Debug Option Various kinds of monitor and debug option is available to set up The follow shows the configuration method e Select Project Option Monitor Debug Option in the menu e Monitor display type the type which displays the monitored variables e SFC monitor On monitoring itis scrolled automatically according to monitoring locations e Debug option On LD debugging debug unit can be divided by point or line as required types APP1 4 Appendix 1 System Definitions 5 Make Option In the Make Option compile type output file and M area size are available to set up The follow shows the configuration method e Select Project Option Make Option in the menu e Select compile type gt All Compile Compile is executed again from beginning without regard to editing source program gt Incremental Compile Only modified part of source program is compiled based on previous compiled information gt Preserve Retain In case of PLC restarts in warm mode when selecting preserve retain the variable which is defined to retain variable e Select output file It is available to select whether to include comment when executing Make Upload program is
81. e input terminal and CPU Is the indicator LED of the output module ON terminal Is the indicator LED Of the input module ON Is the voltage of power supply for load applied Check the input signal OFF in monitor mode with the peripheral devices Check the wiring load of the power Supply for load and restore the power Is the voltage of power supply for load applied pply pp Check external wiring and external input equipment Output module defect Check the wiring load of the power supply for load and restore the power Contact the nearest service center 1 If the input or load signals are not switched OFF see Section 12 4 1 l Chapter 12 TROUBLE SHOOTING 12 2 5 Troubleshooting flowchart used when a program cannot be written to the CPU module The following flowchart shows the corrective action procedure used when a program cannot be written to the PLC module Program cannot be written to the PC CPU No Set the key switch to the remote STOP mode and execute the program write Is the key switch set the remote STOP mode Yes Read the error code using the peripheral devices and correct the contents Is the STOP LED flickering Chapter 12 TROUBLE SHOOTING 12 3 Troubleshooting Questionnaire When problems have been met during operation of the GM4 series PLC please write down this questionnaires and contact the service center via telephone or facsi
82. e or module error when handling module change be sure to set error mask function as above steps 1 In case of mounting module if the module is mounted incorrectly it can cause malfunctions of the other modules Be sure to that above hook of module is inserted to above joint of base entirely Chapter 4 CPU module 3 Initialization of special module Special module is necessary to initialize again in case of being reset special module on CPU operation because special modules have initialization function of channel specification by S W 1 Initialization of special module by GMWIN e In case of changing special module as the above module changing method 4 select Initialize special module in the Online menu of GMWIN and then initialize as follow method G4F DA2V G4F DA2I G4F DA3V and G4F DA3I are not necessary to initialize gt Assign slots of the special module to initialize gt Assign the value which is the same with initial value of initial function block in the program Changing remote base Remote base can be attached and detached on operation so when changing module extra handling is not necessary because there is initialization program of special module on operation program Chapter 4 CPU module 4 7 4 0 Reservation Function 1 Uses and operation introductions I O Reservation Function is the function which can be used in order to add other I O modules without stopping system
83. e power supply module 8 1 Selection of power supply module Selection of the power supply module is determined by the total current consumption of digital input modules special modules and communications modules etc whose powers are supplied by the power supply module If total load overrun the rated output capacity the system will not normally operate When configuring a system select a power supply module with due consideration of current consumption of each module Current consumption of GM4 series modules unit mA Modules Models c umen Modules Models Current Consumption Consumption GM4 CPUA 130 l G4F AD2A 400 A D Conversion Module CPU Module GM4 CPUB 130 G4F AD3A 500 GM4 CPUC 700 G4F DA1A 450 G4l D22A 70 G4F DA2V 400 G4l D22B 125 D A Conversion Module G4F DA2I 680 G4l D22C 125 G4F DA3V 700 DC12 24V Input Module G4l D24A 125 G4F DA3I 60 G4l D24B 70 G4F HSCA High Speed Counting G4l D24C 70 Module G4F HO1A G4l D28A 100 G4F HD1A 110VAC Input Module 220VAC Input Module Relay Output Module G4I A12A 70 G4F POPA G4I A22A 70 G4F POPB G4Q RY2A 100 G4F PP10 G4Q TR2A 120 G4F PP 20 Positioning Module G4Q TR2B 120 G4F PP30 G4Q TR4A 160 G4F PP1D G4Q TR4B 160 G4F PP2D G4Q TR8A 250 G4F PP3D Transistor Output Module 8 1 Chapter 8 POWER SUPPLY MODULES Modules Models Current Co
84. e sure to 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 Chapter 10 INSTALLATION AND WIRING The following shows the procedure for calculating the PLC system power consumption 1 PLC system power consumption block diagram AC110 220V Sewer eee nee 2 Power consumption of each part 1 Power consumption of a power supply module Approximately 70 of the power supply module current is converted into power and 30 of that 70 dissipated as heat i e 3 7 of the output power is actually used e Wow 3 7 Isv x 5 Izv x 24 W where Isv 5 VDC circuit current consumption of each module lav 24 VDC circuit average current consumption of output modules with points simultaneously switched ON Not for 24 VDC power supplied from external or power supply modules that has no 24 VDC output 2 Total 5 VDC power consumption The total power consumption of all modules is the power of the 5 VDC output circuit of the power supply module e Wsv I5v x 5 W 3 Average 24 VDC power consumption with points simultaneously switched ON The total power consumption of all modules is the average power of the 24 VDC output circuit of the power supply module e Wav 124y x 24 W 4 Average power consumption by voltage drop of output modules with points simultaneously switched ON e Wout lout x Vdro
85. ecifying the used channel No Line 7 ADO1_DT Specifying the data type Line 8 ADO1_FE ad Filter enable disble specification Line 9 ADO1_FV Setting the filter value Line 10 ADO1_AE Average processing enable Line 14 idisable specification ADO1_AS 2 Specifying count time averaging Line 12 ADO1_NT Setting count time average value Comment F H The moduk D A 02 intiaization H ine 14 DA02_INI Ane DAAIN 10FF Line 15 REQ DONE ine 16 0 4 BASE STAT DA02 STAT ee Line Specifying the loaded base No Indicafing the error status during initialization function block execution ine 17 2 SLOT ACT DA02_ACT D Specifying the loaded slot No Indicating the run channels during initialization function block execution Line 18 DA_CH CH Specifying the used channel Line 19 DA02_DT Specifying the data type Indicating the error status during initialization A DA02 SE function block execution Line 20 Specifying the D A conv rsion module output status when the CPU modules is in the STOP state Comment HHH The moduk D A 03 intialization HH DAO4_WR 10FF A aa DA4AWR Indicating the error status ine 22 RE DONE REQ DONE during initialization Line Q function block execution eos BASE STAT _ DA03 STAT 0 BASE STAT j DAQS_STAT i Specifying the loaded base fe Spectiing the loaded base No Line 24 3 SLOT ACT L DA03 act a CoS pb AEN oe indicating the run channels Specifying the loaded slot No J Speciying he W during initialization Line 25 2 CH function block
86. ect variable area Stack area 4K byte 4K byte 4K byte Chapter 4 CPU module 3 Purpose 1 System area Used to store the self created data of the CPU module for system management and GMWIN system control data 2 System flag area Used to user flags and system flags The user operates it with flag name 3 Input image area Used to store input data read from input modules Overall size is IX0 0 0 to IX63 7 63 however the area IX 0 0 0 to IX3 7 63 is really used for input module area The area that is not used by the real input module loaded is a free area that the program can use Especially it will be convenient to use that free area for storing remote input data through high speed link 4 Output image area Used to store operation results The stored data are automatically output to output modules Overall size is QX0 0 0 to QX63 7 63 however the area QX 0 0 0 to QX3 7 63 is really used for output module area in the GM3 4 series The area that is not used by the real output module loaded is a free area that the program can use Especially it will be convenient to use that free area for storing remote output data through high speed link 5 Direct variable area The user can use this area to access direct memory data through the variable names such as MX0 MBO MWO MDO and MLO which was pre defined by the system 6 Symbolic variable area Used to store the variabl
87. ed and applied to the continuing operations 2 Direct output e Direct output is executed by use of the DIRECT_O function If this function is used the data of the output image area which has the operation results by the time will be directly output to the direct output module 3 Force on off e Force on off settings are still effective when processing direct I O 1 For detailed direct I O functions refer to the GLOFA GM commands 4 6 7 History Log In History Log In is classified into three types i e error history mode change history and power off history Up to latest 16 histories are stored 1 Error recording time and content 1 Error history e Recording time When an error has occurred during operation e Stored content Occurrence time and error code 2 Mode change history e Recording time When an operation mode change has occurred e Stored content Occurrence time operation mode and restart mode 3 Power off history e Recording time When a power off has been occurred during operation in the RUN mode e Stored content Occurrence time 16 Occurrence count 1 2 Stored History Data Reset The stored history data will not be cleared until it is cleared by menu selection in the GMWIN 1 For detailed instructions refer to the PLC information in the GMWIN User s Manual Chapter 7 On line Chapter 4 CPU module 4 6 8 External Device Error Diagnosis function Flags are gi
88. ely engaged 1 0 modules e Check if the upper cover is securely mounted Securely engage the hook Retighten r p Check for loose terminal screws Screws should not be loose t 9 Connecting conditions erminal screws of terminal block or Check the distance between solderless The hook should be securely engaged Proper clearance should be provided Correc extension cable terminals Check connectors of extension cable Connectors should not be loose Correc Power LED Check that the LED is ON ON OFF indicates an error See chapter 12 Run LED Check that the LED is ON during Run ON ON or flickering indicates an error Stop LED Check that the LED is OFF during Run OFF ON indicates an error Input LED Check that the LED turns ON and OFF ON when input is ON OFF when inputis off ON when output is ON OFF when output is OFF Output LED Check that the LED turns ON and OFF Chapter 11 MAINTENACE 11 3 Periodic Inspection Check the following items once or twice every six months and perform the needed corrective actions Check Items Corrective Actions Checking Methods J udgment Ambient environment temperature Ambient humidity Ambience Measure with thermometer and hygrometer Measure corrosive gas 0 to 55 C 5 to 95 RH There should be no corrosive gases PLC conditions Looseness Ingress of dust or foreign material Move the unit Vis
89. ere the operation has to stop are specified the operation stops when the specified operation occurs at the specified contact Executed by the specified If the number of scan that will be operated is specified the operation stops scan number after it has operated by the specified scan number 4 Operation method 1 Execute the operation after the debug operation conditions have been set in the GMWIN 2 In task programs each task can be specified to operation enable disable For detailed operation method refer to the GMWIN User s Manual Chapter 9 4 5 5 Operation mode change 1 Operation mode change methods The following method are used to change the operation mode 1 Change by the CPU module mode keys 2 Change by the GMWIN connected with the CPU module communications port 3 Change by the GMWIN connected to the remote CPU module through Fnet 4 Change by the user s command using FAM or computer link module etc 5 Change by the STOP function during program execution 2 Operation mode change by the CPU module mode keys The following shows the operation mode change by the CPU module mode keys Mode key position Operation mode RUN Local RUN STOP Local STOP STOP PAU REM Remote STOP PAU REM gt RUN 1 Local RUN RUN PAU REM Local PAUSE PAU REM STOP Local STOP 1 1 If the operation mode changes from RUN mode to local RUN mode by the mode key the PLC operates continuously
90. erences Operating ambient 5 temperature eee Storage ambient temperature Operating ambient humidity Storage ambient humidity 25 475 C 5 95 RH non condensing 5 95 RH non condensing Occasional vibration Frequency Acceleration Amplitude Sweep count 10s f lt 57 Hz 0 075 mm 57 lt f lt 150 Hz 9 8 m s 1 G Continuous vibration Vibration 10 times per IEC 61131 2 axis 10 lt f lt 57 Hz 57 lt f lt 150 Hz 4 9 m s2 0 5G Maximum shock acceleration 147 m s2 15G Shocks Duration time 11 ms IEC 61131 2 Pulse wave half sine pulse 3 shocks per axis on X Y Z axis Square wave Impulse Noise 1 500V Electronic discharge Radiated electromagnetic field 27 500 MHz 10 V m noise Frequenc Acceleration Amplitude on X Y Z axis Mossin osm IEC 61131 2 IEC 801 3 IEC 61131 2 IEC 801 3 Voltage 4 kV contact discharge Noise Immunity Digital 1 0 Power Digital 1 0 lt 24V ane Item supply gt 24V Analog 1 0 interface Voltage 2 KV 1 kv 0 25 kV Free of corrosive gases and excessive dust IEC 61131 2 IEC 61131 2 IEC 801 4 Operating ambience Altitude 2 000 m or less Pollution 2 Cooling method Air cooling 1 IEC International Electromechanical Commission An international civilian institute who establishes international standards in area of electric s and electronics 2 Pollution An indicato
91. errupt operation method If a situation occurs which is requested to be urgently processed during execution of a PLC program this operation method processes immediately the operation which corresponds to interrupt program The signal which informs the CPU module of those urgent conditions is called interrupt signal The GM4 CPU module has two kind of interrupt operation methods which are internal and external interrupt signal methods 4 3 2 Operation processing at momentary power failure occurrence The CPU module detects any momentary power failure when the input line voltage to the power supply module falls down below the defined value when the CPU module 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 t 2 The operation processing is resumed when normal status is restored Input powe 3 The output voltage of the power supply module retains the defined value Momentary powey fallure wilh 20 ms 4 The watch dog timer WDT keeps timing and interrupt timing normally while the operations is at a stop 2 Momentary power failure exceeding 20 ms e The re start processing is executed as the power is applied Sewn input power Momentary power failure exceeding 20 ms 1 Momentary power failure The PLC defining power failure is a state that the voltage of power has been lowered outside the allowable
92. es that the user created that is whose names the user defined when writing a program Global variables and instance memory are located in this area The variables used in program blocks locates in the PB instance memory of the program and the memory used in function block locates in the FB instance memory The maximum size of the PB instance memory is 32K byte If the used size overruns the maximum size divide the program blocks or use global variables Chapter 4 CPU module 4 9 1 0 No Allocation Method 1 I O No allocation means to give an address to each module in order to read data from input modules and output data to output modules 2 Fixed 64 points are allocated to each module for I O points 3 Fixed 64 points are allocated regardless of mounting dismounting or type of modules 4 The following shows I O No allocation method Input I X 0 0 0 Output Q X 0 1 15 1 0 Module junction No 0 to 63 Slot No 0 to3 M4 0 to6 HINT The main base having 12 I O slots is recognized as base no 1 O U Cc Slot no 123 45 67 8 9 10 11 YC oY Base no 0 1 Chapter 5 BATTERY Chapter 5 BATTERY 5 1 Specifications Item Specifications Normal voltage Warranty life time Application Programs and data backup and RTC runs in power failure Specifications Lithium Battery 3 V External dimension mm 0145 x 26 5 2 Precautions
93. evice Oo O Other Base board Se o O i S Heat generating device gt Fig 10 1 PLC mounting 50mm or more Chapter 10 INSTALLATION AND WIRING pa D Oo rey te ee relay etc LC a a EO Hee 100mm or more al Fig 10 2 Clearance from the front device Fig 10 3 Vertical mounting Bad Fig 10 4 Horizontal mounting Bad 10 6 Chapter 10 INSTALLATION AND WIRING 10 1 3 Mounting and Dismounting of module The following explains the mounting and dismounting of various modules 1 Module mounting e Insert the module fixing projections in the upper part into the module fixing hole in the base board e Install the module onto the base board by pushing the bottom forward and fix it onto the base board with module fixing screws e Check that the module is firmly mounted onto the base board by pulling the upper part of the module Module fixing hole y 1 When installing the module make sure that the module fixing projections is inserted into the module fixing hole and fixed If the module is forcibly mounted the pins in the module connector may be bent or damaged Chapter 10 INSTALLATION AND WIRING 2 Module dismounting e First release the module fixing screws in the bottom from the base board e While pushing the hook latch pull the upper part of the module toward you e While lifting the module upwards and remove the m
94. execute programs Each task consists of one or more program blocks in the three types of program Those programs are called task programs A program to which a task has not been specified as marked with 1 will be automatically specified to scan program Chapter 4 CPU module 1 Task types and functions The following table show the types and functions of tasks iia Di Time driven task External interrupt task Internal interrupt task Specification 8 GM4 CPUA B Number 32 GM4 CPUC 8 16 Time driven interrupt Rising or falling edge of The rising eagen the G BOOL variable data which Start up condition up to 4 294 967 29s by the interrupt module input v has been specified of 10ms contact buffer data Immediately executed Executed with edge Detection and Executed periodically as when an edge occurs in detection after scan exouion setting ime the interrupt module program has been finished Maximum 5ms delay pekan delay Up to Sms delay Interrupt module delay Delayed or he sang ime time within 0 5ms as maximum scan time Sa Level 0 to 7 Execution priority Level 0 has highest priority Level 0 to 7 Level 0 to 7 Task N mber 0 to 31 User set it up notto 32 to 39 User set it up not 48 to 63 User set it up not overlap to overlap to overlap 2 Task program processing Method The following explains the common processing method and instructions for task programs 1 Tas
95. executed from the state just before the power failure continuity of the program is maintained even at the momentary power failure 3 If the allowable hot restart time has been overrun the restart mode which has been set by the parameter will be executed 4 Cold restart will be executed if data contents are abnormal i e the data does not remain at a power failure 1 Consider the followings when setting the allowable hat restart time 1 The system executes the hot restart initialization program if the time from a power failure to completion of system check after the restore is less than the setting time 2 If a power failure occurs again before the hot restart initialization program completes its execution the hot restart program executes again If a power failure of 20 ms or more has occurred about 0 5 sec delay can occur until the system operates normally after it has been restored form the power failure The allowable hot restart time is set by the second Chapter 4 CPU module e Restart mode is executed as the figure given below when the power has been re applied during execution of the CPU module Power applied Operation mode STOP Operation in the STOP mode Abnormal RUN Data that remains at power failure Hot restart time Over the time Within the time Cold Restart Restart mode Warm Restart Hot Restart executed Warm Restart executed a Operation in the RUN mode 4 Da
96. execution DA03_CH S Indicating the run channels during initialization q Specifying the used channel function block execution Line 26 reaa e a DATA DA03_OUT 4 DATA J TYPE Inputting the digital Specifying the data type SEL data to be set Line 27 DAQ3_SE 4 Specifying the D A conversion Line 28 module output status when the CPU modules is in the STOP state Line 29 F ADONI DAO2INI DAQ3_INI _INIT_DON 7 DONE DONE DONE E Line 30 TE The initialization The initialization The initialization Initialization program function block function block function block complete AD01_INI has normally DA02_INI has normally DA03_INI has normally finished finished finished 4 27 Chapter 4 CPU module e Program scan src scan program Comment Line Line Line Line Line Comment Line Line Line Line Line Line 11 12 Comment Comment Comment Line Line Line Line Line Line 20 21 A D 01 every scan HH H HH Reading the data of the moduel ADO1_RD AD4RD D A 02 every scan HHH Specifying the loaded Base No Specifying the loaded Slot No Specifying the used channel No REQ DONE 0 BASE STAT AD01_STAT E Indicating the error status during the reading function block execution AD01_DT Indicating the A D conversion value data of the used channels 1 SLOT DATA ADO1_CH CH HHH Reading the data of the moduel DAO2_WR DA4AWR
97. expansion base F Enet reset operation is finished _RCV_SERVx_M_CH BIT FEne The indication of channel of module e The flags which are used for monitor of the status of the FEnet in order to reset ARRAY in the slot No x of main base FEnet _RCV_SERVx_E_CH BIT FEne The indication of channel of module ARRAY in the slot No x of expansion base _RCV_SERV_CNT_M BIT FEne The indication of count value of ARRAY receiving of the module in the main base _RCV_SERV_CNT_E BIT FEne The indication of count value of ARRAY receiving of the module in the expansion base 11 Access Pass Configuration of Flag GM4 CPUC The parts of flags is registered for access variables automatically so variable service through network is available without special handling in the user s program 1 Access variable configuration Flag Group Access Variable Name of writing data User Flag _INIT_DONE RTC_DATE RTC_TOD RTC_WEEK ailable to write INIT_DONE only System Error Represent Flag CNF ER Unavailable System Error Mask Flag CNF ER M ANNUN ER M BASE Min SLOT Min System Warning Represent Flag _CNF_WAR Unavailable _IO_TYER_N _lO_TYERR n lO _DEER_N IO _DEERR n ilable to write only s FUSE ER_N FUSE _ERRInj 10 RWER_N 10 _RWERRIn C_ERRIn _ANC_WAR n System Error and Warning Details Flag SP IFERN SP_IFERR n ANC ERR n ANC WARIn ANC_WBIn C WBhn TC_BMAP n TC_BMAP n _TC_CNTIn BAT ER_ TM AC F_CNT AC F_TMIn CNTIn
98. f connection it set to 1 and when connection is released it will be case of connection set to 1 cleared with 0 _FSMn_reset BIT Fne Remote 1 0 station S W reset e Requests reset for remote 1 0 station Write is enabled Request can be done individually or wholly complying with the settings in the FSMn_st_no _FSMn_io_reset BIT Fne Remote 0 station digital output e Requests output reset for remote O station Write is enabled reset e Request can be done individually or wholly complying with the settings in the FSMn_st_no _FSMn_hs_reset BIT Fne Remote O station high speed e If a momentary power failure occurs in the remote I O station the operation ink information initialization mode bit of high speed link information turns off and link trouble has the value 1 If the bit is turned on to clear that bit the operation mode bit tums on and ink trouble is cleared with 0 e Request can be done individually or wholly complying with the settings in the FSMn_st_no _FSMn_st_no USINT Fnet Numbers of I O stations where e Sets the numbers of I O stations where FSMn_reset FSMn_io_reset and _FSMn_reset _FSMn_io_reset _FSMn_hs_reset will be executed Write is enabled and _FSMn_hs_reset willbe e00 to 63 gt individual station No setting executed Write is enabled 255 gt Whole station No setting 2 Detailed High Speed Link Information Flag List nis slot No where high speed link module is mounted n GM4A 1
99. flag by the operation function FN or function block FB ERR BOOL Enable eae z flag Itis newly changed whenever an operation is executed _T20MS BOOL 20 msec Clock These clock signals are used in the user programs toggles on off every _1100MS BOOL 100 msec Clock half cycle The clock signal can be delayed or distorted in accordance with _T200MS BOOL 200 msec Clock program execution time as the signal toggles after scan has been JTS BOOL 1 sec Clock finished therefore it is recommended that clock of enough longer than _T2S BOOL 2 sec Clock scan time be used Clock signals starts from Off when the initialization T105 BOOL 10 sec Clock program or scan program starts T205 BOOL 20secclock Example _T100MS clock _T60S BOOL 60 sec Clock _ON BOOL Always On Usable in user programs _OFF BOOL Always Off Usable in user programs _10N BOOL Firstscan On Turn On only during the first scan after the operation has started _10FF BOOL Firstscan Off Turn Off only during the first scan after the operation has started Toggles On Off at every scan while a user program is being executed On _STOG BOOL Scan Toggle atthe first scan INT DONE BOOL Enable Initialization Program If this flag is set to on in the initialization program in an user program the ora Complete initialization program stop its operation and the scan program will starts _INT_DATE DATE RTC present date Date Data of standard for
100. g dismounting occurred and indicates the slot locations in the bit map of base Oto6 error occurred units GM4A B FUSE ER N UINT 0 to 31 The number of slot This flag detects that fuses of fuse mounted modules has broken F aye GM4C where fuse breaks and indicates the lowest slot No of the detected slot numbers 0 to 56 n GM4A B FUSE ERR n BYTE 0to3 The location of slo This flag detects tha fuses of fuse mounted modules has broken GM4C where fuse breaks and indicates the slot locations in the bit map of base units 0 to 6 GM4A B 0to31 The number of slot This flag de ects that inpu modules of a slot cannot be normally _IO_RWER_N UINT GMAC where I O module read from or written to and indicates the lowest slot No of the 0 10 56 read write occurred detected slot numbers Tee The location of slot This flag detects that input modules of a slot cannot be normally _IO_RWERR n BYTE GMAC where 1 0 module read from or written to and indicates the slot locations in the bit map 006 read write occurred of base units GM4AB This flag detects that initialization cannot be executed for special or SP IFER N UINT 0 to 31 Special link module link module of a slot or normal interface is impossible due to module se GM4C interface error slot No malfunction and indicates the lowest slot No of the detected slot 0 to 56 numbers n GM4A B This flag detects that initialization cannot be executed for special or SP IFERRIn BYT
101. gram designate task number 48 to _STSK_NUM and start task with GMWIN Measure the value of _STSK_MAX BS After stop other task program and start the program including interrupt task program designate task number 32 to _STSK_NUM and make input of interrupt input module turn on Measure the value of _STSK_MAX Ga It is available to measure this by set the priority of measuring task as most significant to prevent from any delay by another task after executing the main program in task of 2 to 4 S If the measured max operation times are Tp0 17ms Tp1 2ms Tp2 7ms Tp3 2ms the basic scan time will be 24ms Tp0 Tp2 when single task is started during program operation Time driven interrupt occurs 2 times in the above case so scan time is 28ms Tp0 Tp2 Tp1 X 2 If external interrupt occurs in here scan time will be 30ms Tp0 Tp2 Tp1 X 2 Tp3 and max scan time will be 32ms Tp0 Tp2 Tp1 X 3 Tp3 because time driven interrupt can be occur 1 time If the external interrupt can be occur in 32ms consider the number of occurrence of time driven interrupt after adding the operation time See the timing chart in chap 4 4 3 4 3 4 Scan Watchdog 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 GMWIN 2 When watchdog timer detects an exceeding of preset watchdog time the operation of PLC is stopped
102. he 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 software The system enter into the STOP state 3 Operation error during execution of the user programs If 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 watch dog time or I O modules loaded are not normally controlled the system enters into the STOP state 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 1 In 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 Chapter 4 CPU module 4 4 5 Precautions when using special modules This system offers convenien
103. he operation mode has been changed into the RUN mode again all execution requests occurred during the operation with the PAUSE mode will be ignored 5 Internal task program processing method The following explains the processing method when the task start up condition of a task program has been set to the contact of direct variable area I Q or M or automatic variable area 1 Settings that have to be set for the task e Set the contact and priority that will be the startup conditions of the task program that will be executed Check the task No for task control 2 Internal contact task processing e After the execution of scan program has been completed in the CPU module the contacts that are the start up conditions of the task program will be checked and the internal task programs where rising edge has been occurred will be executed with its priority Task program will be executed only once when rising edge is detected 3 Precautions when using an internal task program e The internal task program is executed when scan program has finished its execution Therefore though the execution condition for the internal task program has been invoked in the scan program or task program time driven external the task start up condition will not be immediately executed but will be executed when scan program has finished its execution Chapter 4 CPU module e f execution of an internal task program is requested the execution condition
104. hed 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 2 Debug operation is executed complying with the setting status 3 Output refresh is executed after the debug operation has been executed to the end of a program 4 Normal or abnormal operation and mounting conditions of the loaded module are checked 5 Communications service or other internal operations are processed Chapter 4 CPU module 3 Debug operation conditions e Two or more of the following four operation conditions can be simultaneously specified Operation conditions Description Executed by the one If an operation command is ordered the system operates one operation unit operation unit step over and stops Executed to the specified e f breakpoints are specified in the program the operation stops at those breakpoint breakpoints e Up to 32 breakpoints can be specified Executed according to If the contact area to be watched and the condition Read Write Value the contact state wh
105. his buffer area is an area where direct addressing is available by the direct addressing parameter M when writing a program The buffer size set by the parameter limits the buffer area that can be addressed directly by M APP1 6 Appendix 1 System Definitions 4 Restart Mode e This parameter is used to set the restart mode in the PLC system When the system re starts one of the cold restart or warm restart is selected in compliance with the parameter setting 5 Hot Restart e This parameter is used to set the hot restart mode and hot restart allowable time The allowable time can be set to up to the 23 hour 59 minutes 59 second by the 1 second 6 Resource CPU Name e Resource Name is the name that each CPU module configuring the PLC has When configuring a network system the name is used to designate each CPU module that is used the system e Only one CPU module can be mounted in the GM4 series therefore only the resource 0 is valid 7 Scan Watch Dog Time e This parameter is used to set the maximum allowable execution time of an user program in order to supervisor its normal or abnormal operation e Only one CPU module can be mounted in the GM4 series therefore scan watch dog is valid to only the resource 0 APP1 7 Appendix 1 System Definitions 3 0 Configuration Parameter These parameters are used to set the configuration of a system that will be operated They set the modules
106. i 1 HHH The module A D 01 intialization H iy RE 0 4 Specifying the loaded Base No 1 Specifying the loaded Slot No 7 ADO1_CH CH Specifying the used channel No ADO1_DT DATA Specifying the data type TYPE AD01_FE 7 FILT Filter enable disble specification EN ADO1_FV FILT Setting the filter value VAL AD01_AE AVG_ Average processing enable EN disable specification AD01_AS AVG_ Specifying count time averaging SEL ADO1_NT NUM ADO1_INI DONE BASE STAT ADO1_STAT Indicating the error status during initialization function block execution SLOT ACT ADO1_ACT TIME Setting count time average value M HHH The moduk D A 02 intialization 4H L Specifying the D A conversion DAQ2_SE REQ DONE DAQ2_INI DAAINI Indicating the run channels during initialization function block execution Indicating the error status during initialization function block execution 0 4 BASE STAT DA02 STAT Specifying the loaded base No SLOT Indicating the run channels during initialization function block execution 2 ACT DA02_ACT Specifying the loaded slot No DA_CH CH Specifying the used channel DA02_DT 4 DATA Specifying the data type TYPE SEL es S E a Eram Ly module output status when the CPU modules is in the STOP state i HH The module DIA 03 intiaization HH agg iy DAAINI a REQ DONE Ce canes eae tatus during initiali
107. in the user defined mode the bit corresponding to k Station No received Indicated at each setting No is turned ON If RCV_MSG F B has read that that bit will be setting No Received 1 cleared with 0 APP2 7 Appendix 2 Flag List 1 Communications Module Information Flag List continued Keyword Type ae Name Description _ECMn_CHx_FL BIT Enet FEnet The indication of received frame e When a receiving frame is received through using Enet function is received in AG k ARRAY FDEnet about each of channels each channels defined No Bit of frame editor RCV is set to 1 If F B has x 0 to15 k 0 to ndicated at each setting No read that that bit will be cleared with 0 7 k Station No Received 1 RCVn_ECMIk BIT Enet FEnet The indication of even one of e When a receiving frame is received through using Enet function is received in k 0 to 7 ARRAY FDEnet received frame about each of each channels if there is even one of receiving frame No Bit in channel is k Station No channels Indicated at each set to 1 If F B has read that that bit will be cleared with 0 channels Received 1 If ECMn CHnCHx FLAG k is set RCVn ECMIk x k is set to 1 _SERVn_CH_EN BIT Enet FEnet The indication of connection for e When communicating for dedicated service in the high ranked PC or MMI in FDEnet dedicated communication in case o
108. ing by local key Download the program in the stop mode and then set key switch to RUN 2 Starting by GMWIN Set key switch to PAU REM and then select RUN in the GMWIN Online menu 3 Starting by turning on power Set key switch to RUN and then turn on power On the other hand if key switch was Remote RUN mode just before turning off PLC and it is PAU REM mode right now it is available to start when to turn on power 4 Restarting by reset key There are two kinds of reset Reset and Overall reset Chapter 4 CPU module e Reset It is operated by pushing reset switch in front of CPU module It is same operation with turning on power off gt on e Overall reset It is operated by pushing reset switch in front of CPU module over 5 seconds 2 Starting method by system setting 1 Normal starting e When turning on power CPU module checks system configurations If it is late to turn on power of expansion bases it waits turning on power of them In the STOP mode after 10 seconds waiting error is occurred e After editing program the first starting is cold restart e When restarting the system which was stopped by normal method it restarts according to set up parameter There are key switch GMWIN turning off power and reset in the starting methods e If it was stopped by error on running restart method is decided according to kinds of error and release metho
109. int i DIV _ int dint DIV iint EQ int dint Equality comparison AND _ lword Logical multiplication MAX _ intdint MUL lint MUX MUX lint ROL Addi AND word dword Logical multiplication Divis ROL BCD TO DINT ion of BCD type into DINT type 24 280 BCD TO SINT Conversion of BCD type into SINT ype G BYTE_TO_SINT Conversion of BYTE typeintoSINTtype 20 TH DATE TO STRING Conversion of DATE type into STRING type 48 TH DINT TO_INT Conversion of DINT type into INT type HP 172 Conversion of DT type into DATE type Conversion of DT type into TOD type DT_TO_STRING Conversion of DT type into STRING type DWORD TO WORD Conversion of DWORD type into WORD type Conversion of INT type into DINT type Conversion of INT type into BCD type Conversion of number into string MAX St MID To obtain the middle part ofa sting ADD_TIME time DIV_TIME il time 1 The items marked with has following meaning 1 The size of the program memory which a program occupies when it uses the function once 2 The size of the program memory which a program occupies only one time though it uses the function many times 3 of IL programs 2 input variables 10 strings 2 The above shows the function list when programs are written with LD Ladder Diagram Expansion available functions ADD MUL MAX MIN MUX EQ etc are standardized to 2 input variables String operation functions are stand
110. int Division 32 62 9 EQ int Equality comparison 30 1 6 LIMIT int To output upper and lower limits 48 794 11 8 MAX int To output the maximum input value 48 738 12 9 MOVE To copy data 8 1 0 MUL dint Multiplication 24 65 9 MUL int Multiplication 24 35 9 MUX int To output a selected input value 56 682 15 8 MUX dint To output a selected input value 84 682 53 2 ROL To rotate left 40 160 9 7 BCD TO_DINT Conversion of BCD type into DINT type 12 300 273 9 BCD_TO_INT Conversion of BCD type into INT type 12 200 111 9 BCD_TO_SINT Conversion of BCD type into SINT type 12 140 40 9 BYTE TO SINT Conversion of BCD type into SINT type 8 0 4 DATE _TO_STRING Conversion of DATE type into string 48 458 205 9 DINT_TO_INT Conversion of DINT type into INT type 8 1 3 DINT TO BCD Conversion of DINT type into BCD type 12 278 446 9 DT TO DATE Conversion of DT type into DATE type 16 3 3 DT_TO_TOD Conversion of DT type into TOD type 16 12 41 DT TO STRING Conversion of DT type into string 48 780 524 9 DWORD TO WORD Conversion of DWORD type into WORD type 8 1 3 INT_TO_DINT Conversion of INT type into DINT type 12 0 9 INT TO BCD Conversion of INT type into BCD type 12 180 129 9 NUM _TO_STRING int Conversion of number into string 52 808 159 9 SINT_TO_BCD Conversion of SINT type into BCD type 12 140 67 9 STRING TO_INT Conversion of string into INT type 16 1308 281 9 CONCAT To concatenate strings 72 248 54 9 DELETE To delete string 68 298 6
111. ion 2 1 or over 2 GMWIN version Version 4 04 or over 3 Fast Enet O S version Version 1 1 or over 1 After the FEnet reset operation is finished it takes minimum 5 to 6 more seconds to stabilize the system After the FEnet reset operation make sure NOT to retry the FEnet reset function immediately If the FEnet reset function is retried immediately without waiting minimum 5 to 6 seconds when the previous FEnet reset operation is ended it can cause the whole system reset 2 In case of using the scan program in order to set the FEnet reset flag be sure to use Positive transition sensing contact P for the executing condition of the coil If the FEnet reset function is retried be sure to use set the FEnet reset flag after minimum 5 to 6 seconds from the end of the previous FEnet reset operation Do NOT retry the FEnet reset operation immediately without waiting 5 to 6 seconds when the previous FEnet reset operation is ended 3 The FEnet reset function should be executed within the limit of the emergency and also it is need to be executed very cautiously For more details refer to FEnet User s Manual Chapter 4 CPU module 4 8 Memory Configuration The CPU module includes two types of memory that are available by the user One is program memory which is used to store the user programs written to implement a system by the user The other is data memory which stores data during operati
112. is allocated to a digital I O module e A dedicated function block controls a special module and memory is allocated automatically eThE SiotNo 0 2 3 4 5 I O number allocation QX 1 3 0 31 QX 1 2 0 31 0X 1 1 0 15 IX 1 0 0 31 Base No 1 2 7 Chapter 2 SYSTEM CONFIGURATION 2 GM4C System GMAC System is the system which is organized with GM4 CPUC for CPU module and high performance main base GM4 B 4MH B6MH B8MH and expansion base GM4 B4EH B6EH B8EH 0 NA Ya Ron 4 fo 6 7 Main Base High Performance pac WU Hn ia 3 4 3 6 1 Nas Configuration Base No 0 Example Expansion Cabe Slot No j Group Setting J umper Group 0 Expansion Base High Performance Base No 1 Expansion Base High Performance Base No 2 Expansion Base High Performance Base No 3 m Croup Setting J umper Group 1 Expansion Base High Perfomance Base No 4 Expansion Base High Perfomance Base No 5 Expansion Base High Perfomance Base No 6 I O No is for example when to load 16point module 2 8 Chapter 2 SYSTEM CONFIGURATION Maximum Number of Expansion Stages 6 Stages Maximum Expansion Distance 15m Maximum number of Input O utput modules 56 Modules Maximum number of e 16 point module loaded 896 points e 32 point module loaded 1 792 points Input Output points e 64 point module l
113. ish iee seis ioteetet daneistiotere aketer intel nbbriany 7 9 7 2 9 16 point 220VAC input moduleseeececeeececeeenreeieeeeneiieneriemene 7 10 1 2 10 Inter ptinp tmodyl seas iaeiei es eraa ean biasae t 7 11 7 3 Digital Output Module Specifications e eeeeeeeneneneeneneeeenerinnneeee 7 12 7 3 1 16 point relay gutp tMod l e testise tnst teneor peetanhy ott idigado imties 7 12 7 3 2 16 point transistor output module Sink type rrr ttt te 7 13 7 3 3 16 point transistor output module source type vsti tte 7 14 7 3 4 32 point transistor output module Sink type rrr tite 7 15 7 3 5 32 point transistor output module source type vsti 7 16 7 3 6 64 point transistor output module sink type esveseseneeecenenenereermrun 7 17 7 3 7 16 point triac output module sesvesereececenenererenecennnnriinneneren 7 18 7 4 Digital Input Output Hybrid Module Specifications srr 7 19 7 4 1 8 point 12 24VDC input and 8 point relay output Module sss ett ete setae 7 19 7 4 2 8 point 12 24VDC input and 8 point transistor output modules 1 teeees 7 20 Chapter8 POWER SUPPLY MODULE 8 1 Selection of power supply module s stuetseh icc ations cash ineteth eibtecse ite estobe een a aia 8 1 8 29 pECMiCaUONS AE E E E A E E ATA E E Sar 8 3 8 3 Names Of Parser inii eat deiet mites iiie t etea aE ee ttie aE 8 5 Chapter 9 BASE BOARD AND EXPANSION CABLE 9 1 Specifications i ineeie ai r Aate rie T E a tiae neha 9 1 G11 Main Base Board sormiin iena a i ei aa Ea a e a 9 1
114. its execution 20 ms Execution requests for P1 and P3 are simultaneously exist but the higher priority P1 is executed and P3 is ready for its execution 20 to 22 ms PO is stopped and P1 is executed 22 to 24 ms P1 finishes its execution and the higher priority P3 is executed before PO 24 to 25 ms P3 finishes its execution and the PO stopped completes its execution 25 ms Execution request for P2 is checked at the finish time of the scan program P0 and P2 is executed 25 to 30 ms The program P2 is executed 30 to 32 ms Execution request for P1 is input and P2 is stopped and P1 finishes its execution 32 to 34 ms P1 finishes its execution and the P2 stopped finishes its execution 34 ms Anew scan starts PO starts its execution Chapter 4 CPU module 4 4 4 Error Handling 1 Error Classification Errors occur due to various causes such 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 e PLC hardware defect e System configuration error Operation error during execution of the user programs e External device malfunction 2 Operation mode at error occurrence In case of error occurrence t
115. k program characteristics e The task program will be executed when a execution condition is satisfied while the scan program is repeatedly processed at every scan Be sure to consider that point when writing a task program e For example if a timer and a counter have been used in a 10 sec cycle time driven task program the timer can occur up to 10 sec error and an input which has been changed within 10 sec will not be counted because the counter checks its input status every 10 sec 2 Execution priority e The higher priority task program will be first executed if several tasks are ready for their execution If same priority tasks are ready the FIFO will be applied e If a newly invoked task has higher priority than that of existing tasks which are under execution they are temporary stopped and task has higher priority will be executed e When determining the priority of a task program consider the characteristics importance and urgency of the program 3 Processing delay time The following factors influence on the processing delay of task program consider the characteristics importance and urgency of the program e Task detection delay Refer to the detailed description of each task e Execution delay due to the execution of prior task programs e Delay due to the execution of higher priority task programs while executing task programs Chapter 4 CPU module 4 Relationship of task program to initializatio
116. ler Rated load voltage current 12 24 VDC Operating load voltage range 10 2 to 26 4 VDC Maximum load current 0 5A 1 point 3A 1COM Off leakage current 0 1 mA Maximum inrush current 4A 10 msec or less Maximum voltage drop atON circuit 1 5 VDC Surge absorber Barrister Response Off gt On 2 msec or less time On Off 2 msec or less Common terminal arrangement 8 points 1 COM Internal current consumption 110 mA 24 VDC all points ON External Voltage 24 VDC 10 ripple voltage 4VP P or less power supply Current 100 mA or less 24 VDC per COM Operation indicator LED turns on at ON state of output External connections 20 point terminal block connector M3 x 6 screws Weight 0 27 kg Circuit configuration External connections G4Q TR2A 9 External load 1 m circuit DC12 24V 1 G4A TR2A includes a barrister as s surge absorber Chapter 7 INPUT AND OUTPUT MODULES 7 3 3 16 point transistor output module source type Models GM4 Specifications G4Q TR2B Number of output points 16 points Insulation method Photo coupler Rated load voltage current 12 24 VDC Operating load voltage range 10 2 to 26 4 VDC Maximum load current 0 5A 1 point 3A 1COM Off leakage current 0 1 mA Maximum inrush current 4A 10 msec or less Maximum voltage drop at ON circuit 1 5 VDC Surge absorber Barrister Response Off On 2 m
117. lky talky more than 30cm 11 81 inch away from the PLC Not doing so can cause a malfunction Disposal Precaution gt When disposing of this product treat it as industrial waste Not doing so could cause poisonous pollution or explosion CONTENTS Chapter INTRODUCTION Lele UNIG to Users Majua ves etree esi eatie a evan seats ad nner ninni sgn tron er maa ots 1 1 Li2 FR atUTe Sst st ete e i eenia ent A e a Pa tane aeE n Maen eei einas 1 2 Li TUITION Gt theres ae E pa a a e TR S E TERE at an Mite Sank aS 1 4 Chpter2 SYSTEMCONAGURATION 2 LOverall Configuration sit ais wks resna ni eied Mah ren HSE CHG CEES 2 1 2 2 System Configuration Component Units Listevesesesesenererenecereeneeerree 2 2 22 L OMA4series COMMA PALO ee ea apt Rae neh a anta KEANE NN 2 2 2 3 System Configuration Types rit ataa erana i aea aaaea taatia a 2 6 DFW IE ASIC SYSTEM IR E A O A E 2 6 2 32 Computer LINK SYSTE mie A ni a G Kan Ee E hah nel etna Ns lara Ea 2 10 23 Netyork System mei reeet niest dniae aa aaee aata dedina 2 11 Chper3 GENERAL SPECIFICATION 3 LGeneral Specifications Se mariana teoriaosaan eee enean 3 1 Chapter 4 CPU MODULE 4 1 Performance Specifications e eeeseseenenenereeenecreennnneenenrriieree 4 1 A 2P ans Name andDecriptigns e es tye ase a E E S AREE AE we Rr aNS TRE AED 4 2 4 3 O p ration processing eene sestien eiai iiien em sh pho AEE 4 4 4 3 1 Operation processing Methods eeeeeeertesterererenetientetientititnmertn 4
118. losed or with an inductive load as in those cases the life span of a relay output module will become shorter than specified 7 1 Chapter 7 INPUT AND OUTPUT MODULES 7 2 1 16 points 12 24 VDC input module source sink type 7 2 Digital Input Module Specifications Model GM4 Specifications G4l D22A Number of input points 16 points Insulation method Photo coupler Rated input voltage 12 24 VDC Rated input current 5 11 mA Operating voltage range 10 2 to 26 4 VDC ripple less than 5 Maximum simultaneous input points 100 simultaneously ON ON voltage ON current 9 5 VDC or higher 4 0 mA or higher OFF voltage OFF current 6 VDC or lower 1 0 mA or lower Input impedance Approx 2 2 KQ Response time OFF gt ON 10 msec or less ON gt OFF 10 msec or less Common terminal 8 points common COM Internal current consumption 70 mA Operating indicator External connections LED turns on at ON state of input 20 points terminal block connector M3 x 6 screws Weight Circuit configuration Terminal No 0 25 kg External connections 7 2 Chapter 7 INPUT AND OUTPUT MODULES 7 2 2 16 points 12 24 VDC input module source type Specifications GM4 G4l D22B Number of input points 16 points Insulation method Photo coupler Rated input voltage 12 VDC 24VDC Rated input current 5 mA 11 mA
119. ly one time though it uses the function many times 3 The size of the program memory which a program occupies whenever it uses the function block once 2 The occupied memory size and processing speed of IL programs are same as LD programs APP3 4 Appendix 4 Dimensions Appendix 4 Dimensions Unit mm 1 CPU Module GM4 CPUA DOODDCOUOOOCODOUN ANE R U gi GM4 CPUA RUN STOP PAUREM RUN STOP 2 Input Output Module APP4 1 Appendix 4 Dimensions 3 Power Module GM4 PAIA PWR 4 Main Expansion Base Unit GM4 B04M GM4 B4MH 4 B06M GM4 B6MH 4 B08M GM4 B8MH 4 B04E GM4 B4EH G G GM4 B12M G G 4 B06E GM4 B6EH Expansion GM4 B08E GM4 B8EH APP4 2 WARRANTY ee WARRANTY 1 Warranty Period The warranty period for the purchased product is 18 months from the manufactured date 2 Warranty Range For problems that occur during the warranty period a partial replacement or repair is available But the following cases are excluded from the warranty range 1 Problems caused by improper conditions environment or treatment other than that described in the user s manual 2 Problems caused by from another manufacturer s product 3 Modification or repair outside LGIS or the branches designated by LGIS 4 Used for
120. m initialization task program If the hot restart is used the same initialization program should also be written in the hot restart initialization program 3 Control of special modules In control the operations of special modules write the program using function blocks which correspond to the operations that have to be controlled These function blocks can locate at any place within the program 1 If a power failure occurs in the base unit where special units are loaded special modules data are removed Therefore data should be newly written down in the program 2 If hot restart is used the data in the other parts of the system continues However output modules such as the D A conversion module output standard output of the STOP mode before new data are to be written in the program If data are written to the special modules every scan normal output is immediately output but standard output maintains if the output data are changed or written periodically In this case in order to maintain continuity of output it is recommended that an output data restore program be written in the hot restart program Chapter 4 CPU module 4 Control of special module on the remote base unit e In order to the operations of special modules on the remote base unit use remote function blocks offered for control of each module in programming Initialization and control of the module are similar with those of special modules on the exten
121. mat Reference date J an 1 1984 _RTC_TOD TOD RTC present time Time Data Reference time 00 00 00 Day data 0 Monday 1 Thuesday 2 Wednesday 3 Thursday 4 Friday _RTC_WEEK UNIT RTC present day 5 Saturday 6 Sunday 1 Flags with the mark are initialized when the initialization program starts and after its execution has been competed the flags will change in accordance with the restart mode set e f cold or warm restart has been set the flags will be initialized when the scan program starts its execution If hot restart has been set the flags will be restored to the state before the last stop when the scan program starts its execution 2 Representative System Error Flag List Keyword Type BitNo Name Description _CNF_ER WORD Representa System error fatal This flag handles the following operation stop error flags in batch tive error keyword _IO_TYER BOOL Bit1 Module type This representative flag indicates that I O configuration parameters differ inconsistency error from the real loaded module or that a certain module is loaded onto a slot where it should not be loaded Refer to_lO_TYER_N and _IO_DEER n _10 DEER BOOL Bit2 Module loading unloading This representative flag indicates that module configuration of each slot error has been changed during operation Refer to IO _DEER_N and _10_DEER n _FUSE _ER BOOL Bit 3 Fuse
122. mile e For errors relating to special or communications modules use the questionnaire included in the user s Manual of the unit 1 Telephone amp FAX No Tel FAX 2 Used Equipment 3 Details of used Equipment CPU module 0S version No Serial No GMWIN version No used to compile programs 4 General description of the device or system used as the control object 5 Operations used by the CPU module Operation by the key switch Operation by the GMWIN or communications Memory module operation 6 Is the STOP LED of the CPU module turned ON Yes No 7 GMWIN 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 Error character sties e Repetitive Periodic Related to a particular sequence Related to environment e Sometimes General error assurance interval 12 Detailed Description of error contents 13 Configuration Diagram for the applied system Chapter 12 TROUBLE SHOOTING 12 4 Troubleshooting Examples Possible troubles with various circuits and their corrective actions are explained 12 4 1 Input circuit troubles and corrective actions The followings describe possible troubles with input circuits as well as corrective actions Condition Cause Corrective Action Input signal close not turn OFF Leakage
123. n by selection switch External connections 37 pin D sub connector Weight 0 19 kg Response time circuit configuration External connections 7 7 Chapter 7 INPUT AND OUTPUT MODULES 7 2 7 64 points 12 24 VDC input module source sink type Specifications GM4 G4I D28A Number of input points 64 points Insulation method Photo coupler insulation Rated input voltage 12 24 VDC Rated input current 3 7mA Operating voltage range 10 24 26 4 VDC ripple 5 or less Maximum simultaneous input points 19 points ICOM 60 ON voltage ON current 9 5 VDC 3 0 mA OFF voltage OFF current Input impedance 6 VDC 1 5 mA About 3 3kQ 10 msec or less 10 msec or less Response time 10 msec or less 10 msec or less Common terminal 32 points 1 com Internal current consumption 250 mA Operating indicator LED display External connections 40 pin D sub connector 2 connectors Weight 0 46 kg Circuit configuration External connections i 7 7 7 8 Chapter 7 INPUT AND OUTPUT MODULES 7 2 8 16 points 110 VAC input module Models GM4 Specifications G4I A12A Number of input points 16 points Insulation method Photo coupler Rated input voltage 100 to 120 VAC 50 60 Hz R
124. n off processing area e Input output areas for force on off setting are larger than the real I O areas If remote I O is specified using this area the force on off function is as just available in it as in the basic I O areas 4 Precautions e Turning the power off and on changed of the operation mode or operations by reset key does not change the previous force on off setting data They remain within the CPU module and operation is executed with the same data e Force I O data will not be cleared even in the STOP mode e If 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 e When setting new data disable every I O settings using the setting data clear function and set the new data 1 For detailed operation refer to the GMWIN User s Manual Chapter 7 Force I O setting Chapter 4 CPU module 4 6 6 Direct I O 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 1 Direct input e Direct input is executed by use of the DIRECT_IN function If this function is used the input image area will be directly updat
125. n or scan program e User defined tasks will not start while the initialization task program is being executed In case of hot restart the ready tasks before the power failure will be executed after the power has been restored e As scan program has the lowest priority if a task is invoked the scan program will be stopped and the task programs will be processed prior to them Therefore if tasks are invoked many times or concentrated sometimes the scan time may be extended abnormally Be cautious when setting task conditions 5 Protection of the programs under execution from task programs e f problems can be occur in case that program lose its execution continuousness by the task programs which have higher proprieties the execution of task programs can be partly perverted For program protection use the DI function Task program start up disable or El function task program start up enable 3 Time driven task program processing method The followings explain the processing method of a task program when its task condition start up condition has been set to be driven by time 1 Settings that have to be set for the task e Set the task execution cycle and its priority which are used as start up conditions for the task programs to be executed Check the task NO for task control 2 Time driven task processing e The corresponding time driven interrupt task program will be executed every setting time internal execution cycle 3 Precautions fo
126. nal wires If possible provide more than 100 mm distance between the cables and wires 8 As a lightning protection measure connect a surge absorber as shown below Surge absorber for lightening 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 9 Use a insulating transformer or noise filter for protection against noise 10 Twist every input power supply wires as closely as possible Do not allow the transformer or noise filter across the duct 10 10 Chapter 10 INSTALLATION AND WIRING 10 2 2 Input and Output Devices Wiring 1 Applicable size of wire for I O wiring is 0 3 to 2 mm However it is recommended to use wire of 0 3mm for convenience 2 Separate the input and output lines 3 1 0 signal wires must be at least 100 mm away from high voltage and large current main 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 PLC Shielded cable 5 If wiring has been done with a piping ground the piping 6 Separate the 24 VDC I O cables from the 110 VAC and 220 VAC cables 7 If wiring over 200 m or longer distance problems can be caused by leakage currents due to line capacity Refer to the Section 12 4 Examples 10 2 3 Grounding 1 This PLC has sufficient protection against n
127. ned for input output 3 Maximum points of input output variables are as follow e GMAC 32 000 points when to use 64 point module IX0 0 0 to 1X63 7 63 QX0 0 0 to QX63 7 63 5 Assignment of Input Output in the Remote System Configuration e Assignment of input output in the remote system configuration is same with basic input output system For example if itis assigned to starting address 1X12 0 0 and 32 word size for receiving data of remote 12 stage in the high speed parameter and starting address QX12 0 0 and 32 word size for sending data 12 stage remote base is assigned input output number in the same way to assign base No 12 of basic system configuration 6 Base Expansion of Remote Stage e If the size of Rx Tx data is assigned to 64 words itis assigned to IX0 0 0 to IX0 7 63 QX0 0 0 to Qx0 7 63 in the 12 stage base and also itis assigned to IX3 0 0 to IX3 7 63 QX3 0 0 to QX3 7 63 in the 12 stage expansion base REMARK 1 Pay attention not to overlap sections when to assign remote stage number and area 2 Only in case of assigning the Input output by input output variable lW QW it can support input output service such as I O Forcing Pay attention to assign input output using internal variable MW Chapter 3 GENERAL SPECIFICATIONS Chapter 3 General Specifications 3 1 General specifications The following shows the general specifications of the GLOFA GM series Item Specifications Ref
128. net I F Module Main Base In these slots the network modules are not available to Main Base Fnet Remote I F Module 2 In case of installing remote system by Fnet remote I F module the installing method is same with existing system however the follow modules are not available Section Name Items Special Module PID Control Module G4F PIDA PIDB Process Control Module G4F TMCA Position Module G4F POPA POPB G4F PP 10 20 30 G4F PP1D 2D8D Analog Timer Module G4F AT3A Communication Module Fnetl F Module L FUEA Computer Link I F Module L CUEA DeviceNet I F Module L DUEA Profibus I F Module L PUEA L PUEB Ethernet I F Module L EUEA Rnet I F Module L RUEA Fast Enet I F Module Fast Dedicated E net I F Module Master L EUTB EUFB EU5B L EUTC EUFC EUSC Fast Dedicated Enet I F Module Slave G4L ERTC ERFC ER5C Chapter 2 SYSTEM CONFIGURATION 3 The follow shows the possible mounting number of Fnet I F module and possibility of mounting on expansion base as CPU models The Possible mounting number Possibility of mounting on Items of Fnet Module expansion base GM4 CPUA 2 X GM4 CPUB 4 0 GM4 CPUC 8 0 4 Assignment of Input Output 1 Variables of remote input output could be assigned by high speed link parameter 2 Input output variable or internal variable could be assig
129. ns The following desires possible troubles with output circuits as well as corrective actions Condition Cause Corrective Action When the output is Off excessive voltage is applied to the load e Load is half wave rectified inside in some cases itis true of a lolenoid e When the polarity of the power supply is as shown in O C is charged When the polarity is as shown int the voltage charged in C plus the line voltage are applied across D Max voltage is approx Output a y 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 e Connect registers of tens to hundreds kQ across the load in parallel The load does not turn OFF e Leakage current by surge absorbing circuit which is connected to output element in parallel Output Leakage current e 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 TRY fae fee er When the load is C R type timer time constant fluctuates e Leakage current by surge absorbing circuit which is connected to output element in parallel e Drive the relay using a contact and drive the C R type timer using the since contact e Use other timer than the C R con
130. nsulation Rated input voltage DC12 24V Rated load voltage DC12 24V Rated input current 5 11 mA Operating load voltage DC10 2 26 4V Operating voltage Max simultaneously on DC10 2 26 4V 100 simultaneously on Max load current Leakage current 0 5A 1 point 3A 1COM 0 1 mA AC220V 60Hz On voltage current 9 5 VDC 3 5 mA Max inrush current 4A 10ms or less Off voltage current 5 VDC 1 5 mA On state voltage drop 1 5 VDC or less Input impedance About 2 2 kQ Surge absorber Barrister Response Off gt On 10msorless Response Off gt On 2 ms or less time On gt Off 12 ms or less time On gt Off 2 ms or less Common 8 points 1COM Common 8 points 1COM External Voltage DC24V 10 ower y Current 50 mA Operation Indicator LED External wiring 20 points terminal block connector M3 X6 screw Internal current consumption o m Weight 0 26 kg c 0O Input Lagot d 9 tr itera i 7 2 2 19 LE T HY pH oO Output fe 16 oa 17 L hH o 18 19 20 T pene 4 Terminal No OC12 24y Chapter 8 POWER SUPPLY MODULES Chapter 8 POWER SUPPLY MODULE This chapter describes the selection method type and specifications of th
131. nsumption 75 mA Operating indicator 16 points indication by selection switch External connections 37 pin D Sub connector Weight 0 19 kg Circuit configuration Internal circuit 7 4 External connections Input No Chapter 7 INPUT AND OUTPUT MODULES 7 2 4 32 points 12 24 VDC input module source type Specifications GM4 G4I D24B Number of input points 32 points Insulation method Photo coupler Rated input voltage Rated input current 12 VDC 3mA 7 mA Operating voltage range 10 2 to 26 4 VDC ripple less than 5 Maximum simultaneous input points 60 19 points 1 COM simultaneously ON ON voltage ON current 9 5 VDC or higher 3 0 mA or higher OFF voltage OFF current Input impedance 6 VDC or lower 1 5 mA or lower Approx 3 3 KQ OFF gt ON 10 msec or less Response time ON OFF 10 msec or less Common terminal 32 points 1 COM common Internal current consumption 70 mA Operating indicator LED turns on at ON state of input External connections 37 pin D sub connector Weight Circuit configuration 0 19 kg External connections Input No 7 5 Chapter 7 INPUT AND OUTPUT MODULES 7 2 5 16 points 24 VDC input module source sink type GM4 Specifications G4I D24C Number of input points 16 points Insulation method Photo coupler Rated input
132. nsumption Modules Models unit mA Current Consumption Triac Output Module G4Q SS2A 330 Thermocouple Module Input G4F TC2A 450 G4Q SS2B 330 Temperature measuring input Module Resistor G4F RD2A 600 Input Output Hybrid Module G4H DR2A 100 G4H DT2A 100 PID Control Module G4F PIDA 200 G4F PIDB 600 Interrupt Module G4F INTA 65 Analog Timer Module G4F AT3A 200 Process control Module G4F TMCA 360 Fnet I F Module G4L FUEA 160 Fnet Module Remote F G4L RBEA 150 Cnet I F Module G4L CUEA 100 Rnet I F Module G4L RUEA 160 Enet I F Module G4L EUEA 270 Pnet I F Module G4L PUEB 680 Dnet I F Module G4L DUEA 270 Fast Enet I F Module G4L EUxB 600 Fast Dedicated Enet F module Master G4L EuxC 600 8 2 Fast Dedicated Enet F module Slave G4L ERxC 600 Chapter 8 POWER SUPPLY MODULES 8 2 Specifications Item GM4 PA1A GM4 PA2A GM4 PA1B GM4 PA2B GM4 PA2C GM4 PD3A 110 VAC 220 VAC 110 VAC 220 VAC 220 VAC Input voltage g5to132v 1700 264v 5t0132V 170 to 264V0 170 to 264 VO 24VDC Input frequency 50 60 Hz 47 to 63 Hz 1 3 A 0 8 A 0 65 A 0 35 A 0 6A Inputcurrent io vac 220vac 10 vac 220VAC 220 VAC 124 Input Inr
133. nt 4 channels G4F PIDA e Controls maximum 8 loops PID control module G4F PIDB e Controls maximum 8 loops Transistor output e 2 channels of analog input Process control module G4F TMCA Je 2 channels of analog transistor output e PID function e Timer point 8 points Analog timer module G4F AT3A e Setting value range 0 1 to 1 0 sec 1 to 10 sec 10 to 60 sec 60 to 600 sec Interrupt input module G4F INTA Je Input point 8 points i Chapter 2 SYSTEM CONFIGURATION poms Modes Description Remarks G4L EUTB e 10 100BASE TX UTP Fast EnetI F module G4L EUFB e 100BASE Fx Fiber Optic GAL EUSB_le 10BASE 5 AUI For GM4A B O S FastDedicated Enet yf E LEUTE fe 10 100BASE TX UTP _ er 2 7 or over module Master G4L EUFC e 100BASE Fx Fiber O ptic For GM4C O S G4L EU5C_ e 10BASE 5 AUI er 2 0 or over Fast Dedicated Enet F ELERTE te 1O 00BASE TX UTP module Slave G4LERFC le 100BASE FxFiberOnic GAL ER5C_ 10BASE 5 AUI G4L FUEA e For Fnet I F a Fnet I F module e 1 Mbps base band For mounting GOL FUEA For twisted cable inside computer e For Rnet I F RUEA Rnet I F module G4L RU o For wisted cable e For Fnet remote F L RBEA Fnet remote I F module G4 For Wicked cable GOL SMIA e 16 point 12 24 VDC input GOL SMQA e 16 point relay output 1 A f e 8 point 12 24 VDC input Standalone remote I F Stans e 8 point relay output 1 A oo Commu module e Voltage current input 8 channels tot
134. nt 9 5 VDC 3 5 mA Max switching frequency 3 600 times hour Off voltage current 5VDC 1 5 mA Surge absorber None Input impedance About 2 2 KQ Lifetime of Mechanical Respon Off gt On 10 ms or less contact Electrical SANE KARIR setime On gt Off 10 ms orless Response Off On 10 ms or less Common 8 points 1COM time On gt Off 12 ms or less Common 8 points 1COM External Voltage DC24V 10 power supply Current 45 mA Operation Indicator LED External wiring 20 points terminal block connector M3 X6 screw current consumption 100 mA Weight 0 26 kg Circuit configuration External connections on lt ol Input Internal Circuit es Fe l a 1 amp B a pee ER m o o R Ay 3 GM R Te M ir pci2 2av ae E External EY 1 Tsy l B N qe w ae jas 18 Le DWN 19 i a 20 Out put Terminal No 7 19 24 VDC 2A resistive load Chapter 7 INPUT AND OUTPUT MODULES 7 4 2 8 points 12 24VDC input 8 points transistor output module G4H DT2A Input Output Input point 8 points Output points 8 points Insulation method Photo coupler insulation Insulation method Photo coupler i
135. nu Using Online Flash memory Set Mode check Flash Run Mode Setting and then click OK Flash Run Mode Setting gt Flash Run Mode Within flash run mode setting Source code is copyed in flash memony when Program download Set Run Mode C None Set Run Mode oane Incase of selecting None Set Run Mode flash operation does not work Initial setting is Set Run Mode 6 6 Chapter 6 Memory Module And Built in Flash Memory What is Flash operation mode It means that PLC is operated by backup program in the flash memory in case of that data in the program RAM get damaged In case of selecting Flash Memory operation when PLC restarts or operation mode is changed to RUN data are copied to program memory in the CPU module and then operation is started After setting once in the GMWIN flash operation mode is maintained if it is not set to Off by GMWIN GM4 CPUC is available to write to flash memory in the RUN mode On program debugging operate in the state of flash operation mode is set to Off After completion of debugging if flash operation mode is set up itis convenient to write flash memory 2 Program storing method in the built in flash memory There are three methods to store program in the built in flash memory 2 1 When downloading program When flash operation mode is set if program is written to GM4 CPUC the following message is displayed in the GMWIN GMWIN
136. oaded 3 584 points CPU Module OM4CPUC Power Module CM4PAL2A GM4 PD3A GM4 PA2C Main Base GM4 B4MH B6MH B8MH Configuration Expansion G M4 B4EH B6EH B8EH units Base ie G4C E041 E 061 E121 E 301 E601 E 102 E 152 G4l 1 0 Module G40 G4F 1 0 number allocation REMARK e 64 I O points have been fixedly allocated for every slot in the base unit e 64 points are allocated to each slot in a base unit whatever it is empty or not e There s no imitation in the loading location and loading number of special modules e Special modules do not have fixed I O numbers while a fixed I O number is allocated to a digital 1 0 module e A dedicated function block controls a special module and memory is allocated automatically e O Parame er must be same with actual mounted I O Module If not the PLC does not start running e High performance expansion bases GM4 B4E H GM4 B6EH GM4 B8EH are separated by Group 0 and 1 Groups are set up by jumps on expansion bases Initial group setting is Group 0 Setting Group J umper Pins Group 0 Setting Group 1 Setting 1 Main base No is fixed to No 0 and expansion base No is assigned to 1 2 3 as sequence In case of high performance base jumpers must be set to group 0 2 In case of installing expansion base 4 stages or over of GM4C System install expansion base additionally and then jumps of addition
137. odule hook from the module fixing hole Chapter 10 INSTALLATION AND WIRING The followings explains the wiring instructions for use of the system 10 2 1 Power Supply Wiring 1 When voltage fluctuations are larger than the specified value connect a constant voltage transformer Base Constant voltage transformer 2 Use a power supply which generates minimal noise across wire and across PLC and ground When excessive noise is generated connect an insulating transformer 3 When wiring separate the PLC power supply from the I O and power device as shown below Main power supply PLC power supply os oo 1 0 power supply kE A Main circuit power supply Coil Chapter 10 INSTALLATION AND WIRING 4 Notes on using 24 VDC output of the power supply module e To protect the power supply modules do not supply one I O module with 24 VDDC from several power Supply modules connected in parallel e If 24 VDC output capacity is sufficient for one power supply module supply 24 VDC from the external 24 VDC power supply as shown below 5 Twist the 110 VAC 220 VAC and 24 VDC cables as closely as possible Connect modules with the shortest possible wire lengths 7 To minimize voltage drop use the thickest max 2 mm2 wires possible for the 100 VAC 200VAC and 24 VDC cables 8 Do not bundles the 100 VAC and 24 VDC cables with main circuit high voltage large current wires or the I O sig
138. of 1 to 65535 is usable Error detection Example MOV 10 _ANC_ERR 0 3 External device Ordinary fault Warning Processing 1 If a warning of external device is detected and the corresponding flag of the system flag _ANC_WBJn is set to on the flag will checked from the _ANC_WB 0 at the time that scan program finishes its execution If an error is indicated on the flag it will be also indicated on the ANNUN_WR of the representative system warning flag _CNF_WAR External device waning numbers will be written to from _ANC_WARJ 0 to _ANC_WARJ7 according to occurrence sequence 2 The user can know the cause of error by use of the GMWIN and also by direct monitoring of the flags _ANC_WARJn and _ANC_WBIn 3 If an external device waning is removed that is the elements of ANC_WARJn are released from warning the corresponding _ANC_WAR n will be automatically cleared If all element flags are cleared the flag _ANNUN_WR of the system flag _CNF_WAR will be reset Chapter 4 CPU module Example Error detection ANCWB 10 pe EE If the user program had detected a system fault and set _ANNUN_WR 1 _ANC_WAR Q 10 _ANC_WB 10 to ON the states of _ANNUN_WR and _ANC_WAR 1 0 _ANN_WAR 0 7 will be shown as left after the scan has been _ANC_WAR 2 0 finished _ANC _WAR 3 0 _ANC _WAR 4 0 _ANC _WAR 5 0 _ANC _WAR 6 0 _ANC _WARI7 0 _ANNUN_WR 1 After the next scan has been finished if the n
139. oise 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 100 Q orless 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 J oint grounding Not allowed 4 Use 2 mm or more wire for grounding line Make the distance as short as possible with the grounding point located to nearest to the PLC 10 11 Chapter 10 INSTALLATION AND WIRING 5 Ground LG Power Supply Module separately with FG Base board a a fl a Power Suppl a Q ep E Power Supply A Independent grounding BEST B J oint grounding GOOD C J oint Grounding NotAllowed 6 If a malfunction occurs depend on grounding point separate FG Base Board with ground 10 2 4 Cable Specifications for wiring Cable Specifications mm Kinds of external connection Minimum Maximum Digital Input 0 18 AWG 24 1 5 AWG16 Digital Output 0 18 AWG24 2 0 AWG14 Analog Input Output 0 18 AWG24 1 5 AWG16 Communication 0 18 AWG 24 1 5 AWG16 Main Power 1 5 AWG16 2 5 AWG12 Grounding 1 5 AWG16 2 5 AWG12 10 12 Chapter
140. om the first step to the end step e f the interrupt task execution condition has been satisfied by a time driven task or event driven task module during scan program execution the program that is under execution will be temporary stopped and the corresponding task program will be executed e f the scan program has been completely executed the single task internal interrupt execution condition will be checked and the corresponding task program will be executed Chapter 4 CPU module 2 configuration e Up to 180 scan programs can be used If task programs are used the usable number is reduced as many as that of the used task programs e Program has been not specified to initialization or task program when writing that program it will be automatically specified to scan program e Scan program has lowest execution priority and the priorities of scan program are determined their registration sequence in the GMWIN screen when writing those programs 3 Task program 1 Function e In order to process internal external signal which occurs periodically or non periodically the task program temporarily stop the operation of scan program and processes first the corresponding function 2 Types e Task programs are classified into the three types as below gt Time driven task program Up to 32 programs are applicable gt Single internal task program Up to 16 programs are applicable gt Interrupt external task program Up to 8 p
141. on 1 Program memory configuration The table given below shows the contents to be stored and the storage capacity of program memory Item GM4 CPUA B GM4 CPUC Overall program memory area 129K byte 1M byte System area e System program area e Backup area 1 5K byte 13K byte Parameter area e Basic parameter area e O parameter area e High speed link parameter area e Interrupt setting information area 3 5K byte 10K byte Program area e Scan program area e Task program area e Standard library area e Access variable are 2 Data memory Configuration e User defined function function block area e Variable initialization information area e Protective variable specification information area 123K byte 977K byte The table given below shows the contents to be stored and the storage capacity of program memory Item GM4 CPUA GM4 CPUB GM4 CPUC Overall data memory area 64K byte 64K byte 512K byte System area e O information table 7 5K byte 6 5K byte 50K byte e Force I O table System flag area 1 5K byte 1 5K byte 4 096 byte Input image area IX 512 byte 1K byte 4 096 byte Output image area QxX 512 byte 1K byte 4 096 byte Direct variable area M 2 to 16K byte 2 to 16K byte 8 to 64K byte Symbolic variable area maximum 52K byte the size of direct variable area 50K byte the size of direct variable area 428K byte the size of dir
142. onsistency error the specified modules Refer to the flags _10 TYER IO DEER_N e Change into the RUN 30 by parameters and the _IO_TYER n and correct the incorrective slot and re STOP 0 4 sec mode Cold loaded modules startthe system dule mounting dismounting error Module dismounting or g Aa Refer to the flags _10_DEER O_ DEER_N T 31 acetona mounting IO DEER n and correct the in corrective slot and re STOP 0 4 sec When scan completes Cold 9 start the system Fuse disconnection error Fuse disconnection Refer to the flags _ FUSE_ER FUSE _ER_N T 32 during run FUSE_ER n and correct the in corrective slot and re STOP 0 4 sec When scan completes Cold startthe system O module read write error When scan completes 33 Abnormal I D module Refer to the flags IO_RWER _IP_RWER_N STOP 0 4sec During execution of cold data access during run _lO_RWER n and restart the system program When power is applied Abnormal special link Special link module interface error When an ABE es 34 module data access Referto the flags _SP_IFER _IP_ IFER_N _IP_IFER STOP 0 4 sec Duri A f cold during run n and restart the system uring execution 0 program During run Scan time P Check the scan delay time specified by parameters and 40 a pen eee correct the parameters or the program and then re STOP 0 4 sec During execution of cold y P Y start the program program parameters Unreadable instructions i 5 During execution of
143. or system O S error _CnCRDER BIT 11 Communications module system error error 1 _NETn_LIV k BIT Fnet Cnet Dnet Stations connected to the Indicates whether k remote station or local PLC is connected to the network k 0 to 63 ARRAY Pnet Rnet Fenet network 1 connected or not The state value is written to each bit These values shows present k Station No FDEnet 0 disconnected state of the network Write is disabled _NETn_RST k BIT Fnet Cnet Dnet Re connection of a station e Indicates re connected stations which had been disconnected before on a k 0 to 63 ARRAY Pnet Rnet Fenet 1 re connected 0 no changed bitmap Because this value has been replaced with 1 when re connected k Station No FDEnet condition he user program has to clear this value with 0 so that next re connection can be detected Write is enabled _NETn_232 k BIT Cne The indication that the user e When a receiving frame is received through RS 232C while the part of RS k 0 to 63 ARRAY defined frame has been 232C in Cnet is operating in the user defined mode the bit corresponding to k Station No received Indicated at each setting No is turned ON If RCV_MSG F B has read that that bit will be setting No Received 1 cleared with 0 _NETn_422 k BIT Cne The indication that the user e When a receiving frame is received through RS 422 while the part of RS k 0 to 63 ARRAY defined frame has been 232C in Cnet is operating
144. ory operation Selection of DIP switch Operation CPU is operated by the program in flash memory when power on or PLC m on reset LE CPU recognizes that no program is in flash memory and is operated by E ON program which is stored in program memory Caution Lower switch should be at the off position State of dip switch for flash memory is not concerned with storing program In case of storing program in the flash memory set GM4 CPUB to STOP mode In case of trying to store in the RUN mode the follow message is displayed amp Memory Module Error Can t write to memory module 6 5 Chapter 6 Memory Module And Built in Flash Memory 6 3 GM4 CPUC Using Built in Flash Memory GM4 CPUC does not use separate memory module in order to operate ROM operation function of GM4 CPUA Using Built in flash memory of GM4 CPUC instead of memory module it can execute the function which stores user program or corresponds to ROM operation function of GM4 CPUA Moreover GM4 CPUC has built in flash memory of large capacity Upload program is stored in the storing area for upload program in the flash memory In short the follow shows flash memory structure PRAM FLASH 1M Program Program 1M Upload 5M 6 3 1 Program storing method by using built in flash memory 1 Flash operation mode setting GM4 CPUC executes ROM operation function by using flash operation mode setting in the GMWIN me
145. ounted 3 Slot No Slot number of the module where the communications module has been mounted 4 Self station No Self station number of the module which executes high speed link communication APP1 11 Appendix 1 System Definitions High SpeediLink Otem Edit Station type Station No Mode Block No Local fi Send fo Remote C Receive Area Send period F D 200ms rom E SMW C Sh CO SOV o SizeVord To MY I amp wavy h 1 cancel Ho 1 Station type Type of the communications module in the opposite station Local or remote will be set 2 Station No Used to indicate the station that has invoked data during communications 3 Mode Used to set the communications mode to Send or Receive 4 Block No Designating number for identification of a data block in the same communications module 5 Data communications cycle Used to set the cycle of sending and receiving of data 6 Area Q and M areas should be set by the decimal number or word 7 Size Number of words that will be sent and received APP1 12 Appendix 2 Flag List Appendix 2 Flag List 1 User Flag List Keyword Type Write Name Description Operation error latch Operation error latch flag by the program block BP Error indication LER BOOL Enable flag occurred while executing a program block Operation error latch Operation error
146. p x output points x the rate of points switched on simultaneously W lout output current actual operating current A Vdrop voltage dropped across each output load V Chapter 10 INSTALLATION AND WIRING 5 Average power consumption of input circuits if input modules with points simultaneously switched ON e Win lin x E x input points x the rate of points switched on simultaneously W lin input current effective value for AC A l E input voltage actual operating voltage V 6 Power consumption of the special module power supply e Ws Isy x 5 lav x 24 l100v x 100 W The sum of the above values is the power consumption of the entire PLC system e W Wpw Wsvy Wav 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 C W Power consumption of the entire PLC system obtained as shown above A Control panel inside surface area m2 U 6 if the control panel temperature is controlled by a fan etc 4 if control panel air is not circulated Chapter 10 INSTALLATION AND WIRING 10 1 2 Handling Instructions To installing each module be sure to check the following e Do not drop it off and make sure that strong shock should not be applied e Do not unload the PCB from its case It can cause faults e During wiring be sure to check any foreign matter like wire scr
147. put DC input module G4I D22A 16 points G4I D24A 32 points G4l D22B 16 points 110 VAC input 110 VAC input module G4I D24B 32 points G4I A12A 16 points 220 VAC input 220 VAC input module G4l A22A 16 points Relay output Relay output module G4Q RY 2A 16 points SSR output Triac output module G4Q SS2A 16 points G4Q SS2B 16 points TR output Interrupt input Analog timer Transistor output Interrupt input module Analog timer module G4Q TR2A 16 points G4Q TR4A 32 points G4Q TR8A 64 points G4F INTA 8 points G4F AT3A 8 points A D A D conversion module G4F AD2A 4 channels G4F AD3A 8 channels DAV DAI D A conversion module G4F DA2V 4 channels voltage type G 4F DA2I 8 channels current type G4F DA1A 2 channels voltage current type T C Thermocouple module input G4F TC2A 4 channels RTD Temperature measuring input module resistor G4F RD2A 4 channels PID PID input module G4F PIDA 8 loops HSC Position Control Pulse High speed counting module Positioning module pulse output G4F HSCA 1 channel G4F POPA 1 axes G4F POPB 2 axes G4F PP10 20 30 1 2 3 axes G4F PP1D 2D 3D 1 2 3 axes Process Process control module G4F TMCA GLOFA Fnet Fnet I F module G4L FUEA GLOFA Enet Enet I F module G4L EUEA APP1 9 Appendix 1 System Definitions lt
148. r using the time driven task program e While a time driven task program is being executed or ready for its execution if a same priority task program has been invoked to be executed the newly invoked task will be ignored the representative task collision warning flag _ TASK_ERR will be set to ON the detailed system error flag _TC_BMAP n will be set to ON at its corresponding location and occurrence time of the time driven tasks whose execution requests have been ignored will be written at its corresponding location of the flag_TC_CNT n e The timer that invokes the execution request for time driven task programs will be incremented only when the operation mode is in the RUN mode If the RUN mode has been changed into the PAUSE mode while operating with the RUN mode and then the operation mode has been changed again into the RUN mode the operation time spent with the PAUSE mode and the power failure time of Hot restart will all be ignored e When setting the execution cycle for a time driven task program be cautious that execution requests for many time driven task programs can occur If four time driven task programs of cycle 2 4 10 and 20sec are used four execution requests will occur every 20 sec and scan time can be momentarily extended Chapter 4 CPU module 4 External contact program processing method The following explains in the case that the task start up condition of a task program has been set to an external interrupt conta
149. r which indicates pollution degree which determine insulation performance of equipment Pollution 2 means that nonconductive pollution usually occurs but temporal conduction occurs with condensing Chapter 4 CPU module Chapter 4 CPU Module 4 1 Performance Specifications The following shows the general specifications of the GM4 CPU module Ladder Diagram Programming language Instruction List Sequential Function Chart 194 Floating Point Arithmetic 0 2 us instruction 0 12 us instruction a 37 Programming memory capacly 12ko wy o mex opns oons o S Data memory ee 7 7 Symbolic variable area 54 50 K byte Direct variable area 428K byte Direct variable area er No limitations in points 1 point occupies 20 bytes Time range 0 001 to 4 294 967 295 sec 1 193 hours ic vari Counter No limitations in points Counting range 32 768 to 32 767 Initialization programs 2 _INT _H_INIT Program Timedriventasks 8 0 3 External interrupt we tot fe ferortsk A E CS F Watch dog timer Memory error detection I O error detection Battery Self diagnostic functions error detection Power supply error detection etc Data protection method at power failure Set to Retain variables at data declaration Maximum extension stages Internal current consumption 130mA 700mA Weight 0 25 Kg 0 23 Kg lof symbolic variable area 1 point occupies 8 bytes lof symbolic variable area Chapter 4 CP
150. rmation flag _STSK_NUM in the GMWIN variables monitor mode and then monitor _STSK_MAX _STSK_MIN and STSK_CUR For details of system run status information flags refer to the APP 2 3 Example of calculation of scan time GM4 C PUC The following shows an example of calculation of maximum scan time when the user program has the same structure as shown below and the system executes data communications through communications modules e Task T_SLOW interval T 10 ms priority 0 task No 0 PROC_1 single MXO priority 3 task No 48 E_INT1 Interrupt 0 priority 2 task No 32 e Program program PO program P1 with task T_SLOW program P2 with task PROC_1 Program P3 with task E_INT1 1 Maximum scan time _SCAN_MAX will be measured while communications service through the communications module and monitoring through the GMWIN are being executed under the condition that only the scan program except for task programs has been executed 2 In order to measure the execution time of a time driven interrupt program start the program including time driven interrupt task programs and then register the flags STSK_NUM _STSK_MAX STSK_MIN and _STSK_CUR and enter 0 to _ STSK_NUM 4 6 Chapter 4 CPU module as the task No 0 and then measure the value of _STSK_MAX B After stop other task program and start the program including single task pro
151. rograms are applicable e Time driven task program gt The program is executed by the time internal set before e Single internal task program gt The corresponding program will be executed if the rising edge of the internal contact occurs gt The detection of the rising edge will be executed after the scan program has been processed e Interrupt external task program gt The program is executed according to the external signal a input to the interrupt module 1 Refer to section 4 4 3 task for details of task program 4 Error Task program e The program which is executed when system error is occurred during the operation of user s program e User make error task program and then program is executed on condition of _ERR_SYS task User can protect system operation failure according as the user controls system error mask flag in the error task program For details refer to section 4 4 4 Error Handling Chapter 4 CPU module 4 4 3 Task The followings explain the program structure and tasks of the GMWIN that is the GLOFA GM programming S W in order to give an understanding of the task function Program 1 Program Block program 1 Program 2 Function Program 3 Program Block Program 4 Task 2 Function Block program 3 Program 5 Program Block Task 3 Program 6 program 7 Function Program 1 Program Block 1 A task executes the some function as the control panel which are used to
152. roject window fey PLC Type GMAC restart prj Writer LGIS JE CONFIGURATION PLC UNNAMED ACCESS VARIABLES 0 variables declared Direct variable Comments 0 variables declared RESOURCE CPU 0 RESO f RESOURCE GLOBALS 0 variables declared ag Scan Program D INSTO ct gmwinttsourcetrestartinonameDO src G TASK DEFINITIONS 3 variables declared Single Interval Interrupt D Hot Restart 9 Cold Warm Restart a Project eH Library Project window Hey PARAMETERS ff BASIC PARAMETERS f 1 0 PARAMETERS LINK PARAMETERS w Project gt Parameter Project window Library Function D Standard Function Function Block D Standard Function Block fo APP f COMMUNI F re F E Project 5 Parameter ig Library 4 25 Chapter 4 CPU module e Program cw_rst src cold warm restart initialization program Comment Comment Line 2 Line 3 Line 4 Line Line 6 Line 7 Line 8 Line 9 Line 10 Line 11 Line 12 Comment Line 14 Line 15 Line 16 Line 17 Line 18 Line 19 Line 20 Comment Line 22 Line 23 Line 24 Line 25 Line 26 Line 27 Line 28 Line 29 Line 30 leaded onto the basic and extension base units Initialization of special moduk at cold warm restart which are L
153. roperly arranged The lower priority tasks still may not be processed after its time due to delay by higher priority tasks In some cases if the prior tasks have been delayed and next task occurs task collision can occur Set the priority with due consideration of items such as urgency and execution time of a task 3 Task programs are written as shortly as possible If execution time of a task program is long the scan time may become longer and irregular and also collision of task programs may occur Therefore write task programs as shortly as possible 4 Protection of lower priority programs against higher priority program isn t needed during execution of those programs If the priority of a task program or a scan program has been set to lower priority and other tasks must not interrupt during its execution use the function DI and El to protect the program partly When processing global variables used commonly in other programs special modules or communications modules problems can occur 1 For examination on processing speed of scan program and task program refer to the Scan time Calculation Example in the Section 4 2 3 Scan Time Chapter 4 CPU module 8 Example of program configuration and processing When the task and program have been registered as below e Task registration T_SLOW interval T 10ms priority 0 PROC_1 single MXO priority 3 E_INT1 interrupt 0 priority
154. rrent 25 mA 220 VAC 60 Hz Maximum inrush current 25 A 10 msec or less 20A 10 msec or less Maximum voltage drop at ON circuit 1 5 VAC or less 1A 1 5 VAC or less 0 6 A Surge absorber Barrister 387 to 473 V C R absorber Response time Off On 0 5 cycle 1 msec or less On Off 0 5 cycle 1 msec or less Common terminal arrangement 8 points 1 COM Internal current consumption 330 mA all points ON Operation indicator LED turns on at ON state of output External connections 20 point terminal block connector M3 x 6 screws Weight 0 35 kg Circuit configuration External load AC110 220V 0 External load Internal circuit ZC Zero Cross Circuit Terminal No Chapter 7 INPUT AND OUTPUT MODULES 7 4 Digital Input Output Hybrid Module Specifications 7 4 1 8 points 12 24VDC input 8 points relay output module G4H DR2A Input Output Input point 8 points Output points 8 points Insulation method Photo coupler insulation Insulation method Photo coupler insulation Rated input voltage DC12 24V Rated load voltage current 220 VAC 2A cosy 1 Rated input current 5 11 mA in load voltage current DC5V 1mA Operating voltage DC10 2 26 4V M Max load voltage current AC250V DC125V a eimuienedus y 100 simultaneously on Leakage current 0 1 mA AC220V 60Hz On voltage curre
155. rror Mask Function 1 Uses and operation introductions Error mask function is the function which makes program to be continued and ignores the error even if the specific module makes error on operation The module which is assigned to error mask renews the I O data normally and executes error diagnosis until the error is occurred If the module makes error on operation CPU module indicates the error to flag or GMWIN and continues operating blinking RUN LED 40ms 2 Error mask setting up e Error mask function can be set up module error and user generated error For details refer to Appendix 2 Flag List e Error mask function can be set up by GMWIN and user programs e Error mask function can be set up in advance or set up by the error task program HINT 1 2 3 Even if the cause of error is removed if error flag of CPU module is not initialized and then error mask is released system is shut down Before error mask flag is released check error flag Even if there are power on off changing operation mode and handling reset key error mask data is operated because the state is maintained in the CPU Therefore in case of revision of error mask function use GMWIN or user programs In case of the follow error mask data is erased 1 In case of re operating after downloading program by GMWIN 2 In case of memory backup is broken up because battery is dead Chapter 4 CPU module 4 7 2
156. s Direct Variable Variables used without separate declaration of names and type 1 Q M area correspond to this variable Example e 1X0 0 2 e QW1 2 1 e MD1234 1 4 Chapter 1 INTRODUCION Terms Definition Remarks Symbolic Variable Variables used after the user s definition of their names and types Declarations as INPUT 0 IX0 0 2 RESULT MD1234 makes INPUT_0Q and RESULT be able to used instead of IX0 0 2 and MD123 in programming A peripheral device for the GLOFA GM series It executes program creation edit compile and debugging Abbreviation of the word Factory Automation Monitoring S W It is used to call S W packages for process supervision It means startup conditions for a program There are three types of plus cycle task internal junction task and external junction task External junction task starts by the input signals of external input modules Abbreviation of the word Real Time Clock Used to call a general IC which includes clock function Sink Input Current flows in from the switch to the PLC input terminal if a input signal turns on Source Input Current flows in from the PLC input terminal to the switch if a input signal turns on Switch Sink Output Current flows in from the load to the output terminal if the PLC output junction turn on Output contact A power source 1 5 Chapter 1 INTRODUCI
157. s when adding the I O modules later on e I O Reservation Function can be applied to digital I O module and D A conversion module Operation The method of I O Reservation Function is as follow 1 Using GMWIN check Use Reserved I O Function in the GMWIN basic parameter 2 Download the basic parameter to PLC 3 Using GMWIN set I O parameter about the modules which will be added later on 4 Download the I O parameter to PLC 5 Using GMWIN set I O module skip function and error mask function about the specific I O slots which the additional modules will be mounted in later on 6 Execute H W Reset by PLC Reset Switch or S W Reset by GMWIN or turn on the PLC 7 Start operation In case of mounting the additional module 8 9 10 Release I O module skip function in the slot of the additional module Mount the additional module to the I O slot which was set in the step 3 without stopping system CS OC In case of mounting D A conversion module execute Initialize Special Module about the module ee ee eed es 11 Confirm the normal operation of I O module writing reading module loading unloading error flag and other relative flags For more details refer to App 2 7 Detailed System Error and Warning Flag List 12 Release error mask function in the slot of the additional module The I O Reservation Function can be applied in the following environment 1 GM4 CPUC O S ver
158. s will be checked when scan program has finished its execution Therefore if an internal task execution conditions during one scan has been occurred and disappeared if the specified contact has been turned from OFF to ON and then from ON to OFF by scan program or time driven or external task program the task will not be executed as the execution condition can not be detected at the time that execution conditions are being checked 6 Task processing at momentary power failure e f the momentary power failure time has been longer than the allowable hot restart setting time and the system restarts with cold restart or warm restart mode the ready tasks and the tasks invoked during the power failure will all be ignored and only the tasks from the start time will be processed e In case of the power failure of 20 ms or less the ready tasks before the power failure will be executed a time driven task will be invoked with calculation of the power failure time and time driven tasks invoked repeatedly before the power failure will be ignored 7 Examination on task program After writing down a task program be sure to examine the following items 1 Task setting has been correctly done If tasks are invoked more frequently than necessary or several tasks are invoked simultaneously within one scan the scan time become longer and irregular In case that the task setting cannot be changed check the maximum scan time 2 Task priorities are p
159. sec or less time On Off Common terminal arrangement 2 msec or less 8 points 1 COM Internal current consumption 110 mA 24 VDC all points ON External Voltage 24 VDC 10 ripple voltage 4VP P or less power supply Current 100 mA or less 24 VDC per COM Operation indicator External connections LED turns on at ON state of output 20 point terminal block connector M3 x 6 screws Weight 0 27 kg Circuit configuration Internal Circuit External connections Doi2 24y External Load OC 12 24 17 18 O Terminal No Chapter 7 INPUT AND OUTPUT MODULES 7 3 4 32 point transistor output module sink type Models GM4 Specifications G4Q TR4A Number of output points 32 points Insulation method Photo coupler Rated load voltage current 12 24 VDC Operating load voltage range 10 2 to 26 4 VDC Maximum load current 0 1A 1point 2A 1 COM Off leakage current 0 1mA orless Maximum inrush current 4A 10 msec or less Maximum voltage drop at ON circuit 1 0 VDC Surge absorber None Response Off gt On 2 msec or less time On gt Off 2 msec or less Common terminal arrangement 32 points 1 COM Internal current consumption 160 mA all points ON External Voltage 24 VDC 10 ripple voltage 4VP P or less power supply Current 100 mA or less 24 VDC per COM Operation indic
160. select Project Option Connection Option e In the initial screen Method of Connection is RS 232C for default e For details refer to GMWIN User s Manual APP1 1 Appendix 1 System Definitions 2 Folder configuration In the GMWIN 4 kinds of folder configurations are available The follow shows each of uses The configuration is in order of Project Option Set Folder e Standard library This is the folder where the library for GMWIN is saved and also user defined library is saved e Source file Various kinds of programs functions function blocks which is made by users are saved e Output file When source file is compiled the object file is saved e Temporary file Various kinds of temporary files which are made on operation of GMWIN are saved For details refer to GMWIN User s Manual clgmwin Alib cigmwin 4isource clgmwin 4 output clgmwin 4itemp APP1 2 Appendix 1 System Definitions 3 Auto Save Auto Save is the function which sets up auto save time cycle to save the contents when editing or modifying program The auto saved file is saved for the expansion file name ASV in the same folder where the program exists The auto saved file delete automatically when closing the program window Therefore if Program Error is occurred before saving program it can be restored up to certain point by using the auto saved file The follow shows the configuration method
161. sion Version 2 1 or over 2 GMWIN version Version 4 03 or over 3 GM4 high performance main base GM4 BxMH and high performance expansion base GM4 BxEH In case of mounting module using I O reservation function be sure to follow the above steps of the operation in order to prevent malfunction of the whole PLC system Chapter 4 CPU module 4 7 5 FEnet Reset Function 1 Uses and operation introductions FEnet Reset Function is the function which clears FEnet module only without reset of the whole system when the communication of the FEnet does not work correctly by the certain trouble 2 Operation In order to reset FEnet only set the appropriate flag of the following flag list by using variable monitor on GMWIN or using coil in the scan program When the reset operation is ended the flag is cleared to 0 again e FENET_RESETx To use for reset FEnet of the slot No x 1 _FENET_RESET_Mx Main base 2 _FENET_RESET_Ex Expansion base e RCV_SERx_CHy To display setting slot No x and channel No y by using dedicated service 1 __RCV_SERVx_M_CH Main base 2 _RCV_SERVx_E_CH Expansion base e RCV_SERx_COUNT Receiving count of slot No x by using dedicated service 1 _RCV_SERV_CNT_M Main base 2 _RCV_SERV_CNT_E Expansion base e x Slot 0 55 GM4 CPUC y Channel 0 15 The FEnet Reset Function can be applied in the following environment 1 GM4 CPUC O S version Vers
162. sion base unit e As in remote base unit mounting or dismounting is possible during its operation initialization and data restore programs are requested which should have the condition flags of the remote base unit as its start up conditions 5 Restart Program Example 1 System Configuration The followings give an example for writing the initialization program of the system where a special module has been loaded onto its basic base unit shown as below figure The followings describe an example for writing the cold warm restart program hot restart program and scan program for the scan program where the D A 02 outputs data every scan and the D A 03 outputs data only when the data has been changed A D A D conversion module D A D A conversion module DC32 32 point DC input module RY32 32 point relay output module e As cold warm restart makes the whole system restart the cold warm restart program consists of only initialization program of special module e Initialization of special modules by the hot restart program is needed before the scan program which has been stopped at the hot restart will continue its execution It is possible that the output conditions of the module D A 03 which outputs data only when the data has been changed are restored to the state before the stop of the program Chapter 4 CPU module 2 program e Project Configuration Restart prj P
163. t Dne aximum communications scan e Indicates the maximum time that is spent until every station connected to Pnet Rnet Fenet time unit 1 msec network has the token at least one time and sends a sending frame FDEne _CnSCANAV UINT Fnet Cnet Dne aximum communications scan e Indicates the average time that is spent until every station connected to Pnet Rnet Fenet time unit 1 msec network has the token at least one time and sends a sending frame FDEne _CnSCANMN UINT Fnet Cnet Dne Average communications scan e Indicates the minimum time that is spent until every station connected to Pnet Rnet Fenet time unit 1 msec network has the token at least one time and sends a sending frame FDEne _CnLINF UINT Fnet Cnet Dne inimum communications scan e Indicates operation state of communications module with a word Pnet Rnet F ene ime unit 1 msec FDEne _CnLNKMOD BIT 15 Operation mode RUN 1 e Indicates that operation mode of communications module is in the normal TEST 0 operation mode or test mode _CnINRING BIT 14 n ring IN_RING 1 e Indicates that the communications module can communicates IN_RING 1 with other station or not _CnIFERR BIT 13 nterface error error 1 e Indicates that interface with communications modules has been stopped z 7 e Indicates that service cannot be offered due to insufficient common RAM _CnSVBSY BIT 12 nsufficient common RAM Insufficient 1 e Indicates communications module hardware defect
164. ta initialization according to the restart mode The variables relating to the restart mode are classified into three types i e default variable initialization variable and retain variable The following table shows the initialization method for each type variable Cold Restart executed defined value defined value Mode Variable type Cold Warm Hot Default Initialized with 0 Initialized with 0 Previous value is retained Retain Initialized with 0 Previous value is retained Previous value is retained Initialization Initialized with the user Initialized with the user Previous value is retained Retain amp Initialization defined value Initialized with the user Previous value is retained Previous value is retained 1 Definitions 1 Default variable A variable whose initial value is not defined or previous value will not be retained 2 Initialization variable A variable whose initial value is defined 3 Retain variable A variable whose previous value will be retained Chapter 4 CPU module 4 6 2 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 Error flag If an error occurs
165. tact Some timers have half ware rectified internal circuits therefore be cautious easier E ary The load does not turn OFF e Sneak current due to the use of two different power supplies Output Bisa e E1 lt E2 sneak current e E1 is switched Off and E2 is switched ON sneak current e Use only one power sypply e Connect a sneak current prevention diode Figure below If the load is the relay etc connect a counter electromotive voltage absorbing code as show by the dotline Chapter 12 TROUBLE SHOOTING Output circuit troubles and corrective actions continued Condition Cause Corrective Action The load off response time is long e Over current at Off state The large solenoid current fluidic load L R is large such as is directly driven with the transistor output Output Off current e 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 e Insert a small L R magnetic contact and drive the load using the same contact Output Output transistor is destroyed Surge current of the white lamp Output A surge current of 10 times or more when turned ON 12 10 e To suppress the surge current make the dark current of 1 3 to 1 5 rated current flow Output Source type transistor output Chapter 12 TROUBLE SHOOTING 1
166. the basic instructions for troubleshooting 1 Visual checks Check the following points e Machine motion In stop and operating status e Power ON or OFF e Status of I O devices e Condition of wiring I O wires extension and communications cables e Display states of various indicators such as POWER LED RUN LED STOP LED and I O LED After checking them connect the 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 e Set the key switch to the STOP position and then turn the power ON and OFF 3 Narrow down the possible causes of the trouble Deduce where the fault lies i e e Inside or outside of the PLC e O module or another module e PLC program 12 2 Troubleshooting This section explains the procedure for determining the cause of troubles as well as the errors and corrective actions for the error codes Occurrence of error Is the power LED turned OFF Flowchart used when the POWER LED is turned OFF Is the stop LED flickering Flowchart used when the STOP LED is flickering Are the RUN and STOP LED turned OFF Flowchart used when the RUN and STOP LED is turned OFF I O module dose not operate properly Flowchart used when the output load of the output module dose not turn on Program cannot be written Flowchart used when a program cannot be written to the PLC i 12 1 Chapter 12 TROUBLE SHOOTING
167. time to this flag It will be reset if the battery alne he ered Momentary power The accumulated momentary power failure occurrence times during ese ied Oito 63535 failure occurrence count operation in the RUN mode is written to this flag _AC_F_TM n TE n 0to15 A POWET The times of the latest sixteen momentary power failures are written The times and error codes of the latest sixteen errors are written to l this flag _ERR_HIS n n 0to15 Error history e Stop time DATE amp TIME 8 bytes e Errorcode UINT 2 bytes The times operation modes and restart modes of the latest sixteen 0 d operation mode changes are written to this flag _MODE_HIS n n 0to 15 i aE mode eChange time DATE amp TIME 8 bytes 9 y e Operation mode UINT 2 bytes e Restart UINT 2 bytes Write is available in user programs APP2 4 Appendix 2 Flag List 8 System Operation status Information Flag List Keyword Type gehen Name Description _CPU_TYPE UINT 0 to 16 System type GM1 0 GM2 1 GM3 2 GM4 3 GM 4 FSM 5 6 Twofold 16 _VER_NUM UINT O S version System 0 S version No No _MEM_TYPE UINT 1to5 Memory Type of program memory module 0 Unloading state type 0 to 5 module type _SYS_STATE WORD Representati PLC mode and System operation mode and operation state information
168. tion and fault 7 Be cautious that strong shock does not applied to the I O module Do not separate the PCB from its case 2 Base board mounting instructions The following explains instructions for mounting the PLC onto the control panel 1 Allow sufficient distance from the upper part of the module for easy module replacement 2 Do not mount the PLC in a vertical or horizontal position because it affects on ventilation 3 Do not mount the base board together with a large sized electromagnetic contactor or no fuse breaker which produces vibration on the same panel Mount them on different panels or keep the base board away from such a vibration source 4 Mount the wire duct as itis needed If the clearances are less than those in Fig 10 1 follow the instructions shown below e f the wire duct is mounted on the upper part of the PLC make the wiring duct clearance 50mm 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 50 mm or more 100mm or more O O Base board O oO High voltage 100mm or more d
169. to 2 GM4B 1 to 4 GM4C 1 to 8 Keyword Type Satay Name Description _HSmRLINK Bit Fnet Cnet Dn High speed link RUN link Indicates that all stations are normally operating complying with the parameter et Pnet Rnet information set in the high speed link This flag turns on under the following conditions Fenet FDEnet 1 All stations set in the parameter are in the RUN mode and have no error and 2 All blocks set in the parameter normally communicate and 3 The parameter set in all stations which are set in the parameter normally communicate e Once this flag is turned on it maintains that state as long as link enable does not make that state stopped _HSmLTRBL Bit Fnet Cnet Dn High speed link trouble e This flag turns on when under the condition that _HSmRLINK is turned on et Pnet Rnet information communications of the stations and data blocks set in the parameter is under Fenet FDEnet the following conditions 1 A station set in the parameter is notin the RUN mode or 2 A station set in the parameter has an error or 3 The communications of data blocks set in the parameter does not normally Operate e This flag turns on if the above conditions 1 2 and 3 occur If those conditions are restored it will turn off again _HSmSTATE k Bi Fnet Cne Dn K Data Block overall Indicates overall communications state of every blocks of the parameters set k 0 to 63 Array
170. to ROM operation function of GM4 CPUA GM4 CPUB executes ROM operation function by using dip switch for flash memory operation Dip Switch for Flash Memory Operation Flash Memory 6 2 2 Storing program in the built in flash memory and operation method 1 Change operation mode of GM4 CPUB module to STOP mode 2 There are two methods to write program in the GM4 CPUB 1 In general when writing program to the GM4 CPUB GMWIN shows the below message Q There is a flash memory in PLC If you switch to run mode execution program in PLC is changed to a program in flash K memory Write execution program to flash memory Yes No Incase of storing downloading program to flash memory click Yes Y The above message is displayed in case of selecting Online Write Parameter and program in the GMWIN menu 6 4 Chapter 6 Memory Module And Built in Flash Memory 2 The follow shows the method to store in the flash memory without overwriting program The below message is displayed in case of selecting Online Flash memory F Write W in the GMWIN menu Write to the Flash Memory 512K Flash Memory omy exteral Nash monary Program C Upload Program C Program and Upload Program Cancel Select the item which should be stored to flash memory and then click OK 3 In case of restarting PLC system operate as follow according to dip switch for flash mem
171. to UDINT type LREAL_TO_UINT Conversion of LREAL into UINT type LREAL_TO_ULINT Conversion of LREAL into ULINT type LREAL_TO_USINT Conversion of LREAL into USNT type MUL real Irea Multiplication REAL_TO_DINT Conversion of REAL type into DINT type REAL_TO_INT Conversion of REAL type into INT type 14 REAL_TO_LINT Conversion of REAL type into LINT type 80 REAL_TO_LREAL Conversion of REAL type into LRE AL type 7 REAL_TO_SINT Conversion of REAL type into SINT type 20 REAL_TO_UDINT Conversion of REAL type into UDINT type 17 REAL_TO_UINT Conversion of REAL type into UINT type 20 REAL_TO_ULINT Conversion of REAL type into ULINT type 76 REAL_TO_USINT Conversion of REAL type into USINT type 20 SIN real Ireal Sine operation 75 100 SINT_TO_LREAL Conversion of SINT type into LREAL type 9 SINT_TO_REAL Conversion of SINT type into REAL type 3 5 SQRT real Ireal Square root operation 7 11 real Ireal Subtraction 1 9 real real Tangent operati 90 120 TRUNC real Ireal Truncation operation 44 18 74 UDINT_TO_LREAL Conversion of UDINT type into LREAL type 24 7 UDINT_TO_REAL Conversion of UDINT type into REAL type 24 7 UINT_TO_LREAL Conversion of UINT type into LREAL type 24 5 UINT_TO_REAL Conversion of UINT type into LREAL type 36 5 APP3 3 Appendix 3 Function Function Block List Floating point Arithmetic Function List GM4 CPUC Continued ULINT_TO_LREAL Conversion of ULINT
172. transistor output module 0 5 A sink output 5 VDC 1 for 1 0 GM4 PAIA Input 110 VAC e 5VDC 1 4 A 5VDC 2 1A modules e 24VDC 0 7A 5 VDC 2 Power supply canes MPU AZIYA for peripheral devices module GM4 PA1B finput110VAC GM4 PAIB linput220VAC oO AENDE NA GM4 PA2C Input 220VAC e 5VDC 8A eI GM4 PD3A Input24VDC_ e 5VDC 4A Po G4H DR2A Input output hybrid module 2 2 Chapter 2 SYSTEM CONFIGURATION e ee e e Up to four modules can be mounted GM4 B4MH e Up to four modules can be mounted high performance module e G G G 4 B04M 4 B06M e Up to six modules can be mounted 4 B08M e Up to eight modules can be mounted M4 M4 M4 M4 j M4 GM M4 j M M4 i M M4 4 B04E e Up to four modules can be mounted GM4 B06E e Up to six modules can be mounted Expansion base unit GM4 B6EH e Up to six modules can be mounted high performance module GM4 BO8E e Up to eight modules can be mounted GM4 B8EH e Up to eight modules can be mounted high performance module Main base unit GM4 B6MH e Up to six modules can be mounted high performance module GM4 B4EH e Up to four modules can be mounted high performance module G4C E152 e 15 0 m long Memory module G4M M032 e Flash memory 32Kstep an M4 CPUA 2 3 Chapter 2 SYSTEM CONFIGURATION Description G4F AD2A e Voltage current input 4 channels e DC 5 to 5V 10 to 10V DC 20 to 20 mA A
173. ty is percent of on time off time Pe eae Omen mere T4 lt T2 n T1 T1 T2 x 100 T1 gt T2 n T2 T1 T2 x 100 Chapter 4 CPU module 4 4 Program 4 4 1 Program Configuration A program consists of all of the function elements that is needed to execute a particular control It is to be stored in the internal RAM of the CPU module or the flash memory of the memory module The function elements are classified as below Function Elements Processing Operation e Executed when the power is applied or the CPU operation is transited to the RUN mode Initialization e Executes the initial fixes data setting for execution of scan program and the program initialization of peripheral devices on special modules e The execution method of initialization differs according to the setting of Restart Mode etc Scan program e Processes the constantly repeated signals which are executed every scan e When the following time conditional processings are required the program is executed complying with the time interval setting gt In case that the processing need a shorter interval than that of average one scan processing time gt In case that the processing need a longer interval than that of average one scan processing time gt In case that the processing should be executed by the specified time interval Time driven task program Event driven task program e A shorter processing is executed for internal or e
174. ual check The module should be play mounted securely No dust or foreign material Retighten screws Connecting conditions Loose terminal screws Retighten Screws should not be loose Retighten Distance between solderless terminals Visual check Proper clearance Correct Loose connector Visual check Connectors should not be loose Retighten connector mounting screws Line voltage check Measure voltage across 110 220 VAC terminal 85 to 132VAC 170 to 264VAC Change supply power Battery Check battery replacement time and battery capacity reduction e Check total power failure time and the specified source life e Battery capacity reduction should not be indicated If battery capacity reduction is not indicated Change the battery when specified service life is exceeded Visual check No melting disconnection If fuse melting disconnection change the fuse periodically because a surge current can cause heat Chapter 12 TROUBLE SHOOTING Chapter 12 TROUBLESHOOTING The following explains contents diagnosis and corrective actions for various errors that can occur during system operation 12 1 Basic Procedures of Troubleshooting System reliability not only depends on reliable equipment but also on short down times in the event of faults The short discovery and corrective action is needed for speedy operation of system The following shows
175. umbers 1 2 3 10 15 _ANC _WAR O 10 40 50 60 and 75 of ANC_WBJn are tuned on _ANC_WAR n will be _ANC _WAR 1 0 shown as left _ANC _WAR 2 0 f CANC WAR 0 As the number 10 has turned on has occurred in the previous scan _ANC_WARI4 0 though the number 10 has lower priority than the numbers 1 2 and 3 it _ANC _WAR 5 0 will be the lower element of ANC_WARJ n The _ANC_WB 75 is not _ANC _WAR 6 0 indicated as it is turned on and the warning that occurred before has _ANC _WARI7 0 written to the _ANC_WARJn _ANNUN_WR 1 After the next scan has been finished if the numbers 1 2 3 10 15 _ANC _WAR 0 10 40 50 60 and 75 of ANC_WBJn are tuned on _ANC_WAR Jn will be _ANC _WAR 1 0 shown as left aie WARE 3 The No 10 warning has been released the content of ANC_WARJQ will TANC WARYA 0 be cleared and the contents of _ANC_WAR 1 7 will shift into the lower ANC _WAR 5 0 elements The content of _ANC_WAR 7 will has been cleared by the ANC _WAR 6 0 shifting and the content of _ANC_WB 75 will be written to ANC_WAR 7 _ANC _WARI 7 0 _ANNUN_WR 1 If all warnings indicated on the _ANC_WBJn are released during _ANC _WAR 0 10 operation the ANNUN_WR and _ANC_WAR n will be shown as left _ANC _WAR 1 0 _ANC _WAR 2 0 _ANC _WAR 3 0 _ANC _WAR 4 0 _ANC _WAR 0 _ANC _WAR 6 0 _ANC _WARI7 0 Chapter 4 CPU module 4 7 GM4 CPUC Dedicated Functions 4 7 1 E
176. ur modes the RUN STOP PAUSE and DEBUG mode The following describes the PLC operation processing in each operation mode 4 5 1 RUN mode In this mode programs are normally operated The first scan start in the RUN mode If the operation mode is the RUN mode 7 when the power is applied Mode condition at the start If the operation mode has been changed Data area initialization complying with the restart mode set from the STOP mode to the RUN mode Data area initialization complying with the restart mode Check on the effectiveness of the program and decision on the possibility of the execution Execution of input refresh Execution of programs and task programs Check on the normal operation of the loaded modules and their mounting conditions Processing the communications service or other internal operations Execution of output refresh The RUN mode is maintained Is the operation mode changed Changed into another mode Operation with the operation mode changed 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 restart mode set cold warm hot 3 The possibility of execution of the program is decided with check on its effectiveness
177. urrent sink input and current source input When selecting DC input modules consider the specifications of those input devices as the wiring method of the external input power supply varies complying with the type of digital input In the GM4 series the types are dedicated source input and source sink common DC input 1 The method to connect sink type external connection device to Source type DC input module External Connect ion DC Device Input Module DC POWER e The external connection device is located between negative terminal of DC input module and DC power e In case of turning on input current flows to external connection device from DC input module terminal 2 The method to connect sink type external connection device to Source type DC input module External Connect ion De ico Input DC POWER Module e The external connection device is located between positive terminal of DC input module and DC power e Incase of turning on input current flows to DC input module terminal from external connection device 2 The number of maximum simultaneous input points differs with the type of a module Check the specifications of the input module to be applied before use 3 Use the interrupt module if high speed input response is requested But only one interrupt module can be mounted in each CPU module 4 Use transistor output modules or triac output modules with a load that is frequently opened and c
178. ush current 40 A or less 60A or less ae Efficiency 65 or more rated load 110 220 VAC 5A Slow Input fuse 3 A Slow 250 VAC 250VAC Allowable momentary 20 msec or less i gi a or power failure Output 1 Output voltage Output current 5VDC 4A 3A 8A Over current protection 5 VDC 4 4A or more 3 2 Aor more 4 4A or more Output 2 Output voltage 24VDC Output current 0 7A 0 5A Over current protection 0 8 A or more 0 6 A or more Voltage status indicator LED is turned ON at normal output voltage Used wire specifications 0 75 to 2 mm Weight 0 4 kg 8 3 Chapter 8 POWER SUPPLY MODULES 8 3 Names of Parts The followings describe names of parts and their purposes of the power supply module Name Purpose Power LED Use to indicate the 5 VDC power supply P ower fuse or fuse holder Used to fix the AC power input 3 A fuse onto the holder Power input terminal Used to connect 110 or 220 VAC power LG terminal Use to ground the power supply filter 24 VDC and DC24G terminal Use to the 24 VDC power to the output module as the internal power supply 8 4 Chapter 9 BASE BOARD AND EXPANSION CABLE Chapter 9 BASE BOARD AND EXPANSION CABLE 9 1 Specifications 9 1 1 Main base board Models Items GM4 B04M GM4 B4MH GM4 B08M GM4 B8MH GM4 B06M GM4 B6MH GM4 B12M Loaded
179. variable error Bit 4 High speed link Checks and indicates High speed link parameter error parameter error 2 Operation Mode Key Status Information Data Setting Keyword Type range Name Description _KEY_STATE BYTE Representative Key setting position Indicates CPU module key switch state keyword Bito KEY_STOP Indicates that the key switch is in the STOP state Bit1 KEY_RUN Indicates that the key switch is in the RUN state Bit2 KEY_PAUSE REMOT Indicates that the key switch is in the PAUSE REMOTE state E 3 1 0 Module Installation Status Information Keyword Type Data Setting range Name Description 10_INSTALL n BYTE n 0 to 3 1 0 module installation location Locations of slots where I O modules are loaded are indicated in the bitmap of base units APP2 6 Appendix 2 e nis the numbe Flag List 10 Communications Flag GLOFA Fnet Cnet Enet Dnet Pnet Rnet FEnet FDEnet Flag List 1 Communication Module Information Flag List r of slot where communication module is loaded n GM4A 0 to 7 GM4B 0 to 31 GM4C 0 to 55 Keyword Type args Name Description _CnVERNO UINT Fnet Cnet Dnet Communications module e Communications module 0 S version No
180. variation range of it The momentary power failure is a power failure of short interval several to tens ms 4 5 Chapter 4 CPU module 4 3 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 Task program processing time PLC internal processing time e Scan program processing time The processing time used to process a user program that is not specified to a task program e Task program processing time Total of the processing times of task programs executed during one scan e PLC internal processing time Self diagnosis time I O refresh time Internal data processing time Communications service processing time 2 Scan time differs in accordance with the execution or non execution of task programs and communications processing etc 2 Flag 1 Scan time is stored in the following system flag area e SCAN_MAX Maximum scan time unit 1 ms e SCAN_MIN Minimum scan time unit 1 ms e SCAN_CUR Current scan time unit 1 ms 2 Measuring Processing Time of Task Program GM4 CPUC only To measure the processing time of the task program for calculation of the scan time write the number of the task that will be measured to the system run status info
181. ve keyword operation status Bit0 Local control Operation mode change is possible only by mode key or GMWIIN Bit1 STOP CPU module operation state Bit2 RUN Bit 3 PAUSE Bit 4 DEBUG Bit5 Operation Operation mode change by key mode change factor Bit6 Operation Operation mode change by GMWIN mode change factor Bit7 Operation Operation mode change by remote GMWIN mode change factor Bit8 Operation Operation mode change by communications mode change factor Bit9 STOP by Operation in the RUN mode is stopped by STOP function after the scan has STOP function finished Bit 10 Force input Input junction force On Off is being executed Bit 11 Force output Output junction force On Off is being executed Bit 12 STOP by Operation in the RUN mode is directly stopped by ESTOP function ESTOP function Bit 13 Bit 14 During External monitoring is being executed for programs or variables monitoring Bit15 Remote mode Operation in the remote mode ON _GMWIN_CNF BYTE Representati GMWIN Connection state between CPU module and GMWIN ve keyword connection state Bit 0 Local GMWIN Local GMWIN connection state connection Bit1 Remote Remote GMWIN connection state GMWIN connection Bit2 Remote Remote communications connection state communication s connection _RST_TY BYTE Representati Restart mode Restart type of program which is being executed in present History ve keyword information Bito Cold restart See the Section 4 6 1 Bit1 Warm restart Bit
182. ven for the user to implement easily the program in which the error detection of external devices and system stop and warning are coded By use of these flags error indication of external devices is possible without complex programming and monitoring of the error location can be done without special tools GMWIN etc or source programs 1 External device fault detection and classification 1 The user program detects external device faults The faults are classified into fatal fault error where the PLC stops its operation and ordinary fault warning where operation continues 2 The flag ANC_ERR n is used to indicate error The flag ANC_WN n is used to indicate warning 2 External Device Fatal fault Error Processing 1 If an error of external device is detected and the error type where other value than 0 is used is written to the system flag ANC_ERRJn the flag will checked at the time that scan program finishes its execution If an error is indicated on the flag it will be also indicated on the ANNUN_ER of the representative system error flag _CNF_ER the PLC turns all output modules off and the error state will be same as the PLC self diagnosis 2 The user can know the cause of error by use of the GMWIN and also by direct monitoring of the flag _ANC_ERRJn 3 As the flag ANC_ERR n has sixteen elements n 0 to 15 the user can classify error states largely User defined error No can be written to the elements A number
183. would cause erroneous operation Installation Precautions gt Use the PLC in an environment that meets the general specification contained in this manual or datasheet Using the PLC in an environment outside the range of the general specifications could result in electric shock fire erroneous operation and damage to or deterioration of the product Completely turn off the power supply before loading or unloading the module Not doing so could result in electric shock or damage to the product Make sure all modules are loaded correctly and securely Not doing so could cause a malfunction failure or drop Make sure I O and extension connector are installed correctly Poor connection could cause an input or output failure When install the PLC in environment of much vibration be sure to insulate the PLC from direct vibration Not doing so could cause electric shock fire and erroneous operation Be sure to there are no foreign substances such as conductive debris inside the module Conductive debris could cause fires damage or erroneous operation SAFETY INSTRUCTIONS Wiring Precautions gt Completely turn off the external power supply when installing or placing wiring Not doing so could cause electric shock or damage to the product gt Make sure that all terminal covers are correctly attached Not attaching the terminal cover could result in electric shock gt Be sure that wiring is done correctly be che
184. xternal interrupt e Error task program is executed when error is occurred if the user has made Emor Task progran error task program GM4 CPUC only Chapter 4 CPU module 4 4 2 Program Execution Procedure The followings explain the program execution procedure when the power is applied or the CPU module key switch is in the RUN status Program operation processing is executed as the procedure given below Operation start Initialization program i e Executed when the power has been applied lt 4 bes eee ba Satete oxen ete cous ccDveuta dcnsees veces duccscndueddeaes tats ceeweees coneueve outeeats or the CPU operation is in the Run mode e Restart operation is executed complying with the initialization task _INIT HINIT 4 Executed only when the condition has been satisfied Executed only when the condition has been satisfied Error task program heen Error task ERR_SYS 1 GM4 CPUC only END processing Executed only when the condition has been satisfied 1 1 In the GLOFA PLC the time driven task programs and event driven task programs are called task program Event driven programs are classified into single task internal interrupt or interrupt task external interrupt according to the S W and H W interrupt signaling method Chapter 4 CPU module 1 Initialization program 1 Function e The Initialization program initializes the program to execute sc
185. zati iy Indicating the error Status during Initialization Specifying the loaded base No function block execution 3 SLOT ACT gt DAQ3_ACT Specifying the loaded slot No Indicating the run channels during initialization DA03 CH CH function block execution Specifying the used channel DA03_DT DATA Specifying the data type TYPE H DA03_SE 7 SEL J Specifying the D A conversion module output status when the CPU modules is in the STOP state i AD01_INI DA02_INI DA03_INI NERON DONE DONE DONE SNE INES 1t The initialization The initialization The initialization Initialization program function block function block function block complete AD01_INI has normally DA02_INI has normally finished finished DA03_INI has normally finished 4 26 Chapter 4 CPU module e Program hot_rst src hot restart initialization program Comment Initialization and data restore of special moduks at hot 4 restart which are baded onto the basic and extension base units 4 Comment ss The module A D 01 intialization 4 Line 2 H ADO1_INI od 10FF Line3 p REQ DONE F AD01_STAT Indicating the error status during initialization function block execution Line4 F 0 BASE STAT F AD01_ACT 2 Specifying the loaded Base No Indicating the run channels during initialization Line 5 1 SLOT ACT function block execution a Specifying the loaded Slot No Line 6 H ADO1_CH Sp

Manual GLOFA-GM4 Programmable Logic Controllers

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