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1. fig 9 1 3 Do not mount the base board together with a large sized electromagnetic contact or no fuse breaker which produces vibration on the same panel Mount them on different panels or keep the unit or module away from such a vibration source Chapter 9 Installation and Wiring 4 Mount the wire duct as it is needed If the clearances are less than those in Fig 9 1 follow the instructions shown below e f the wire duct is mounted on the upper part of the PLC make the wiring duct clearance 50 mm or less for good ventilation Also allow the distance enough to press the hook in the upper part from the upper part of the PLC e f the wire duct is mounted on the lower part of the PLC make optic or coaxial cables contact it and consider the minimum diameter of the cable 5 To protect the PLC from radiating noise or heat allow 100 mm or more clearances between it and parts Left or right clearance and clearance from other device in the left or right side should be 100 mm or more Other High voltage device device Heat generating device Fig 9 2 PLC mounting 6 MK80S has hooks for DIN rail in the base unit and expansion modules DIN rail Fig 10 3 Chapter 9 Installation and Wirin 9 1 3 Connection of expansion module The following explains the Connection of
2. RS 232C interface b Wiring method MK80S base unit Pin assignment And direction Pin No Signal 1 5V Female Type TXD1 RXD1 are for loader communication and TXD2 RXD2 are for Cnet 8 2 Chapter8 Communication Function 2 1 1 connection with a monitoring device like PMU PMU LGIS K80S base unit RS 232C interface MK80S base unit Pin assignment and direction Pin no Signal 1 5V Female Type 8 3 Chapter8 Communication Function 3 1 1 connection with other MK80S For the detailed information refer to 8 1 7 1 1 Dedicated Protocol Communication K80S base unit K80S base unit RS 232C interface MK808 base MK80S base unit unit Pin assignment and direction Pin no Pin no Signal 1 5V 2 Male Type 8 4 Chapter8 Communication Function 8 1 3 Frame Structure 1 Base Format 1 Request frame external communication device gt MK80S base unit Max 256 Bytes Station Command Frame check Command Structurized data area number type BCC 2 ACK Response frame MK80S base unit external communication device when receiving data normally max 256 Bytes Header Station Tail Fra
3. 06 Slave Device Busy It s sending or waiting to receive 09 Parameter Error Communication parameter setting error Link enable setting error 10 Frame Type Error Frame does not setting or frame does not sending 8 57 Chapter 8 Communication Function 8 2 4 Example of Use 1 This example is supposed that there s a communication between MK80S s by the user defined protocol The system configuration is as follows and the cable is the same with the one of 1 1 dedicated protocol communication MK80S base unit MK80S base unit Master Station no 0 Slave Station No 1 1 1 dedicated protocol communication between MK80S s The data in M area of the master station is sent to the slave station and the slave station saves the received data in M area outputs as direct variable and sends the data back to the master This process repeats between the master and the slave Chapter 8 Communication Function 1 The Programming and setting communication parameter of the master station 1 Select the communication parameter and then select communication method and communication channel And then select user Defined at protocol and mode item list item is activated Bar meler Mew Prefect Basic Intanrupt Camm PHMTUN PIDUCALY Pulse Qut Anaia Cammenicatien cab E Cormmricanan Meir Timeo in Master Made ps m Stan Member DNNINE Dedicated Baud Raie E 3 a aoa C Mai 7 Party Eit Mre
4. K7M DR40S PROGRAMMABLE LOGIC 41 4243 47 48 CONTROLLER K7M DR60S PROGRAMMABLE out LOGIC 4142 47 48 49 51 555657 CONTROLLER R 4 4 Chapter 4 Names of Parts 4 2 Expansion Module 4 2 1 Digital I O Module 4 2 2 AID D A Combination Module G7F AT2A PROGRAMMABLE Losic No Names RUN LED Analog Input Terminal Analog Input Voltage current selecting jumper pin Analog Output Terminal External Power Supply Terminal DC24V Expansion Cable 910 0 060 E Expansion Cable Connecting Terminal No Names RUN LED Analog Timer Volume Control Resistance Expansion Cable 8 e e Expansion Cable Connecting Terminal Chapter 4 Names of Parts 4 2 4 Option Modules Option modules are attached the expansion slot of main unit or expansion unit and supplies optional functions such as memory expansion or real time clock K80S series have two option modules external memory module and RTC module No Names D Option module 2 Connector Chapter 5 CPU Module Chapter 5 CPU 5 1 Specifications The following table shows the general specifications of the MASTER K80S series Specifications K7M DR10S K7M DR20S K7M DR30S K7M DR40S K7M DR6
5. Station Device Station Device Remarks 0 1 D4400 16 17 D4408 2 3 D4401 18 19 D4409 Each device contains the Information 45 D4401 20 21 D4410 of 2 station 6 7 D4403 22 23 D4411 The information of each station is 8 9 D4404 24 25 D4412 saved in 1byte 10 11 D4405 26 27 D4413 12 13 D4406 28 29 D4414 14 15 D4407 30 31 D4415 Error code Error code Contents Remarks 1 Timeout error for response 2 Received NAK 2 Sending receiving error contents of each station total 32 stations Error count number is saved following area according to station Station Device Station Device Remarks 0 1 D4416 16 17 D4424 2 3 D4417 18 19 D4425 Each device contains the Information 45 D4418 20 21 D4426 of 2 station 6 7 D4419 22 23 D4427 The information of each station is 8 9 D4420 24 25 D4428 saved in byte 10 11 D4421 26 27 D4429 12 13 D4422 28 29 D4430 14 15 D4423 30 31 D4431 3 Slave PLC mode and error contents of each station total 32 stations Error Information of PLC is saved following area according to station Station Device Station Device Remarks 0 1 D4432 16 17 D4440 2 3 D4433 18 19 D4441 Each device contains the Information 4 5 D4434 20 21 D4442 of 2 station 6 7 D4435 22 23 D4443 The information of each station is 8 9 D4436 24 25 D4444 saved in 1byte 10 11 D4437 26 27 D4445 12 13 D4438 28 29 D4446 14 15 D4439 30 31 D4447 8 36 Chapter8 Communication Function
6. Down Input condition Reset condition lt S gt XXXX 4 Ring counter The current value is increased with the rising edge of the counter input signal and the counter output relay is turned on when the current value reaches the preset value Then the current value and counter output relay is cleared as 0 when the next counter input signal is applied Input condition Reset condition REMARK 1 Maximum counting speed The maximum counting speed of counter is determined by the length of scan time Counting is possible only when the on off switching time of the counter input signal is longer than scan time Maximum counting speed Cmax con x times sec N duty 76 ts scan time 2 Duty Duty is the ratio of the input signal s on time to off time as a percentage If T1x T2 Ti x100 T1 T2 If T1 T2 TZ 100 6 T1 T2 5 10 Chapter 5 CPU Module 5 3 Program 5 3 1 Classification of program All functional elements need to execute a certain control process are called as a program In MASTER K series a program is stored in the RAM mounted on a CPU module or flash memory of a external memory module The following table shows the Classification of the program Program type Description The scan program is executed regularly in every scan If the scan program is Scan program not stored the CPU cannot execute not only the scan program but also other programs Time driven interr
7. 1 MODBUS Available Device Flag Instruction Step Error Zero Carry M P K L F T C S D _ D ie o EnO 1 12 S1 JO O JO JO JO O JO O O 7 MODBUS s2 O O jo O O O O O O 3 O O JO JO O 0 O O roms st s ss JH Device address which is stored communication data Device address which is displayed communication status Example program F0012 1 MOV h0301 D0000 Itdesignates slave station no and function code MOV h0013 D0001 Itdesignates address MOV h0025 D0002 ltdesignates no of reading M0020 M0020 turns on MODBUS communication starts MODBUS D0000 D1000 M100 Receive data stores D1000 M100 stores communication status S3 format is as below bit 15 bit 8 bit bitO tS MNT Error code Error bit NDR bit NDR when the communication ends normally this bit tums on during 1 scan Error bit when communication error occurs this bit turns on during 1 scan At that time error code stores bit 8 bit 15 Chapter 8 Communication Function Error code is as follow Error type Meaning Illegal Function Error in inputting function code in instruction Illegal Address Error of exceeding the area limit of reading writing on the slave station Illegal Data Value Error when the data value to be read from or write on the slave sta
8. 5 9 2 Usage 1 Saving the user s program on the external memory module Turn the power of the base unit off Install the memory module When only basic unit is used Connect to the expansion connector of the basic unit When expansion unit is used Connect to the expansion connector of the last connected expansion unit Tum the dip switch for ROM mode setting of the base unit to OFF ROM MODE This switch is for Cnet 4 Turn the power of the base unit on 5 Connect KGLWIN and PLC 6 Select Online Flash memory Write external memory in menu and the following message box will displayed IESNCUETETTTE a 8 Choose an item to be saved in the flash memory and press OK 9 Turn the power of the base unit off 10 Remove the external memory module Through the above steps a user can save a program into the external memory module 5 29 Chapter 5 CPU Module 2 Run the PLC with a program of external memory module 1 Turn the power of the base unit off 2 Install the memory module When only base unit is used connect to the expansion connector of the base unit And when expansion unit is used connect to the expansion connector of the last connected expansion unit 3 Set the dip switch for ROM mode setting of the base unit to OFF position This switch is for Cnet ROM MODE 4 Turn on the power of the base unit 5 As RUN LED and ERR LED are on the contents of the memory module
9. ASCII value H15 H3031 H3031 Error code 4 8 24 Chapter8 Communication Function 6 Monitor execution Y 1 Introduction This is a function that carries out the reading of the variable registered by monitor register This also specifies a registered number and carries out reading of the variable registered by the number 2 PC request Format Format name Header Station No Command Registration No Frame check Frame Example ENQ H10 H09 BCC ASCII value H05 H3130 Item Explanation Register No uses the same number registered during monitor register for monitor execution It is possible to set from 00 09 H00 H09 When command is lowercase y only one lower byte of the value resulted by adding 1 byte Register No BCC each to ASCII values from ENQ to EOT is converted into ASCII added to BCC 3 Response Format ACK response QD In case that the register Format of register No is the Individual reading of device Station Registratio Numberof Number of Format name Header Command Data No nNo Blocks data Frame Example ACK H10 H01 H04 H9183AABB H3931383341 ASCII value H06 H3031 414242 In case that the register Format of register No is the continuous reading of device Registration Format name Command Number of data Data 0 Frame Example H09 H04 H9183AABB ASCII value H3
10. Stop Bit Set 1 or 2 bit s When parity bit is set Set as 1 bit When parity bit isn t set Set as 2 bits Communication Channel Time out in Master Mode RS232C Nul Modem or RS422 485 It s a communication channel for the communication using MK80S base unit s built in communication and Cnet I F module G7L CUEC RS232C Modem Dedicated Line It s to be selected for the communication using an dedicated modem with Cnet I F module G7L CUEB RS232C Dial Up Modem It s to be selected for the general communication connecting through the telephone line by dial up modem and Cnet I F module G7L CUEB Footnote Using Cnet I F module G7L CUEB supporting RS232C RS232C dedicated or dial up modem communication can be done but not through Cnet I F module G7L CUEC supporting RS422 485 It s the time waiting a responding frame since the master MK80S base unit sends a request frame The default value is 500ms It must be set in consideration of the max periodical time for sending receiving of the master PLC lfitssetsmallrthan the max send receive periodical time it may cause communication error Modbus Master Slave If itis set as the master it s the subject in the communication system If it s set as the slave it only responds to the request frame of the master Transmission Mode Select ASCII mode or RTU mode Chapter 8 Communication Function 8 3 4 Instruction and example
11. 1 It s possible to select from 1ms to 15ms by 1ms at KGLWIN 2 Circuit diagram Its the same with the one for the base unit 3 Input wiring Chapter 6 Input and Output Modules 6 3 Digital Output Specification 6 3 1 Base unit Relay Output 1 Specification Model Base Unit K7M DR10S K7M DR20S K7M DR30S K7M DR40S K7M DR60S Specifications K7M DR10S DC K7M DR20S DC K7M DR30S DC K7M DR40S DC K7M DR60S DC Output point 4 points 8 points 12 points 16 points 24 points Insulation method Relay insulation Rated load voltage current DC24V 2A rlload AC220V 2A COS 1 1 point 5A 1COM Min load Voltage current DC5V 1mA Max load voltage current AC250V DC110V Current leakage when off 0 1mA AC220V 60Hz Max On off frequency 1 200 hr Surge Absorber None Mechanical More than 20 000 000 Rated on off voltage current load 100 000 or more Life Electrica AC200V 1 5A AC240V 1A COS 0 7 100 000 or more AC200V 1A AC240V 0 5A COS 0 35 100 000 or more DC24V 1A DC100V 0 1A L R 7ms 100 000 or more Response Off gt On 10 ms or less time On gt Off 12 ms or less Common method 1 point 1COM 2 points 1COM 4 points 1COM Operation indication LED is on at on status of output 2 Circuit Internal circuit Chapter 6 Input and Output Modules 3
12. character time is 0 83ms 8 bits 6 64ms 3 584 984 A B X executes frame division using intervals of more than 1 sec without LRC in processing internally 8 68 Chapter 8 Communication Function 3 Address area 1 Setting range is available from 1 to 247 but MK80S supports from 0 to 31 2 Address 0 is used for broadcast address Broadcast address is all slave device recognize and respond to like the self address which can t be supported by MK80S 4 Function code area 1 MK808 supports only 01 02 03 04 05 06 15 and 16 among Modicon products function codes 2 If the response format is confirm ACK it uses the same function code 3 If the response format is confirm NCK it returns as it sets the 8th bit of function code as 1 Ex If function code is 03 we write here only function code part Because only function codes are different Request 0000 0011 H03 Confirm 0000 0011 H03 Confirm 1000 0011 H83 function code of request frame 5 Dataarea 1 It sends data using ASCII data ASCII mode or hex RTU mode 2 Data is changed according to each function code 3 Response frame uses data area as response data or error code 6 LRC Check CRC Check area 1 LRC Longitudinal Redundancy Check It works in ASCII mode It takes 2 complement from sum of frame except header or tail to change into ASCII code 2 CRC Cyclical Redundancy Check It works in RTU mode It uses 2 byte CRC check
13. 100 50 50 50 x1x2 380 deceleration pulse is also 380 8 acceleration time Automatically calculate at KGL WIN if the maximum pulse and slop are set by user Calculation method is as below acceleration time maximum pulse 50 50 x acceleration slop x 10 ex maximum pulse 1000pps acceleration slop 1 acceleration time 1000 50 50 x 1 x 10 380ms deceleration time is also 380ms Acceleration slop and deceleration slop of MK80S pulse output are set up as the same Set up proper value by the sort of motor because if a d slop increases the arrival time to the designated max Cycle also increases 7 16 Chapter 7 Usage of Various Functions 7 pulse out operation explanation Condition 1 Set up as acceleration slop 1 max frequency 1000 no of pulse out 5000 QD If as acceleration slop 1 1 pulse is output on the 1st step velocity 50pps Pulse velocity is 50pps so time consuming is 20ms 2 pulses are output on the 2nd step velocity 100pps and time consumes 20ms By calculation in the same way the time to reach to 1000pps is 20ms x 20 1 380ms and the no of output pulses are 1 2 3 18 19 190 units Decreasing velocity inclination is 1 thus 190 units of pulses are needed The no of pulses in the uniform velocity region are 5000 190 190 4 620 units Whole spent time is 50 380ms Uniform velocity Time 4 620ms Deceleration time 380ms Accele
14. D RUN LED Indicate the operating status the G7F ADHA Analog input terminal Voltage Input Current input When current input is used short the V and I terminal Jumper pin of analog input Input I Voltage Current iij Input ms Input Right is CH 1selecting Connect upper Connect lower parts by left is CH 0 selecting parts pa jumper pins Analogoutputtermind fo Voltage output Current output gt Only one type of output Current or Voltage is available on a module External power input terminal gt External voltage 24VDC needs to this terminal Extension cable gt This cable is used to connect while analog mixture module is used Extension cable connector The connector connects extension cable when extended module is used 7 5 1 Chapter 7 Usage of Functions 3 Parameter setting The same or less than KGLWIN V2 13 The same or more than KGLWIN V2 14 Parameter New Project1 4 Reading A D conversion value amp Writing D A conversion value A D conversion value and D A conversion value stores special data register as following The table which is shown below is possible to use under the same or less than K80S CPU ROM V1 3 Special gala Explanation Remark register D4980 A D conversion value of channel 0 stores D4981 A D conversion value of channel 1 stores A D D A combinatio
15. DC 4 20 mA input resistance 2509 Current DC 0 20 mA input resistance 2502 Classified by parameter Setting by input terminal Voltage Current When current input is used short the V and I terminal Selection Voltage Current is selected by KGL WIN parameter Digital output 12bit binary 0 4000 0 10VDC 2 5nV 1 4000 Maximum DC 0 20 mA 5 u 1 4000 resolution DC 4 20 mA 5 HA 1 3200 Overall accuracy 0 5 Full Scale Max absolute input Voltage 15V Current 25 mA Between input terminal and PLC power supply Isolation Photo coupler isolation No isolation between channels Terminal connected 2 points 16 points terminal block Current 100mA TECTUM Voltage DC216 264V DC216 264V 6 26 4V External Powersupply Current 400 mA consumption Weight 200g gt Offset Gain value can t be changed because it is fixed gt Analog inputting is set the current since this is manufactured gt Itis possible to use to extend max 2 Modules gt The A D conversion module is possible only to use in more than K80S ROM V1 4 KGL WIN V2 14 7 5 9 Chapter 7 Usage of Functions 2 Names of parts and functions The Names of parts and functions of the analog input module are following No Contents RUN LED Indicate the operating status the G7F AD2A Analog input terminal Voltage input Current input gt When current input is used short the V an
16. ENQ H10 H09 Refer to registration Format ASCII value H05 Explanation px Register No registered again the one currently being executed is registered When command is lowercase x only one lower byte of the value resulted by adding 1 byte each to ASCII values from ENQ to EOT is converted into ASCII added to BCC This can be registered up to 10 0 to 9 H00 H09 and if an already registered No is Register Format Xx Register Format Register Format of request Formats must select and use only one of the followings continuous Individual reading of device RSS Number of blocks 2 Byte Q Continuous reading of device RSB Device length 2 Byte reading and named variable reading Device length 2 Byte Po 1 block max 16 blocks Device name 16 Byte Device name 16 Byte This is used to before EOT in command of Formats of separate reading of variable Number of data Chapter8 Communication Function 3 Response Format ACK response Format name Header Station No Command Registration No Frame check Frame Example ACK H10 H09 BCC ASCII value H06 H3039 Explanation When command is lowercase r only one lower byte of the value resulted by adding 1 Byte each to ASCII values from ACK to ETX is converted into ASCII and added to BCC and sent 4 Response Format NAK response Registration Error
17. P080 PO8F Expansion unit output P090 POOF Chapter 7 Usage of Functions 7 2 3 Analog timer 1 Performance specification The performance specification of the analog timer module are following Item Specification Number of channels 4 Output value range 8 Bit Digital output range 0 200 Setting type Setting by variable resistance Accuracy of timer 2 0 Accuracy about max value Operation method Storing data register automatically Internal current 50 mA consumption Number of module Max 3 modules installment Weight 200g 2 Names of parts and functions G7F AT2A PROGRAMMABLE Locic No Name Contents Indicate the operating status the G7F AT2A D IRUN LED On normal operating Off DC 5V power off or the G7F AT2A module fault Channel Setting up the length of timer through variable resistance to every channel 3 Extension cable 4 Extension cable connection terminal 7 6 5 Chapter 7 Usage of Functions 3 Reading A T conversion value AIT conversion value stores special data register as following speed gala Explanation remark register D4966 A T conversion value of channel 1 stores Expansion A T module 1 D4967 A T conversion value of channel 2 stores Expansion A T module 1 D4968 A T conversion value of channel 3 stores Expa
18. Replace the fuse Does the power led turn on Yes Is the voltage within the rated power Is the power supply cable connected Connect the power cable correctly Does the power led turn on Yes Over current protection device 1 Eliminate the excess current activated 2 Switch the input power OFF then ON Yes Write down the troubleshooting questionnaire and contact Does the power led turn on the nearest service center Complete Chapter 11 Troubleshooting 11 2 2 Troubleshooting flowchart used when the ERR LED is flickering The following flowchart explains corrective action procedure use when the power is supplied starts or the ERR LED is flickering during operation ERR LED goes flickering Check the error code with connected KGLWIN See App 2 System Warning Flag and remove the cause of the error Waming error Yes Is ERR LED still ficking Write down the Troubleshooting Complete Questionnaires and contact the nearest service center Though warning error appears PLC system doesn t stop but corrective action is needed promptly If not it may cause the system failure Chapter 11 Troubleshooting 11 2 3 Troubleshooting flowchart used when the RUN turns off The following flowchart explains corrective action procedure to treat the lights out of RUN LED when the power is supplied operation starts or operation i
19. Sta Bi M 3 no i Saa E Cicer runic ation Ch arimia Masta ranemisian Made amp ABPC Hull Modem ar ASA I sna E r RSEEC MademiDedicsed Line ni Commaed User Defined C REZE Dial un Modem pr Master C aua 1 Click the list Frame List Frame Information ot Detine Not Defined Tx Rx Not Defined 3 Not Defined Header 4 Not Defined SGI 5 Not Defined 6 Not Defined G2 7 Not Defined 83 8 Not Defined 9 Not Defined SG4 10 Not Defined SG 11 Not Defined 12 Not Defined SG 13 Not Defined SGT 14 Not Defined 15 Not Defined SG8 Tailer BEG Cancel Double click the number 0 Chapter 8 Communication Function Designate BCC Setting as above Click the OK button and then you can see the frame list window which is designated Chapter 8 Communication Function BCC Setting method is same frame 0 After the frame setting and BCC setting completes click the OK button You can see the frame list window which is designated as below Chapter 8 Communication Function Program i EHE When the data is received at frame no 1 link relay L001 turns on during 1 scan At that moment M000 increases and the value of M000 moves output relay P004 The new value of M000 is sending again every 1 second period F092 is 1second period flag The number of sending normally stores D000 When error occurs the number of sending error stores D001 When data is received
20. Tail Used in Tail type Possible characters as headers are 1 alphabet letter 1 numeric number or control characters as below Control character Available Control Code NUL h00 STX h02 ETX h03 EOT h04 ACK h06 NAK h15 SOH h01 ENQ h05 BEL h07 BS h08 HT h09 LF h0A VT h0B FF hOC CR hOD SO hOE 1 h0F DLE h10 DC1 h18 DC2 h12 DC3 h13 DC4 h14 SYN h16 ETB h17 CAN h18 EM h19 SUB h1A ESC h1B FS h1C GS h1D RS h1E US h1F Del H7F Example 1 NUL ENQ 1 A Possible Example 2 NUL ENQ 12 ABC impossible tis allowed to be only 3 consecutive characters Example 1 ENQ STX NUL Example 2 AJ NUL ENQ STX ts possible to use BCC that can detect errors BCC must be set as BCC to be used To set BCC Possible impossible contents click BCC Setting button on the right side Ex5 Tailer EOT BCC BCC setting set BCC when itis needed BCC Setting BCC Setting Data Type Check Rule C Default C SUM 1 C SUM 2 C XOR 1 C XOR2 C MUL 1 C MUL2 Range ex H 0 T 0 Complement None Mask ex FF FF Cancel amp FF Chapter 8 Communication Function ASCII adds 2 bytes BCC value in ASCII type to frame Hex adds 1 byte BCC value in Hex type to Datatype frame For the detailed setting BCC refer to 8 1 6 Execution of Commands It is that su
21. Users Manual LG Programmable Logic Controller MASTER K Kaos LG Industrial Systems Contents Chapter 1 General ueuaseaNelen apenas PTT eri oe etre ee WR REKMS AERIS UREN SUN Se SMSC Ee IR EREENS AE 1 1 1 6 1 4 Guide to Use this Mangiare cpbdeseutieefedopeiqageo enun gigs ot ratu etree cdi 1 1 TAFSaIuIES ae tpe food gode ee rtt Re 1 2 1 3 Terminologie entro tar a dnte eic t viai arp 1 4 Chapter 2 System Configuration yes TERRI GUY T E SOC 2 1 2 6 2 1 Overall Configuration sineret eng randi Pi eorr toin ath sect ee dotted 2 1 2 VET ASICS VSUGIM ge E ee aa M E 2 2 2 T 2 Cnetl FSystelri esee ees een ees oa a E iniecit E aAa a a canto Meals 2 2 2 2 Product functional mode esset certes iine one nien uc eui cana erik ances stot 24 2 2 A Product function BOCK er eerten dennerien Fee seii eerie dee rendi neci reprise 2 4 2 2 2 GM7 Series System Equipment Product mmm 2 5 Chapter 3 GENERAL SPECIFICATION 3 1 General specifications emen 3 1 4 Base Unit nennen 4 1 4 1 1 10 point basic unit mmn 4 3 4 1 2 20 point basic unit meer 4 3 4 1 3 30 points Basic Unit mme 4 4 4 1 4 40 Points Basic Unit mmm emm 4 4 4 1 5 60 Points Basic Unit mmm emen 4 4 4 2 Expansion Option Module He ieinnetey 4 5 42 1 Digital IO Module mmm nme nnne nnns 4 5 42 2 A D D A Combination Module eem 4 5 4 2 3 Analogue timer Module mme 4 5 4 2 4 Option Module See nnns 4 6 Chapter 5 CPU 5 1 Specifications MTM vM PPM c
22. 16 blocks Explanation When command is lowercase r only one lower byte of the value resulted by adding 1 Byte each to ASCII values from ENQ to EOT is converted into ASCII and added to BCC This specifies how much of the blocks composed of device length device name are in Number of blocks this request Format This can be set up to 16 Therefore the value of Number of blocks must be set between HO1 ASCII value 3031 H10 ASCII value 3030 Device This indicates the number of name s characters that means device which is allowable up to length Name 16 characters This value is one of ASCII converted from hex type and the range is from length of device HO1 ASCII value 3031 to H10 ASCII value 3130 ms Address to be actually read is entered This must be ASCII value within 16 characters and evice in this name digits upper lower case and only are allowable to be entered If the value to be written in MW100 area is H A the data Format must be H000A If the value to be written in MW100 area is H A the data Format must be H000A In data area the ASCII value converted from hex data is entered Ex 1 If type of data to be currently written is WORD the data is H1234 ASCII code converted value of this is 31323334 and this content must be entered in data area Namely most significant value must be sent first least significant value last Chapter8 Communication Function 1 Device
23. 6 7 2 Precautions during installing 1 During drilling or wiring do not allow any wire scraps to enter into the PLC 2 Install it on locations that are convenient for operation 3 Make sure that it is not located on the same panel that high voltage equipment located 4 Make sure that the distance from the walls of duct and external equipment be 50mm or more 5 Be sure to be grounded to locations that have good ambient noise immunity HH re 3 Heat protection design of control box 1 When installing the PLC in a closed control box be sure too design heat protection of control box with consideration of the heat generated by the PLC itself and other devices 2 It is recommended that filters or closed heat exchangers be used Chapter 9 Installation and Wirin The following shows the procedure for calculating the PLC system power consumption 1 PLC system power consumption block diagram Base Unit I 5v 5VDC line Expansion module special Output part module Transistor Output Current Input Current lout x Varop Lin x Varop output part transistor input part Input Current Lin Varop AC power Supply Output Current IOUT x Vdrop le eesssposesvenseesssesmesmehRIMIeees Current 24VDC line lout Extetnal 24VDC power Supply Kum an 2 Power consumption of each part 1 Power consumption of a power suppl
24. NH It can be selected to 0 15ms 7 25 Chapter 7 Usage of Various Functions 7 1 5 PID control function 1 Introduction This chapter will provide information about the built in PID Proportional Integral Differential function of MK80S Basic Unit The MK80S series does not have separated PID module like MK300S and MK1000S series and the PID function is integrated into the Basic Unit The PID control means a control action in order to keep the object at a set value SV It compares the SV with a sensor measured value PV Present Value and when a difference between them E the deviation is detected the controller output the manipulate value MV to the actuator to eliminate the difference The PID control consists of three control actions that are proportional P integral I and differential D The characteristics of the PID function of MK80S is as following the PID function is integrated into the CPU module Therefore all PID control action can be performed with instruction PID8 PID8AT without any separated PID module Forward reverse operations are available P operation PI operation PID operation and On Off operation can be selected easily The manual output the user defined forced output is available By proper parameter setting it can keep stable operation regardless of external disturbance The operation scan time the interval that PID controller gets a sampling data from actuator is changeable for optim
25. b Manual operate value When manual operation is designates manual operation value designates input range 0 4000 c High frequency noise removal ratio high frequency noise removal ratio is used for derivative control operation and shows the ratio of high frequency noise depression If there is a lot of high frequency noise in the control system select the value as higher value Otherwise leave the 1 The range of parameter is 0 10 and it is not scaled up so input the designated value directly it is possible that parameter value designates D area also Be careful if designating D area value and designating value directly over 10 system operate abnormally d Tracking time constant TT tracking time constant parameter is used to designate anti_reset windup operation The range of TT is 0 01 10 and the actual input range that are 100 times scaled up is 0 1000 e Reference value Reference value may be useful parameter according to the control system type especially velocity pressure or flux control system The Reference value input is also 10 times scaled up and the actual range is 0 10 f Differential time and integral time _TIME and D_TIME are 10 times scaled up For example input 18894 if the designated _TIME value is 1889 4 The range of actual input is 0 20000 it is possible that parameter value designates D area also 7 3 7 Chapter 7 Usage of Various Functions g Proportional gain
26. fia p rz pm m peor m m 1 8 points can be used to designate the pulse catch input The input address is from P000 to P007 2 General digital input operates if it is not designated as pulse catch input 7 2 4 Chapter 7 Usage of Various Functions 7 1 4 Input Filter Function External input of MK80S selects input on off delay time from the range of 0 15ms of KGLWIN Credibility secured system may be established by adjustment of input correction no through using environment 1 Usage Input signal status affects to the credibility of system in where noise occurs frequently or pulse width of input signal affects as a crucial factor In this case the user sets up the proper input on off delay time then the trouble by miss operation of input signal may be prevented because the signal which is shorter than set up value is not adopted 2 Operating Explanation input on off gelay time filter time input signal input image data time input signal input image data narrower width pulse than input correction no is not considered as input signal 3 Using method 1 Click twice the basic parameter on the project window of KGLWIN 2 The value of filter can be set up as unit of 1ms to the input on off delay time of the basic parameter window Input on off delay time is set up as default value of 8ms 3 Set up input on off delay time is conformed to all input is used ll LN LUN UM Eri
27. interrupt program 3 Function 1 Max 8 points can be used to external interrupt input within P000 P007 2 Inputting 8points of base unit are set functions like following 00 01 02 03 04 05 06 07 A phase B phase Preset High speed counter Input Input Input External interrupt 0 L L L L 0 L Time driven task 8points are available 3 Max 8points of external contact interrupt are available to use But the no of them is decreased by using other interrupt time driven interrupt 7 4 8 Chapter 7 Usage of Various Functions 4 Designate contact point no of priority and movement condition of the task program which is moved by interrupt inputting Time driven Interrupt execution periodic set interrupt input contact No interrupt input executing condition Rising Falling Rising Fal ling 5 For the details refer to KGLWIN manual 7 4 9 Chapter 7 Usage of Functions 7 2 Special module 7 2 1 AID D A Combination module 1 Performance specification The performance specification of the analog mixture module are following Specifications Voltage DC0 10V input resistance more than 1 M9 Input range Buren DC 0 20 mA input resistance 250Q Classified by DC 4 20 mA input resistance 2500 parameter igj 12Bit 48 4047 Analog Digital output 1 Setting by jumper pin for
28. ood ues b7 b6 b5 b4 b3 b2 b1 b0 bo E ud Error status of slave PLC Operation mode of slave PLC Not used 1 Error b4 STOP 0 Normal b5 RUN b6 PAUSE b7 DEBUG 4 Status flag of the master PLC Status Information of master PLC is saved in D4448 b15 b3 b2 b1 b0 MIELE 4 D4448 b1 be set in case station is duplicated b2 be set in case device area over 5 Max min current sending receiving cycle of set parameter Contents the interval between after sending and before receiving Item Saved area Max D4449 D4450 Min D4451 D4452 Current D4453 D4454 Chapter8 Communication Function 4 Example K80S base unit K80S base unit Master G7E DR10A Slave Station No 0 Station No 31 1 1 built in communication between K80S s Device M000 is increased by program per 1 second Writing M000 to output area P004 of slave Reading slave s output area P004 to master s output area P009 The following example uses the above diagram to explain the operation of MK80S Base Unit The data of the master MK80S Base Unit is increased by INCP instruction and sent to be written on the output contact point PO40f the slave MK80S Base Unit And in return the master MK80S Base Unit reads the data that is written on the output contact point of the slave MK80S to write them on the output contact point of extended
29. 1 S when using the CMP instruction F0124 GTE flag Turns on if S4 gt S2 when using the CMP instruction F0125 NEQ flag Turns on if S1 S2 when using the CMP instruction F0126 to F012F Unused F0130 to F013F AC Down Count Stores AC down counting value App2 4 Appendix 2 Flag List Continued Relay Function Description F0140 to F014F FALS No The error code generated by FALS instruction is stored to this flag F0150 to F015F PUT GET error flag When a common RAM access error of special modules has occurred an output module the corresponding bit to the slot turns on F0160 to F016F Unused F0170 HSC output bit Turn on when the current value of HSC reaches setting value F0171 Carry flag for HSC Turn on when overflow or underflow is occurred on the HSC current value F180 to F19F Current value of high speed Stores the current value of high speed counter counter F18 lower word F19 upper word F200 to F49F Unused F0500 to FO50F Maximum scan time Stores the maximum scan time F0510 to F051F Minimum scan time Stores the minimum scan time F0520 to F052F Present scan time Stores the present scan time F0530 to F053F Clock data Clock data year month year month F0540 to F054F Clock data Clock data daylhour day hour F0550 to F055F Clock data Clock data minute second minute second F0560 to F056F Clock data Clock data day of the week day of
30. 15 44 13 102 7 9 Chapter 7 Usage of Various Functions 5 2 phase operation mode 4 Multiplication Operation D4999 h2014 U D set automatically by the phase difference between A and B phase PR set by external PR input Multiplication 4 times Ladder diagram MOV h2014 D4999 PV 00100 SV 01000 Time chart A phase pulse input zc ese ped eod xe de di B phase input U D CurrentvalueofHSC 10 12 14 16 18 20 22 24 125 123 21 19 17 15 1113 45 47 19 21 23 25 24 22 20 18 16 14 T 1 0 Chapter 7 Usage of Various Functions 7 1 2 Pulse Output Function In the transistor output type of MK80S the pulse output function maximum 2Kpps is internalized By using this function with stepping motor or servo motor driver MK80S is applicable to a simple positioning system 1 Usage of the Pulse Output Transistor output type of MK80S outputs the signals of pulse and direction in an output contact point through the instruction PULSOUT The outputted pulse is connected to motor driver it is controlled position in the following figure K7M DT30S Choose a mode from the pulse out function by parameter setting and operate following 3 modes 1 Trapezoidal operation The pulse output function operates in order of acceleration uniform velocity deceleration velocity increasing decreasing Uniform velocity operation Operates with the uniform velocity without increasing decreasing opera
31. 2ms High speed counter Support high speed counting up to 1 phase 16kHz 2 phase 8kHz External interrupts Using in applications that have a high priority event which requires immediate responses e The input filter function help reduce the possibility of false input conditions from external noise such as signal chattering The filter time can be programmed from 0 to 15 ms Using built in pulse output without separate positioning module it can control stepping motor or servo motor Using RS 232C built in port it can connect with external devices such as computers or monitoring devices and communicate 1 1 with MK80S or MK2008 system e 10 points modules K7M DR10S K7M DR10S DC K7M DT10S have both of RS 232C and RS 485 port e t has PID control function with which it can easily constitute a system without separate module 3 It can easily do On Off of the system using RUN STOP switch 4 It can constitute various system using separate Cnet I F module Except 10 points modules pc m 5 It can easily save the user program by simple manipulation in KGLWIN 6 Strong self diagnostic functions It can detect the cause of errors with more detailed error codes 7 It can prevent unintentional reading and writing using password Chapter 1 General 8 Debugging function On line debugging is available if the PLC Operation mode is set to debug mode executed by one command executed by break point settings execute
32. 3mA or higher Off voltage Off current DC5V or lower 1 8 mA or lower P000 P002 3 3mA or lower Input impedance Approx 2 7 KQ 100 102 approx 1 5 KQ Off On 15msorless Response time On Off 15ms or less Common terminal 6 points COM 12 points COM 18 points COM 12 points COM 18 points COM Operating indicator LED turns on at ON state of input 1 Itis possible to select from 1ms to 15ms by 1ms at KGLWIN 2 Circuit diagram Input no P000 P002 Internal circuit Internal circuit Chapter 6 Input and Output Modules 3 Input wiring Base unit s wiring method is as follows DC input specifications offered by K80S is to be used for both electric current sink and electric current source 1 10 points base unit BUILT IN CNET IK RUN BUILT IN CNET KZ PAU REM ON JOFF sl e STOP ROM MODE P 2 20 points base unit cro pete sel J Lacus Pepee Chapter 6 Input and Output Modules 3 30 point base unit REE 1e PERERA 4 40 point base unit GASAE A S OAE FD TEER 2 iie d C hapter 6 Input and Output Modules 5 60 point base unit en Beee DE JAE PAU REM Arat RI Balsa I NP IU
33. 4A Chapter 8 Communication Function 2 SUM 1 XOR 1 or MUL 1 setting BCC Setting H 1 T 0 None ra Oe Cancel a SUM 1 The last transmitting frame Mois dd ut The value of sum check BCC Type setting xoa ASCII Type Hex Type ASCII Input 05 31 32 33 34 04 D3 05 31 32 33 34 04 44 33 05 31 32 33 34 04 D3 Hex Input 05 12 34 04 4F 05 12 34 04 34 46 05 12 34 04 4F b XOR 1 The last transmitting frame edi ii The value of sum check BCC Type setting idle ASCII Type Hex Type ASCII Input 05 31 32 33 34 04 2 05 05 31 32 33 34 04 30 35 05 31 32 33 34 04 05 Hex Input 05 1234404 2 27 05 12 34 04 32 37 05 12 34 04 27 c MUL 1 The last transmitting frame EE ut The value of sum check BCC Type setting EU ASCII Type Hex Type ASCII Input 05 x 31 x 32x 33 x34 x 04 60 05 31 32 33 34 04 36 30 05 31 323334 04 60 Hex Input 05 x 12 x 34x 04 20 05 12 34 04 32 30 05 12 34 04 20 d Complement setting Complement calculation as below bit 7 bit 0 1 1 0 1 0 0 1 1 h D3 sum check value bit 7 bit 0 0 0 1 0 1 1 0 0 1 complement h 2C the last sum check value bit 7 bit 0 0 0 1 0 1 1 0 1 2 complement T complement 1 h 2D the last sum check Chapter 8 Communication Function Mask setting Masking method is as below bit 7 bit 0 1 1 0 1 0 0 1 1 h D3 sum chec
34. 8 instruction Available Device Flag Instructions inte Steps Eror Zero Cany M P K L F T C HD ger F110 F111 F112 n O O DUTY 9 0 0 04 0 olo olo 7 lt 0 S2 e I PsoU D S amp Output pulse count no Output pulse contact 1 Functions n designates pattern no which is registered at parameter 1 designates device name which will be stored output pulse count no and error code 3 word S2designates output device output P area 2 example of program M0020 L PLSOUT 5 0D0000 P0040 when the M0020 is On jit outputs the pulse at 5 pattern to P0040 It stores the output pulse count no at D0000 and D0001 It stores error information at D0002 All output area is designated for pulse output contact but it can t designate over 2 contact at the same time T 1 9 Chapter 7 Usage of Various Functions 3 instruction Error List Error status Contents Treatment 00 Normal 01 Other PLSOUT instruction pulsating Change the other PLCOUT program 02 Velocity designation error more than 2000 not a multiple of 50 designated 0 Velocity designation adjustment 03 The no of a c velocity pulse is bigger than no of all pulse is to output Acceleration adjustment 04 No output contact point where is designated to the pulse output Output c
35. Command Fomatted data EOT BCC PLC ACK response ENMS Station No Data or null PLC NAK response Chapter8 Communication Function 8 1 4 List of commands Command list for communication Division Command Main command Command type Treatment Code ASCII code Code ASCII code Individual H72 reading H52 A ik SB 5342 Conta toding BIG a reading H52 Individual H77 Writing reading H57 SS 5353 Reads device of Bit Word and type SS 5353 Writes data to device of Bit and Word type device Continuos H77 oe Writes data to Word type in block unit reading H57 Continuous reading Bit is unavailable Reads flag list like PLC operation status and error 5354 information For detailed flag contents refer to MK80S manual CPU H73 Status reading H53 Command Division Main command Register No Treatment Register no Code ASCII code ASCII code Monitoring variable H78 register H58 H00 H09 3030 3039 Register device to monitor Execution of H79 monitoring H59 1 MK80S base unit identifies capitals or small letters for main commands but not for the others H00 H09 3030 3039 Execute registered device to monitor 2 If it s a main command in capitals it calculates BCC value But if it s not it doesn t Therefore when BCC for frame check is used main commands must be in small letters 8 7 Chapter
36. Error code Error type Error condition and causes Treatment H0001 PLC system error Interface with PLC is impossible On Off the power Data error Errors occurred when exchanging ASCII data to numbers Check if other letters than capitals small letters numbers and _ in device and data correct and execute again Command error Set a wrong device memory that is to use commands other than w W r R x X y Y s S Check commands Command type error Wrong command type that is to use characters like wSS wSB using other letters from SS or Sp Check command type Device memory error Set wrong device memory other than P ML K T C F D S Check device type Data size error The number of data in execution is 0 or bigger than 128 bytes Correct length of data If data type is bite the number of data must be from 1 128 Data type error When use other characters than x X w W at MK80S When use b B d D at MK80S Ex1 Use commands like DB or DD Check data type and execute again Device request Format error When omit 96 Check Format correct and execute again Area exceeding error When exceed assigned area Ex1 MX2000 or DW5000 Correct the size within the assigned area and execute again Monitor execution error Exceeding limit of register No Rearr
37. External memory module operation 6 Is the ERR LED of the CPU module tumed ON Yes No 7 KGLWIN error message 8 Used initialization program initialization program 9 History of corrective actions for the error message in the article 7 10 Other tried corrective actions 11 Characteristics of the error e Repetitive Periodic Related to a particular sequence Related to environment e Sometimes General error interval 12 Detailed Description of error contents 13 Configuration diagram for the applied system 11 8 Chapter 11 Troubleshooting 11 4 Troubleshooting Examples Possible troubles with various circuits and their corrective actions are explained 11 4 1 Input circuit troubles and corrective actions The followings describe possible troubles with input circuits as well as corrective actions Condition Cause Corrective Actions Leakage current of external device Input signal Such as a drive by non contact switch doesn t turn off Connect an appropriate register and capacity which will make the voltage lower across the AC input terminals of the input module Leakage current External device 1 AC input C Input signal O Leakage current of extemal device CR values are determined by the leakage current doesn t turn off Drive by a limit switch with neon lamp TTA Neon lamp AC input may be still on Leakage current Reco
38. F Output signal Output signal Sub system Description CPU e Signal processing function Operating system function Application program storage memory function Data storage memory function Application program execution function Input e The input signals obtained from the machine process to appropriate signal levels for processing Output e The output signals obtained from the signal processing function to appropriate signal levels to drive actuators and or displays Power Supply Provides for conversion and isolation of the PLC system power from the main supply Communications Provides the data exchange with other systems such as KGLWIN computers Interface 2 2 2 K80S Series System Equipment Section Items Models Description Remark K7M DR10S K7M DR10S DC K7M DT10S O Points 6 DC inputs 4 relay outputs K7M DR10S K7M DR10S DC 6 DC inputs 4 TR outputs K7M DT10S Program capacity 48 kbytes Built in function High speed counter Phase1 16 kHz phase2 8 kHz 1channel pulse output 1 x 2kHz pulse catch pulse width 0 2ms 4 points external contact point interrupt 0 4ms 8points input filter 0 15ms all input PID control function RS 232C communication RS 485 communication K7M DR20S K7M DR20S DC K7M DT20S Basic Base Unit O Points 12 DC inputs 8 relay outputs K7M DR20S K7M DR20S DC 12 DC inputs 8 TR outputs K7M DT20S Program capacity 48 kb
39. II Po Teee Tro Troe Troe TPA TP TPE T APE TEE TP TPST ETP TEE PTET lov Eria T Pe ZUR Pea las RN N masTer S 04 0 25982 OF 10 11 12 13 14 15 16 17 18 19 1A 1B 1C 1D 1E 1F 20 21 22 a ic Bue Chapter 6 Input and Output Modules 4 Example of external devices To connect with external device of DC output type into DC input module wire depending on the type of the external device as shown External device Input module Sjulod j2ejuo ed 1ndjno 10j29jo9 uedo NdN Same power for sensor and input Consta nt z U zZ o c E oO 2 o c S c S gt lt O ed 1ndino uano dNd edA 1ndino eBejoA Chapter 6 Input and Output Modules 6 2 2 Expansion Module 1 Specifications Model Expansion Module Specification G7E DR10A Number of input points 6 points Insulation method Photo coupler Rated input voltage DC12 24V Rated input current 4 519 mA Operating voltage range DC10 2 28 8V ripple less than 5 Max Simultaneous input points 100 simultaneously On On voltage On current DC9 5V or higher 3 5 mA or higher DC5V or lower 1 8 mA or lower Approx 2 7 KQ 15ms or less Off voltage Off current Input impedance Off On Response time On Off 15ms or less Common terminal 6 points com Operating indicator LED turns on at ON state of input
40. K x integral gain Ti QxTd Nxh QxTd Nxh QXKXNXxTd X QxTd Nxh derivation gain h AO anti windup gain Tt Step 2 Read SV and PV value PV adin ch1 Step 3 Calculate the proportional term P Kx bx SV PV Step 4 Update the derivative term initial value of D 0 D As x D Bd x PV PV old Step 5 Calculate the MV initial value of 0 MV P I D Step 6 Check the actuator is saturated or not U sat MV U low U high Step 7 Output the MV value to the D A module Step 8 Update the integral term bi x SV PV A0 x U MV Step 9 Update the PV old value PV old PV 3 Instruction and parameter setting For the PID operation of MK80S following 2 instruction are included in the KGLWIN software version 2 0 or later No Name Description 1 PID8 Perform the PID operation 2 PID8AT Perform the auto tuning operation 7 3 6 Chapter 7 Usage of Various Functions 1 Refer the KGLWIN manual for the parameter setting 1 Parameter setting and explanation a PlD8 instruction parameter setting and explanation a Scan time scan time is the period of reading data sampling and also 10 times scaled up Generally it should be synchronized with external trigger input EN input of function block to perform proper PID operation The range of sampling time is 0 1 10 seconds and actual input range is 0 100
41. LE 5 1 5 2 Operation Processing Seve edis Tak ure LEER CHEER RIP SERE Se QUY T aul nest ae dames ERR Etat ne spun x 5 3 5 2 1 Operation Processing Method ulia Eu Toe R9 a fica or evens EAT E TREE RO TRIS A E Ton c D RT A 5 3 5 2 2 Operation Processing at momentary power failure occurrence n6 54 5 23 Scan time eH Henne nnne nnne 5 5 524 Scan watchdog illl EM 5 5 5 2 5 Timer processing RPRIRIVERISIBER RR CTARGW KR IDE ERR XGXGWGGY DIES YR IAE 33g al Pra TIR X WR G4lA P P OIRFETR 5 6 5 2 6 Counter processing AIPRPSIMILIRRRGNIESGRRAMIIRRRSRIIGGS RA IEPPR IINE RR DIRPRRIRIIRI TALIEI TTET TT 5 8 53 Program sies wi v is de tial in rs o er ice Re P UR ER EFE eite EXIT stain SR e Cor UT ee aes cT Y 5 10 5 3 1 Program configuration EEE A ERT AARON RRS ARI UDIN A Cu RD LTR Ti p RU RRC AR RENE DISTR Re EU Y Up S 5 10 5 3 2 Program execution procedure RT TT REE uu US ROUEN as TTS US 68 D ON DD QU SIUE Qd TT 5 11 EREE 5 14 5 3 4 Error handling A E A a T a RR Mr 8 Ca CV E 5 21 5 3 5 Precautions when using special modules Vu iit Erw TR M o eJ RD B EAR OC Un APR CR BUR REM Ej fuc ORE 5 22 54 Operation modes Emo T a 5 23 5 4 1 RUN mode SEO CnC RW IEEE RM RET ONEEN RINGTONE KDE ROC CRT UE FL OUR EQGATER EEEIEI RAE ree 5 23 542 STOP mode Hares Rr ER PERS MEETS aye VRBUEINEINFEESIERNSUCUNLESPUES KEINE CUNCENFIES NE DNE UELLE PRESS RAPER MERE E 5 24 5 4 3 PAUSE mode ie ss tera ER NTEGER BTE RR RR RERS EEE ATHE UREE RIPER ANIA BUE RR NAS KEE Ta RIROR EUER RU ALTRE ER ae Mele
42. MK80S search the same protocol at frame list automatically Therefore MK80S has not receive instruction Ifthe same protocol exist MK80S receive the data at the upper frame number Chapter 8 Communication Function 2 Setting and program of slave station Make the new project file and setting new parameter Double click the frame list number 0 Chapter 8 Communication Function Click the BCC Setting after set the header segment tail as above Click the OK button after BCC setting as above 8 64 Chapter 8 Communication Function You can see the frame list which is designated And then set the frame number 1 as below Double click the BCC Setting and then set the BCC as below 8 65 Chapter 8 Communication Function Setting You can see the frame list which is designated User Define ir ae te ot Defined 222727227 E RE oO tx Click OK button 8 66 Chapter 8 Communication Function Program When the data is received at frame no 0 link relay L000 tums on during 1 scan At that moment P004 increases and the value of P004 moves M000 The new value of P004 is sending again every 1 second period F092 is 1second period flag The number of sending normally stores D000 When error occurs the number of sending error stores D001 8 67 Chapter 8 Communication Function 8 3 Modbus Protocol Communication 8 3 1 Introduction MK80S built in commu
43. Output wiring 1 10 points base unit 2 20 points base unit K7M DR20S PROGRAMMABLE LOGIC 4142 47 CONTROLLER ACTOO 240V P40 Pat P42 PAPE mu mum mm KP KP ep ep ee i E CH l I7 IE L Lir rir rri DC5V OC24V AC110 220V Chapter 6 Input and Output Modules 2 30 point base unit K7M DR30S PROGRAMMABLE AC110 220V DC24V DC5V 3 40 point base unit K7M DR40S PROGRAMMABLE CONTROLLER LOGIC AC110 220V DC24V DC24V DC5V 6 10 Chapter 6 Input and Output Modules 4 60 point base unit K7M DR60S PROGRAMMABLE AC110 220V DC24V DC24V DC24V DC5V 6 11 Chapter 6 Input and Output Modules 6 3 2 Base unit Transistor Output 1 Specification Model Base Unit Specifications K7M DT10S K7M DT20S K7M DT30S K7M DT40S K7M DT60S Output point 4 points 8 points 12 points 16 points 24 points Insulation method Photo Coupler insulation Rated load voltage current DC12 24V Operating load voltage DC10 2 26 4V Max load current 0 5A 1point 3A 1COM Current leakage when off 0 1mA or less Voltage drop when turn on 1 5V or less Max load Max Inrush Current 4A 10mA Surge Absorber Clamp Dlode Response Off On 2 ms or less time On 5 Off 2 ms or less Common method 4 point 1COM 8 point 1COM i zu icon ae R
44. S ue 3 a i 3 o w EX E a 025v Y 5 5V 10V Input Voltage Analog input voltage A D conversion characteristics voltage input In voltage input digital amount 0 is output by OV input and 4 000 is output by 10V input Therefore input 2 5mV equals to digital amount 1 but value less than 2 5mV can t be converted b Current input 4000 2004 Ue onem 2002 2001 2000 Digital output value Digital output value E LQ e I A 10 mA Analog input current Input Current A D conversion characteristics Current input Current input OmA becomes output 0 10mA does 2000 and 20mA does 4000 therefore input 5 A equals to digital amount 1 but value less tan 5 HA can t be converted So abandon it 1 5 5 Chapter 7 Usage of Functions 2 Analog output characteristics a Voltage output o bo ise a e gt 2 E a 8 3 5 bo e c E lt Analog output voltage 2000 2001 2002 200 200 200 2000 4000 gt Digital input Digital input value D A conversion character istic voltage output Input of digital amount 0 outputs analog amount OV 4000 does 10V Digital input 1 equals to 2 5mV of analog amount b Current output 10 005 10 000 2000 2001 2002 200 200 200 2000 4000 e Digital input Digital input value Analog output current T E D I H 3 o 2 3 a E 3 o 50 xS c E lt D A conversion characteristic Current ou
45. TR outputs K7M DT60S Program capacity 48 kbytes Built in function High speed counter Phase1 16 kHz phase2 8 kHz 1channel pulse output 1 x 2kHz pulse catch pulse width 0 2ms 4 points external contact point interrupt 0 4ms 8points input filter 0 15ms all input PID control function RS 232C communication Expansion module Digital I O module G7E DR10A e O points 6 DC inputs 4 relay outputs AID D A Composite module G7F ADHA e A D 2 channel D A 1 channel Analog timer module G7F AT2A e Points 4points e Digital output range 0 200 Cnet I F module G7L CUEB e RS 232C 1 channel G7L CUEC e RS 422 1 channel 2 6 Chapter 3 General Specifications Chapter 3 General Specifications 3 1 General specifications Item The following shows the general specifications of the MASTER K series Specifications References Operating ambient Temperature 0 55 C Storage ambient Temperature Operating ambient 25 70 C 3 5 95 RH non condensing Humidity Storage ambient 4 ni 5 95 RH non condensing Humidity Occasional vibration Frequency Acceleration Amplitude Sweep count 10 lt f lt 5 Hz 0 075mm 5 Vibrations 57 lt f lt 150Hz 9 8m s 1G Continuous vibration 10 times foreach X IEC 61131 2 Frequen
46. Therefore when use FOR NEXT or CALL instruction insert WDT instruction to reset the watch dog timer 3 Battery check function When the voltage of the battery for back up the memory IC of CPU are lower than the minimum back up voltage the BAT LED of CPU module will be turned on 5 19 Chapter 5 CPU Module 5 5 2 I O Force On Off function It is possible to input output a designated data regardless of the result of program operation This function is useful to check operation of the input output modules and wiring between the output modules and external devices 1 Force On Off setting method Force on off setting is applied to input area and output area Force on off should be set for each input and output the setting operates from the time that Force I O setting enable is set This setting can be done when I O modules are not really loaded Select the set forced I O from KGLWIN Samia ace mager Select the I O area and then double click aam uam iiss au e nnnm Tum qaaa btaa ac ERN em FEER ef m nanpa nume CEE OES rr shea pone anes a Sebo aane 5 20 Click Chapter 5 CPU Module MEE X Xl X11 i L L LI LI mim V EN Eu u Ni NL mimm m uH Set forced I O data by bit Set forced I O data enable by bit When forced I O set enables forced I O function is executing Click 5 21 Chapter 5 CPU Module 2
47. ai Operation indication LED is on at on status of output 2 Circuit Vec D2 24VD Chapter 6 Input and Output Modules 3 Wiring Diagram 1 10 point base unit 2 20 point base unit 3 30 point base unit K7M DT30S RUN O PR MABLE LC 40 42 43 44 45 46 47 48 49 4A 4B CONTROLLER CRRO OOOOOOOC ooo ic Chapter 6 Input and Output Modules 4 40 point base unit K7M DT40S QNO PROCRAMMABLE 5 60 point base unit K7M DT60S PROGRAMMABLE ocic CONTROLLER IAN PY TR TR LC PCY C C LI C TT EL Lk LJ ENEE TEN ENEN o T7 E EE LE E Chapter 6 Input and Output Modules 6 3 3 Expansion Module 1 Specifications Model Expansion Module Specifications G7E DR10A Output point 4 points Insulation method Relay insulation Voce DC24V 2A rlload AC220V 2A COS 1 1 point 5A 1COM Min load Voltage current D
48. blocks length Ex of frame H20 SS H01 H06 MW100 ASCII value H3031 H3036 H254D57313030 p ee 1 block setting can be repeated up to max 16 blocks Explanation When command is lowercase r only one lower byte of the value resulted by adding 1 Byte each to ASCII values from ENQ to EOT is converted into ASCII and added to BCC For example the BCC of the above frame is gotten as below H05 H32 H30 H72 H53 H53 H30 H31 H30 H36 H25 H4D H57 H31 H30 H30 H04 H03A4 Therefore BCC value is A4 This specifies how much of the blocks composed of device length device name are in this Number of Blocks request format This can be set up to 16 Therefore the value of Number of blocks must be set between H01 ASCII value 3031 H10 ASCII value 3030 js This indicates the number of name s characters that means device which is allowable up to 16 evice characters This value is one of ASCII converted from hex type and the range is from H01 ASCII value 3031 to H10 ASCII value 3130 For example if the device name is MWO it has 4 characters to be H04 as its length If MW000 characters to be H06 length Name length of device Address to be actually read is entered This must be ASCII value within 16 characters and in Device name this name digits upper lower case only is allowable to be entered Chapter8 Communication Function 1 Numerical data of f
49. change the previous force on off setting data They remain within the CPU module and operation is executed with the same data Force I O data will not be cleared even in the STOP mode f a program is downloaded or its backup breaks the force on off setting data will be cleared The oper ating program in memory differs from the program in the flash memory so that if operation restarts with the program in the flash memory the on off setting data will be also cleared When setting new data disable every I O settings using the setting data clear function and set the new data REMARK 1 For detailed operation refer to the KGLWIN user s Manual Chapter 7 Force I O setting 5 22 Chapter 5 CPU Module 5 5 3 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 Direct input output is executed by use of the IORF instruction If this instruction is used the input output image area will be directly updated and applied to the continuing operations REMARK 1 For detailed operation refer to the MASTER K Manual for instruction 5 9 4 System error history When the system is stopped by error occurrence the CPU stores the error occurrence time and error code to the special data register area The most recent 16 error occurring tim
50. connector Check basic units ERR LED if it is flickering every 2 seconds ERR Flickering No Y Yes Complete Battery error Chapter 6 Input and Output Modules Chapter 6 Input and Output Modules 6 1 Input Output Specifications Digital input that offers to MASTER K80S series are made to use both of electric current sink and electric current source To keep use coil load as an output module maximum opening and shutting frequency is 1 second on and 1 second off The following diagram shows maximum life relay for relay output 000 001 x Aouenbe 4 I AC 125V riload DC 30V r load AC 250V r load g Opening shutting of electric current Chapter 6 Input and Output Modules 6 2 Digital Input Specification 6 2 1 Base unit 1 Specification Model Base unit K7M DR10S K7M DR20S K7M DR30S K7M DR40S K7M DR60S Specification K7M DR10S DC K7M DR20S DC K7M DR30S DC K7M DR40S DC K7M DR60S DC K7M DT10S K7M DT20S K7M DT30S K7M DT40S K7M DT60S Number of input points 6 points 12 points 18 points 24 points 36 points Insulation method Photo coupler Rated input voltage DC12 24V Rated input current 4 5 9 mA P000 P002 8 16mA Operating voltage range DC10 2 28 8V ripple less than 5 Max simultaneous input points 10096 simultaneously On On voltage On current DC9 5V or higher 3 5 mA or higher P000 P002 6
51. has written of the task program processing time and the PLC internal processing time 1 Scan time Scan program processing time Interrupt program processing time PLC internal processing time Scan program processing time The processing time used to process a user program that is not specified to a ta sk program Interrupt program processing time Total of the processing times of interrupt programs executed during one scan PLC internal processing time Self diagnosis time I O refresh time Internal data processing time Communi cations service processing time 2 Scan time differs in accordance with the execution or non execution of interrupt programs and communications processing etc 2 Flag Scan time is stored in the following system flag area F50 Maximum scan time unit 1 ms F51 Minimum scan time unit 1 ms F52 Current scan time unit 1 ms 5 2 4 Scan 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 KGLWIN 2 When watchdog timer detects an exceeding of preset watchdog time the operation of PLC is stopped immediately and al output is off 3 If an exceeding of preset watchdog time is expected in sequence program use WDT instruction WDT instruction make elapsed watchdog time as zero 4 In order to clear watchdog error restarting the PLC or mode change to STOP mode are avai
52. her purpose MK80S Basic Unit executes the communication with the other kind of device through the defined protocol For this protocol frame must be defined in KGLWIN Version 2 0 or higher And exact knowledge about the contents of the protocol defined by the user is vital in making the communication possible KGLWIN Version 2 0 or higher can download a user defined protocol frame into MK80S Basic Unit and it is saved it is not erased by power s off on But protocol frames are damaged to download with changes of parameter or to fail to back up the data caused by lower back up battery voltage than the standard For using user defined mode he she should program with instruction controlling sending of PLC as well as edit frames This section explains UDPC setting amp usage Chapter 8 Communication Function 8 2 2 Parameter Setting 1 Setting Communications Parameter 1 Open a new project file from KGLWIN Select MK80S as PLC type 2 After setting communication parameter at KGLWIN Double click it to activate this window 3 Set according to the following table Item Setting range Station No Station no from 0 to 31 Baud Rate 1200 2400 4800 9600 19200 38400 57600 bps Data Bit 7 or8 bits Parity Bit 0 Even or Odd Stop Bit 1 or 2 bit s Communication Channel RS232C Null Modem or RS422 485 It s a communication channel for the communication using MK80S base unit s b
53. is converted into ASCII and added to BCC BCC Device This indicates the number of name s characters that means device which is allowable up to length Name length 16 characters This value is one of ASCII converted from hex type and the range is from of variable H01 ASCII value 3031 to H10 ASCII value 3130 Address to be actually read This must be ASCII value within 16 characters and in this device name digits upper lower case and only are allowable to be entered 1 Protocol of WSB doesn t have the number of blocks Chapter8 Communication Function 3 Response Format ACK response Format name Header Station No Command Command type Frame check Frame Example ACK H10 SB BCC ASCII value H06 H3130 Explanation When command is lowercase r only one lower byte of the value resulted by adding 1 Byte each to ASCII values from ACK to ETX is converted into ASCII and added to BCC and sent 4 Response Format NAK response Error code Frame Format name Header Station No Command Command type Tail Hex 2 Byte check Frame Example ENQ H10 W w SB H1132 EOT BCC ASCII value H05 H3130 H57 77 H5342 H31313332 H03 Explanation When command is lowercase r only one lower byte of the value resulted by adding 1 Byte each to ASCII values from NAK to ETX is converted into ASCII and added to BCC and sent Hex and 2 byte
54. is read D Computer request Format PC MK80S Base Unit Format name Header Station No Command Command type Frame check Frame Example ENQ H01 ST BCC ASCII value H05 H3031 Format name Header Station No Command type Status data Frame check See status data Frame Example ACK H01 ST BCC Format ASCII value H06 H3031 Format name Station No Command type Error code Frame check Frame Example H01 ST Error code 2 BCC ASCII value H3031 Error code 4 8 30 Chapter8 Communication Function 8 1 7 1 1 Built in communication between MK80S s 1 Introduction 1 1 built in communication between MK80S s is that which constitutes a built in communication system with the method of 1 master 1 slave Setting Base parameter and communication parameter in KGLWIN can easily constitute this system Communication protocol currently applied is the same with Cnet I F used for MASTER K Main functions are following e t can organize device area into 64 data access blocks by WORD unit and set a communication time out limit for each block e t can reestablish flag in relation with error codes and slave PLC operating mode according to parameter setting e t can reset flag related with error codes and sending receiving error frequency of each parameter e t monitors communication status using monitoring function of KGLWIN MK80S base unit MK80S b
55. is transferred into the program area of the base unit and ROM operation area of the flash memory It may take about 15 sec 6 7 8 9 Through the above steps the user can operate the PLC with program stored in the external memory module 6 Operate according to the set operation mode 7 Turn off the power of the basic unit Remove the memory module Turn the power on REMARK 1 When the PLC is operated with the external memory module it always operates with restart 2 Remove after the program transfer is finished 5 30 Chapter 5 CPU Module 5 10 RTC Module MK80S series supplies RTC Real Time Clock module for the time scheduling control To use RTC function with K80S series the RTC operation module should be attached to the expansion slot of main unit or expansion special function unit Clock operation by the RTC function is continued with a battery or super capacitor when the CPU is powered off 5 10 1 Structure Installation connector 5 10 2 Usage 1 Clock Data Clock data is the data comprised of year month day hour minute second and date Data name Description Year 4 digits of the Christian Era Month 1 to 12 Day 1 to 31 A leap year is distinguished automatically Hour 0 to 23 24 hours Minute 0 to 59 Second 0 to 59 0 Sunday 1 Monday 2 Tuesday Date 3 Wednesday 4 Thursday 5 Friday 6 Saturday 2 Precision
56. list REED ER CETERO E EET PECORE TETUR EC NEIN c MERE 11 12 Appendix Appendix 1 System definitions n ntn entree niente App1 1 Appendix 2 Flag IiSlsrisseeisigioiivegit eC Ue App2 1 Appendix 3 Function Function block Ist neenon eene frere App3 1 Appendix 4 Dimensions deme crine een jeter nini esent nk nnne rine ee App4 Chapter 1 General Chapter 1 General 1 1 How to Use This Manual This manual includes specifications functions and handling instructions for the MASTER K80Sseries PLC This manual is divided up into chapters as follows Chapters Title Contents Chapter 1 General Describes configuration of this manual unit s features and terminology Chapter 2 System configuration Describes available units and system configurations in the MASTER K80Sseries Chapter 3 General Specification Describes general specifications of units used in the MASTER K80Sseries Chapter 4 Names and functions Describes each kind of manufacturing goods titles and main functions Chapter 5 CPU Part Chapter 6 Digital Input and Output Parts Chapter 7 Guides on Each Function Describes each kind of manufactured goods usage Chapter 8 Communications Function Describes built in communication functions Chapter 9 Installation and Wiring Describes installation wiring and handling instructions for reliability of the PLC system Chapter 10 Ma
57. mode at error occurrence In case of error occurrence the PLC system write the error contents the corresponding flags and stops or continues its operation complying with its operation mode 1 PLC hardware defect The system enters into the STOP state if a fatal error such as the CPU module defect has occurred and continues its operation if an ordinary error such as battery error has occurred 2 System configuration error This error occurs when the PLC hardware configuration differs from the configuration defined in the K80S series The system enters into the STOP state 3 Operation error during execution of the user programs It the numeric operation error of these errors occurs during execution of the user programs its contents ar e marked on the error flags and the system continues its operation If operation time overruns the watchdo g 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 ente rs into the STOP state and if an ordinary error is detected the system continues its operation REMARK 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 5 14 Chapter 5 CPU Modul
58. multiplying the data number of computer request Format by the data size in below table according to memory type B W D included in variable name of computer request Format e gate Data type Available device Data size WORD W P M L K F T C D S W 2 Data In data area there are the values of hex data converted to ASCII code saved Ex 1 When memory type included in variable name of computer request Format is W WORD and data number of computer request Format is 03 data number of PLC ACK response after execution of command is indicated by H06 2 03 06 bytes Byte and ASCII code value 3036 is entered in data area Ex 2 In just above example when data contents of 3 WORDs are 1234 5678 and 9ABC in order actual ASCII code converted values are 31323334 35363738 39414243 and the contents are entered in data area Chapter8 Communication Function 4 Response format NAK response Error code Format name Header Station No Command Command type Frame check Hex 2 Byte Ex of frame NAK H10 SB H1132 BCC ASCII value H15 H31313332 Item Explanation den When command is lowercase r only one lower byte of the value resulted by adding 1 Byte each to ASCII values from NAK to ETX is converted into ASCII and added to BCC and sent Eiern Hex and 2 bytes ASCII code 4 bytes indicate error type For the details see 8 1 8 Error codes 5 Example This example supposes that 2 WORDs f
59. null modem or 19200 None Master RS422 485 8 40 Chapter8 Communication Function Click List button to activate registration list window Dedicated Cun co Cn 0n P COPS C5 10 Co CD CT PA Co P2 C3 roa san ia a A a A a A copy Eata Private Item Edit Set parameters like the following table and click OK button Station No Area to read From Area to save to 31 M000 See the above P004 See the above 8 41 Chapter8 Communication Function The registration list 0 registered in the registration list can be confirmed through a window like the following am UROSOER W d UO MBocm co Double click the No 1 for receive parameter setting Station No Mode Area to read From Area to save to 31 Receive P004 See the above P009 See the above 8 42 Chapter8 Communication Function Set parameters like the following table and click OK button Program 8 43 Chapter8 Communication Function 2 Parameter setting for slave station Set parameters as the following table Protocol Communication Method and mode Commu Station no Baud rate Data bit Parity bit Stop bit Communication channel Dedicated nication RS232C null modem or Enable 31 19200 None slave RS422 485 Slave station does not need program 8 44 Chapter8 Communication Function 8 1 8 Error code
60. operation mode sources cannot change the mode If remote operation mode change has been disabled the operation mode change is possible only by the mode setting switch and KGLWIN To enable the remote operation change set the parameter Enabling the PLC control by communications to enable For details refer to the Append ix 1 System Definitions 5 18 Chapter 5 CPU Module 5 5 Functions 5 5 1 Self diagnosis 1 Functions 1 The self diagnosis function permits the CPU module to detect its own errors 2 Self diagnosis is carried out when the PLC power supply is turned on and when an error occurs the PLC i s in the RUN state If an error is detected the system stops operation to prevent faulty PLC operation 2 WDT Watch dog timer function The watch dog timer is an internal timer of a PLC to detect the error of hardware and a sequence program The default value is set as 200msec and it is changeable with parameter setting Refer the MASTER K programming manual for details on the parameter setting The CPU resets the watch dog timer before step 0 is executed after the END processing is finished When the END instruction has not been executed within the set value due to an error occurred in the PLC or the long scan time of a sequence program the watch dog timer will times out When a watch dog timer error is occurred all outputs of the PLC are turned OFF and the ERR LED of the CPU will flashes RUN LED will be turned OFF
61. resulted by adding 1 Byte each to ASCII values from NAK to ETX is converted into ASCII and added to BCC and sent Hex and 2 bytes ASCII code 4 bytes indicate error type For the details see 8 1 8 Error Error code codes Chapter8 Communication Function Explanation PLC status data data Format is 20 bytes in hex Format and converted into ASCII code Its contents are constituted as below table after converting ASCII code into hex data Status data Format Status data order Hex data HOO Offset H01 H02 H03 PLC status data H04 H05 H06 ode H07 H08 Connection Status H09 Reserved HOA L HOB Reserved HOC L HOD Reserved HOE L HOF Data type Contents Reserved H10 L H11 Reserved H12 L H13 CPU Type CPU Type Code MK80S 41 K200SA K3P 07AS 3A K200SB K3P 07BS 3B K200SC K3P 07CS 3C K300S K4P 15AS 33 K1000S K7P 30AS 32 Version No Ex Bit 0 i9 o id jo lo Ii io Indicates Version 1 2 CPU Mode Ex Bit 0 0 0 0 PNIS RUN Mode H STOP Mode PAUSE Mode DEBUG Mode Connection Ex Bit 3 0 0 p Local Connection Remote Connection 8 29 Chapter8 Communication Function 5 Example This example supposes that the status of MK80S Base Unit of station No 1
62. rising edges of pulses driving its input signal and counts once only when the input signal is switched from off to on MASTER K series have 4 counter instructions such as CTU CTD CTUD and CTR The maximum counter setting value is hFFFF 65535 The followings shows brief information for counter operation 1 Up counter CTU The counter output relay is turned on when the current value reaches the preset value After the counter relay output is turned on the current value will increase until it reaches the maximum counting value hFFFF 65535 When the reset input is turned on the counter output relay and current value is cleared as 0 Input condition Reset condition 2 Down counter CTD When the CPU is switched to the RUN mode the current value is set as preset value The current value is decreased by 1 with the rising edge of counter input signal The counter output relay is turned on when the current value reaches 0 Input condition U CTD Cxxx Reset condition lt S gt XXXX 1 If the retentive counter area is used for down counter the reset input has to be turned on to initialize counter 5 9 Chapter 5 CPU Module 3 Up down counter The current value is increased with the rising edge of up count input signal and decreased with the rising edge of down count input signal The counter output relay is turned on when the current value is equal or greater than the preset value Up Input condition
63. the corresponding bit turns on F0060 to FOO6F Storing error code Stores the system error code See Section 2 9 F0070 to FOO8F Storing the D dd state of a i s ia hera ins ni an output module the F0090 20 ms cycle clock F0091 100 ms cycle clock Turning On Off is repeated with a constant cycle F0092 200 ms cycle clock F0093 1 sec cycle clock On Off F0094 2 sec cycle clock F0095 10 sec cycle clock F0096 20 sec cycle clock F0097 60 sec cycle clock F0098 to FOO9F Unused F0100 User clock 0 Turning On Off is repeated as many times as the scan specified F0101 User clock 1 by Duty instruction F0102 User clock 2 H Hu onn J F0103 User clock 3 N2 scan Off F0104 User clock 4 F0105 User clock 5 434 F0106 User clock 6 N1 scan Off F0107 User clock 7 F0108 to FO10fF Unused F0110 Operation error flag Tums on when an operation error has occurred F0111 Zero flag Turns on when the operation result is 0 F0112 Carry flag Turns on when a carry occurs due to the operation F0113 All outputs off Tums on when an output instruction is executed F0114 Common RAM R W error ee a memory access error of the special module F0115 Operation error flag Latch Turns on when an operation error has occurred Latch F0116 to FO11F Unused F0120 LT flag Turns on if S lt S2 when using the CMP instruction F0121 LTE flag Turns on if S4 S2 when using the CMP instruction F0122 EQU flag Turns on if S S2 when using the CMP instruction F0123 GT flag Turns on if
64. the remote CPU module through Cnet 4 2 Operation mode change by the mode setting switch of CPU module The following shows the operation mode change by the mode setting switch of CPU module Mode setting switch position Operation mode RUN Local RUN STOP Local STOP STOP PAU REM Remote STOP PAU REM RUN 1 Local RUN RUN PAU REM 2 Local PAUSE PAU REM STOP Local STOP de 3 m REMARK 1 1 If the operation mode changes from RUN mode to local RUN mode by the mode setting switch th e PLC operates continuously without stopping 5 17 Chapter 5 CPU Module 3 Remote operation mode change Remote operation mode change is available only when the operation mode is set to the remote STOP mo de i e the mode setting switch positionis in the STOP gt PAU REM Mode change usin Mode setting Mode change by the i Mode Change FAM or computer link switch position 9 KGLWIN P etc Remote STOP gt Remote RUN Remote STOP gt Remote PAUSE Remote STOP gt DEBUG Remote RUN gt Remote PAUSE Remote RUN gt Remote STOP Remote RUN gt DEBUG Remote PAUSE gt Remote RUN Remote PAUSE Remote STOP Remote PAUSE gt Remote DEBUG DEBUG gt Remote STOP DEBUG gt Remote RUN DEBUG gt Remote PAUSE PAU REM 4 Remote operation mode change enable disable It is possible to disable the mode change for system protection so that some parts of the
65. two kind of interrupt operation methods which are internal and external interrupt signal methods 5 2 2 Operation processing at momentary power failure occurrence The CPU detects any momentary power failure when the input line voltage to the power supply falls down below the def ined value When the CPU detects any momentary power failure the following operations will be executed 1 Momentary power failure within 20 ms 1 The operation processing is stopped with the output retained 2 The operation processing is resumed when normal status is restored 3 The output voltage of the power supply retains the defined value Input power gt 4 The watchdog timer WDT keeps timing and interrupt timing normally while the operations is at a stop Momentary power failure exceeding 20ms 2 Momentary power failure exceeding 20 ms The re start processing is executed as the power is applied Input power Momentary power failure exceeding 20ms REMARK 1 Momentary power failure The PLC defining power failure is a state that the voltage of power has been lowered outside the allowable variation range of it The momentary power failure is a power failure of short interval several to tens ms 5 4 Chapter 5 CPU Module 5 2 3 Scan Time The processing time from a 0 step to the next 0 step is called scan time 1 Expression for scan time Scan time is the addition value of the processing time of scan program that the user
66. ue Ane TEE Ln aula n ATA RC a Cn ed RR a CRT L8 On D ART dial P onc fate 5 44 Chapter 6 Input and Output Modules 6 1 Input and Output Specifications e s 6 1 6 2 Digital Input Specifications men rien renta erinnerte 6 2 6 2 1 Base Units rient rente erre nente capers dene ie iguaner stre cei Page inde rae ntastirarteaerty 6 2 6 2 2 Extended Module NE dp D X Ea qo AN A A DUKA A Qu ORT CU DR Qu ARA DUE o ROLE RAN 6 7 6 3 Digital output Specifications mmm 6 8 6 3 1 Base unit Relay Output eterne dr e erede iere eee ierit ede kie 6 8 6 3 2 Base unit Transistor Output esee 6 12 6 3 3 Expansion Module ioi inni nine ann enitn niiret iu inen 6 15 Chapter 7 Usage of Various Functions s n n nnm 7 1 7 60 7 4 Built in FONT EMO Reet rper erneuert ence tah eerie tener dee x npe iie 7 1 7 1 1 High speed counter function br coe trodacerentcen eui tan ceni erc agno cnnonipcnisid 7 1 1 4 2 Pulse Output Function eee inrer nee nnn hene sieves enne 7 11 7 1 3 Pulse Catch furictioni inneren einn tes hen irnn ede veee setae 7 23 C14 Input Filter TUMCMOn ss e irap ete rne cest ehe tege inerte ni cise ented i ea insite Fd 7 25 1 1 5 PID ControlfUriCtion rend et rhe Ft eben aider eterni ose eei ecd Kd 7 26 7 1 6 External Interr pt TUnction c eterne netur reine deterius enne teh saad incite dida 7 48 7 2 pecial Module seen eis eri RE Ni ti career sary ete ener Cosa ener RSE 7 50 12 1 AID DIA Combination iet rene tet etetetetaeds se
67. 034 H3931383341414242 Chapter8 Communication Function 4 Response Format NAK response Format name Header Station No Command Registration No Error code Hex 2Byte Frame check Frame Example NAK H10 H1132 BCC ASCII value H15 H31313332 Item Explanation When command is lowercase y only one lower byte of the value resulted by adding 1 Byte BCC each to ASCII values from NAK to ETX is converted into ASCII and added to BCC and sent ane Hex and 2 bytes ASCII code 4 bytes indicate error type For the details see 8 1 8 Error codes Chapter8 Communication Function 5 Example This example supposes that registered device No 1 of station No 1 is read and BCC value is checked And it is supposed that device M000 is registered and the number of blocks is 1 Computer request Format PC MK80S Base Unit Format name Header Station No Command Registration No Frame check Frame Example ENQ H01 y H01 BCC ASCII value H05 H3031 H3031 For ACK response after execution of command PC lt MK80S Base Unit Registration Number of Format name Header Station No Command i Number of Blocks T Data o ata Frame Example ACK H01 H01 H04 H23422339 H3233343232 ASCII value H06 H3031 H3031 H3034 333339 amp For NAK response after execution of command PC _ lt MK80S Ba
68. 0S Item Remarks 7M DR10S DC 7M DR20S DC 7M DR30S DC 7M DR40S DC 7M DR60S DC K7M DT10S K7M DT20S K7M DT30S K7M DT40S K7M DT60S Program control method Cycle execution of stored program Time driven interrupt Process driven interrupt I O control method Indirect mode Refresh method Direct by program command Program language Mnemonic Ladder diagram Numbers of instructions Basic 30 Application 218 Processing speed 0 5usec step Program capacity 7ksteps 1 0 points 10 20 30 40 60 P P000 P13F I O relay M M000 M191F 3 072points Auxiliary relay K K000 K31F 512 points Keep relay L L000 L63F 1 024 points Link relay Memory F F000 F63F 1 024 points Special relay device 100msec T000 T191 192 points T Timer 10msec T192 T255 64 points C C000 C255 256 points Counter S 00 00 899 99 100100 steps Step controller D D0000 D4999 5 000 words Data register Operation modes RUN STOP PAUSE DEBUG Self diagnosis functions Detect errors of scan time memory I O battery and power supply Data back up method Battery back up Max expansion level Up to 3 level 5 1 Chapter 5 CPU Module Item Specifications Remarks Internal Function PID control function Cnet I F Function Counter function High speed counter Pulse catch Function block control auto tuning forced output adjustable operation scan time for
69. 3 Environment When wiring the I O part if it locates near a device generating an cause short circuit destruction or malfunction 4 Polarity Before applying the power to part that has polarities be sure to check its polarities 5 Wiring e Wiring 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 If an inductive load has been connected to output part connect parallel surge killer or diode to a load Connect the cathode part of the part of the power supply Induction load bci Output part p Induction load 5 Diode OUT Q Output part 6 Terminal block Check its fixing During drilling or wiring do not allow any wire scraps to enter the PLC It can cause malfunction and fault 7 Be cautious that strong shock does not applied to the I O part Do not separate the PCB from its case Chapter 9 Installation and Wiring 2 Mounting instructions The following explains instructions for mounting the PLC onto the control panel 1 Allow sufficient distance from upper part of the Unit for easy module replacement and ventilation Especially the distance between the left side of the basic unit and the control panel should be 100 mn or more for periodic battery replacement 2 Make sure that MK80S is installed in fig 9 1 for most effective heat radiation
70. 8 Communication Function 8 1 5 Data type It s possible to read and write device in built in communication When device is used be aware of data type 1 Data type of variable e Available types of device P M L K C T D S F e When variable is used attach 25H in front of the marking characters Data type Marking characters Examples Bit X 58H PX000 MX000 LX000 KX000 96CX000 TX000 FX000 PWO000 MWO000 LWO000 KWO000 CWO000 96TWO00 F W000 DW000 SWO000 W 57H Device Name Explanation Read Write Bit Word Assignment Input Output relay Available Both Auxiliary relay Available Link relay Available Keep relay Available Counter Available Both Timer Available Both Data Register Available Word Only Step relay Available Word Only Special relay Read Only Both 1 Timer Counter used in word command means current values 2 Data register and Step relay can uses only word commands 3 When Link module is used Link relay must not written it cause communication error 8 8 Chapter8 Communication Function 8 1 6 Execution of commands 1 Individual reading of device RSS 1 Introduction This is a function that reads PLC device specified in accord with memory data type Separate device memory can be read up to 16 at a time 2 PC request format Station Command Number Device Format name Command Device name No type of
71. C dial up modem can be selected when common modem communication calling the opponent station is processed by Cnet I F module G7L CUEC Notes RS232C dedicated modem and RS232C dial up modem communication can be processed only by Cnet I F module G7L CUEC supporting RS 232C not Cnet I F module G7L CUEC supporting RS 422 485 Timeout in Master Mode e It s an interval waiting after sending request frame from Master MK80S before receiving a response e default value is 500ms e Setting must be done in consideration of maximum interval of sending and receiving cycle of a master PLC e f the time out is less than the maximum interval of the s r cycle error can occur Dedicated Master Slave Master MK80S can read from and write on Slave MK80S Read status of slave PLC can be select especially when you read Slave MK80S for monitoring but not for the other purposes lest it may cause decreasing communication speed Chapter8 Communication Function 2 Setting registration list If you click master from exclusive use in protocol and sending mode List button will be activated Click the button to open the registration list window Dedicated 1 1 2 3 4 5 6 1 8 9 0 1 2 3 4 5 6 7 8 3 0 1 1 1 1 1 1 1 1 1 1 e SORY ult 3 Total 64 data blocks can be assigned But it s not possible to set a register number 4 Sending and receivin
72. C5V 1mA Max load voltage current AC250V DC110V Current leakage when off 0 1mA AC220V 60Hz Max On off frequency 1 200 hr Surge Absorber None Mechanical More than 20 000 000 Rated on off voltage current load 100 000 or more Life AC200V 1 5A AC240V 1A COS 0 7 100 000 or more Electrical AC200V 1A AC240V 0 5A COS 0 35 100 000 or more DC24V 1A DC100V 0 1A L R 7ms 100 000 or more Off On 10 ms or less Response time On Off 12 ms or less Common method 1 point 1COM 2 points 1COM Operation indication LED is on at on status of output 2 Circuit It s the same with the output circuit of the base unit 3 Output wiring DC5V DC24V AC110 220V 3EMARK 1 Refer to 7 2 Special Functions for the special function units Chapter 7 Usage of Various Functions Chapter 7 Usage of Various Functions 7 1 Built in Functions 7 1 1 High speed counter function This chapter describes the specification handling and programming of built in high speed counter of MK80S The built in high speed counter of MK80S hereafter called HSC has the following features 3 counter functions as followings 1 phase up down counter Up down is selected by user program 1 phase up down counter Up down is selected by external B phase input 2 phase up down counter Up down is automatically selected by the phase difference between A phase and B Multiplica
73. CPU Module 5 4 2 STOP mode In this mode programs are not operated 1 Processing when the operation mode changes The output image area is cleared and output refresh is executed 2 Operation processing contents 1 I O refresh is executed 2 Normal or abnormal operation and mounting conditions of the loaded module are checked 3 Communications service or other internal operations are processed 5 4 3 PAUSE mode In this mode the program operation is temporarily stopped If it returns to the RUN mode the operation continues from the state before the stop 1 Processing when the operation mode changes Data area and input image are not cleared and the operating conditions just before the mode change is maint ain 2 Operation processing contents 1 I O refresh is executed 2 Normal or abnormal operation and mounting conditions of the loaded module are checked 3 Communications service or other internal operations are processed 5 4 4 DEBUG mode In this mode errors of a program are searched and the operation sequence is traced Changing into this mode is only possible in the STOP mode In this mode a program can be checked with examination on its execution sta te 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 outp
74. File Directory You can set directories for the files to be created in KGLWIN In Source Directory KGLWIN saves source program files of program parameter etc Editor Option Page Setup Connection Option Monitor Display Type C Decimal Unsigned C Decimal Signed C ASCII Source Directory C PROGRAM FILESWLGISWKGL WewWSi Find Auto Save 4h b HI Ho ng Auto save This function is to set the time interval for Auto saving Automatically saved file is saved in the current directory The file is automatically deleted when the program window is closed Therefore if a program cannot be saved by Program Error before program is not saved you can recover some program by loading auto saved file App1 2 Appendix 2 Flag List 3 Page setup You can select print option when the project print out margin cover footer App2 1 Appendix 2 Flag List 2 Basic Parameters The basic parameters are necessary for operation of the PLC Set the Latch area Timer boundary Watchdog timer PLC operation mode Input setting Pulse catch ee inal 1 Latch area setting Set the retain area on the inner device 2 Timer boundary setting Set the 100ms timer boundary the rest of timer area allocates 10ms automatically 3 Watchdog timer setting For the purpose of the watch of normal program execution This parameter is used to set the maximum allowable execu
75. MOV 100 D0000 E MOV 01000 D0010 PV D0000 SV D0010 Time chart A phase pulse input a ay WS ale Lae SE U D input M001 Current value of HSC 0 1 9 i3 i4 i3 2 E 7 6 Chapter 7 Usage of Various Functions 2 1 phase operation mode U D by B phase D4999 h1100 U D set by external input B phase input PR set by sequence program M002 Ladder diagram F012 MOV h1100 D4999 MOT PV 00100 SV 01000 Time chart A phase pulse input ER ec e E B phase input U D PR input M002 Current value of HSC 10 09 08 09 40 441 0 00 401 T T Chapter 7 Usage of Various Functions 3 2 phase operation mode 1 Multiplication Operation D4999 h2011 U D set automatically by the phase difference between A and B phase PR set by external PR input Multiplication 1 Ladder diagram MOV h2011 D4999 PV 00100 EM RN SV 01000 Time chart A phase pulse input BRE ENMEEENM E EM B phase input U D Current value of HSC 10 11 12 13 14 13 12 7 8 Chapter 7 Usage of Various Functions 4 2 phase operation mode 2 Multiplication Operation D4999 2012 U D set automatically by the phase difference between A and B phase PR set by external PR input Multiplication 2 times Ladder diagram F012 MOV h2012 D4999 PV 00100 SV 01000 Time chart A phase pulse input p 1d RT a T B phase input U D CurentvalueofHSC 10 41 42 48 44 45 46 47 18 47 16
76. Max 1 728 second per day general temperature 1 The RTC data does not have factory default setting Please write a correct RTC data before using RTC function first time 2 If unreasonable RTC data is written to the CPU the RTC function may operate abnormally Example 13 month 32 day 5 31 Chapter 5 CPU Module 3 Read write RTC data a Read RTC data The current RTC data Memory Area Word arc pee Upper byte Lower byte BCD format F053 Lower 2 digits of year Month h9812 F054 Day Hour h2219 F055 Minute Second h3746 F056 Higher 2 digits of year Date h1902 Example 1998 12 22 19 37 46 Tuesday b Write RTC data There is two ways to write new RTC data to the CPU The first one is using a handy loader KLD 150S or graphic loader KGL WIN For detailed information refer the user s manual of KLD 150S or KGL WIN The second one is write sequence program By switching a special bit on user can replace the current RTC data with the preset data stored in a specified memory area The followings are the memory address of preset data and an example program 4 The preset RTC data Memory Area Word Marie ec format Upper byte Lower byte D4990 Lower 2 digits of year Month h9901 D4991 Day Hour h1711 D4992 Minute Second h5324 D4993 Higher 2 digits of year Date h1900 Example 1999 1 17 11 53 24 Sunday M1904 RTC data change bit When the M1904 bit is swi
77. PID execution scan time is equal to input clock certainly Data move for SV setting value This value is moved before the PID instruction execution 7 45 Chapter 7 Usage of Various Functions b Incase of using combined function of PID operation and Auto tuning This program is an example of PID operation performing with computed P D values by the auto tuning performing It is performed in 80 of auto tuning SV PID process is performed from 80 of SV PID execution scan time should be equal to input clock certainly As a result of PID8AT execution Proportional gain P Differential time D Integral time l are stored D0102 D0103 D0104 7 4 6 Chapter 7 Usage of Various Functions When PID auto tuning ends PID8 and PID8AT input period should be equal to execution scan time M100 turns on which is designated at parameter T A 7 Chapter 7 Usage of Various Functions 7 1 6 External Interrupt Function In MK80S Series can perform max 8 points of external contact interrupt by using input of base unit without special interrupt module 1 Usage This function is useful to execute a high speed execution regardless of scan time 2 Operating explanation End the interrupt program process then resume to execute scan program External input signal Scan program In case of occurrence of external ee interrupt signal pause being executed scan program and process interrupt program External contact
78. Parts 4 1 1 10 point base unit RUR BULT IN CNET I PAU REM S ON br STOP ROM MODE g Too 102 104 covo 485 485 toi 103 105 Pae 24v In 12 24VDC 4 8 9mA Ty our 97A GLOFA d IN o 5 00 01 02 03 04 05 o o0 OOOOOO o o eo 0 O o0 3 o G7M DR10A o o PROGRAMMABLE Bur o o LOGIC 00 01 02 03 ae o o CONTROLLER OOOO Qu o o Out 24VDC 220VAC 2A P 4ava Acioo 240V G00 J OGL O02 J Qo3 so eonz FG cowo cow cov2 COV5 9069 IN IAD o WA INA JN oa0000 e000 Ly O 4 1 2 20 point base unit K7M DR20S PROGRAMMABLE LOGIC CONTROLLER M ui Pi JL d v No Name Usage 1 Terminal block for power supply Terminal blocks for power supply AC 100V 240V 2 FG circuit Frame ground 3 Output terminal Output connecting terminal 4 Input terminal Output connecting terminal 5 DC24V 24G output terminal Service power supply for DC 24V needed place 4 3 Chapter 4 Names of Parts 4 1 3 30 points base unit L cni IU
79. SCII value H05 Format name H3031 H3032 H3035 H3036 3230 3031 For ACK response after execution of command PC MK80S Base Unit Command Number of Number of Number of Header Station No Command Data Data type blocks data data Ex of frame ACK H01 SS H02 H02 H1234 H02 H5678 ASCII value H06 H3031 H3032 H3032 H31323334 H3032 H35363738 Format name amp For NAK response after execution of command PC MK80S Base Unit Header Station No Command Command type Error code Frame check Ex of frame NAK H01 r SS Error code 2 BCC ASCII value H15 H3031 Error code 4 Xx Frame check BCC is automatically calculated internally 8 12 Chapter8 Communication Function 2 Continuous reading RSB of device 1 Introduction This is a function that reads the PLC device memory directly specified in accord with memory data type With this data is read from specified address as much as specified continuously 2 PC request format Station Command Device Number of data Formatname Header Command Device No type length Max 128 Bytes Ex of fame ENQ H10 SB H06 MW100 H05 ASCII value H05 H3036 H254D57313030 H3035 1 Number of data specifies the number according to the type of data Namely if the data type of device is word and number is 5
80. Special data register for forced I O set The contents of forced I O setting is registered to special data register as below It is possible to use forced I O function to program Item Special Device All Forced I O enable M1910 Forced I O enable by bit D4700 D4731 Forced I O set data D4800 D4831 3 Force on off Processing timing and method 1 Force Input After data have been read from input modules at the time of input refresh the data of the junctions wh ich have been set to force on off will be replaced with force setting data to change the input image are a And then the user program will be executed with real input data and force setting data 2 Force output When a user program has finished its execution the output image area has the operation results At the time of output refresh the data of the junctions which have been set to force on off will be replaced w ith force setting data and the replaced data will be output However the force on off setting does not c hange the output image area data while it changes the input image area data 3 Force on off processing area Input output areas for force on off setting are larger than the real I O areas If remote I O is specified using this area the force on off function is as just available in it as in the basic I O areas 4 Precautions Turning the power off and on changes of the operation mode or operation by reset switch K1000S do es not
81. The MK80S can handle only integer not the floating point type Therefore to enhance the accuracy of PID operation the PID8 instruction is designed to input the P_GAIN data as the 100 times scaled up For example if the designated P_GAIN is 98 actual input data of P_GAIN should be 9800 If the designated P_GAIN is 10 99 input 1099 to the P_GAIN h Mode command set In MK80S only the following 4 operation modes are available Other operation modes such as PD or are not permitted No EN_P EN I EN D Operation 1 1 enable 0 disable 0 disable P operation 2 1 enable 1 enable 0 disable PI operation 3 1 enable 1 enable 1 enable PID operation 4 0 disable 0 disable 0 disable On Off operation i Bias value The Bias data is used for the compensation of offset in the proportional control i SV Target SV setting value the designated value and PV process value present value of MK80S PID operation have the range 0 4000 The range is set with the consideration of the resolution of A D and D A module of MK80S series 12bits and offset value The following table shows error codes and descriptions of PID8 instruction P uU Description Countermeasure STAT output 0 Normal operation 1 SV is out of range Change the SV within 0 4000 2 MVMAN is out of range Change the MVMAN within 0 4000 3 P_GAIN is out of range Change the P_GAIN wit
82. V I selection on upper part of product Input Voltage Current Up voltage Down Current selection 2 Voltage current selected by KGL WIN parameter 3 When current input is used short the V and I terminal No of channel 2Channels Voltage DC 12V Current DC 24 mA Voltage DC0 10V External load resistance 2 kS 1 M amp Output range Current DC 0 20 mA External load resistance 510Q Classified by DC 4 20 mA External load resistance 510Q parameter iai 12Bit 48 4047 Malog output aa eu Separated from terminal selection No of channel 1Channel Voltage DC 12V Absolute max output Current DC 424 mA Voltage DC0 10V 2 5 mV 1 4000 Max resolution Current LDCO 20 A 5 4 1 4000 DC4 20 mA 6 25 HA 1 3200 Accuracy 0 5 Full scale 2 ms CH scan time speed isolation Photo coupler insulation between I O terminals and PLC power supply Common No isolation between channels Absolute max input Connect terminal 9 Points 2 terminals Internal current 20 mA Consumption External power DC216 264V 80 mA supply Weight 2409 1 Offset gain value can t be changed it is fixed 2 Analog inputting is set the current since this is manufactured 3 Extend to use max 2 Modules 7 5 0 Chapter 7 Usage of Functions 2 Names of parts and functions Explain about names of parts and functions No Contents
83. W230 HOOFF H254D5732 ASCII value H05 H3031 H3031 H3036 H30304646 3330 2 For ACK response after execution of command PC lt MK80S Base Unit Format name Header Station No Command Command type Frame check Frame Example ACK H01 w SS BCC ASCII value H06 H3031 3 For NAK response after execution of command PC MK80S Base Unit Format name Station No Command Command type Error code Frame check Frame Example H01 w SS Error code 2 BCC ASCII value H3031 Error code 4 8 18 Chapter8 Communication Function 4 Continuous writing of device WSB 1 Introduction This is a function that directly specifies PLC device memory and continuously writes data from specified address as much as specified length 2 Request format Format Station Device Number of data Header Command Device name No Length Max 128 Byte Frame H06 MW100 H02 H11112222 Example ASCII H254D57 H31313131 value 313030 32323232 1 Number of data specifies the number according to the type of device Namely if the data type of device is WORD and number of data is 5 it means that 5 WORDS should be written 2 Number of data can be used up to 64 Explanation When command is lowercase r only one lower byte of the value resulted by adding 1 Byte each to ASCII values from ENQ to EOT
84. al module e Wszlev X5 lav X 24 W The sum of the above values is the power consumption of the entire PLC system e W Wew Wav 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 l A Control panel inside surface area m U if the control panel temperature is controlled by a fan eft 1777777777777777 6 if control panel air is not Circulated 4 Chapter 9 Installation and Wiring 9 1 2 Handling Instructions Do not drop it off and make sure that strong shock should not be applied Do not unload the PCB from its case It can cause faults e During wiring be sure to check any foreign matter like wire scraps should not enter into the upper side of the PLC If any foreign matter has entered into it always eliminate it 1 Baseunit or Expansion Module handling instructions The followings explains instructions for handling or installing the Base unit or Expansion Module 1 I O specifications re check Re check the input voltage for the input part if a voltage over the maximum Switching capacity is applied it can cause faults destruction or fire 2 Used wire Select the wire with due consideration of ambient temperature and rated current Its minimum specifications should be AWG24 0 18 mm or more
85. al of right direction COMO Common Pulse output common terminal P41 Direction output Direction output terminal COMO Common Direction output common terminal If the motor drive is not input direction but is input right opposite direction pulse the opposite direction pulse can be output through using 2 instruction PULSOUT to P41 contact point 7 13 Chapter 7 Usage of Various Functions 4 Internal circuit and external wiring 12 24V power supply input 12 24V P40 pulse output P41 direction output COMO output common Internal circuit K7M DT30S Transistor output power suppl external wiring Be careful about the counter plan of the noise during the wiring in the pulse output 1 Use twisted pair shields wire for wiring and execute 3rd contact point 2 Be sure to separate from the power supply line and I O lines on which noise usually occurs 3 Length of wire should be as short as possible 4 Be sure to use the stable power supply for the pulse output and separate it from I O power supply 7 14 Chapter 7 Usage of Various Functions 5 The setting of pulse out parameter The setting of pulse out parameter set KGLWIN Setting windows is as below Ci ru ccce cce e cec cumeeOm amcsccdg S153 3353555353555 SSooos55o85 It is possible to set 40 operational pattern When click the pattern no parameter setting window is displayed as bellow 6 parameter explanati
86. an t be converted b Current input 4000 2004 2008 wrrrrrerrseestsensenenae 2009 eere 2001 2000 Digital Output Value o 3 s P FA 5 a D 5 o E 2 2 a lt Te c e e 10 mA Analog Input Current Current Input AID Conversion Characteristics Current Input 0 20 mA Current input OmA becomes output 0 10mA does 2000 and 20mA does 4000 therefore input 5 A equals to digital amount 1 but value less tan 5 xA can t be converted So abandon it 7 6 3 Chapter 7 Usage of Functions 8 Program example 1 Distinction program of A D conversion value Analog input range DC4 20 m 0 10VDC a Program explanation When digital value of channel 0 is the same or more than 2000 and the same or less than 3000 P090 is on When digital value of channel 1 is the same or more than 2000 and the same or less than 3000 P091 is on When digital value of channel 2 is the same or more than 2000 and the same or less than 3000 P092 is on When digital value of channel 3 is the same or more than 2000 and the same or less than 3000 P093 is on b System configuration a Analog input channel 0 1 Voltage input O 10VDC channel 2 3 Current input DC 4 20 mA Parameter setting c System configuration Base Unit A D conversion module Expansion unit output I O allocation Base unit input P000 PO3F Base unit output P050 PO7F A D conversion module
87. ange the monitor register no not to go over than 9 and reset Monitor register error Exceeding limit of register No 8 45 Rearrange the monitor register no not to go over than 9 and reset Chapter8 Communication Function Continued Error code Error type Error condition and causes Treatment Syntax error When use commands that aren t supported Ex1 When use device like MX100 in RSB command Be familiar with the manual Check if the system stopped reset Syntax error Syntax error OVER RUN FRAME error TIME_OUT error Be familiar with the manual Confirm the setting of the communication ports of RS 232C reset Syntax error Syntax error in commands Check if each sends frame has ENQ EOT Syntax error When a FRAME text exceeds over 256 bytes Rearrange send frame not to go over 256 bytes Syntax error BCC error 8 46 Check if BCC is right Chapter 8 Communication Function 8 2 User Defined Protocol Communication 8 2 1 Introduction User Defined Protocol Communication allows users who do communication between MK80S Basic Unit and other kind of device to define the other company s protocol at MASTER K PLC There re a number of kinds of protocols made by many companies that it s difficult to have all protocols in it So if a user defines a protocol that can be applied to his
88. ar gt I O address allocation or type Input part conditions are read and stored into the input image ar Input image area refresh ea before start the processing of a program Program is sequentially executed from the first step to the last st Program operation processing ep Program operation processing Program starts Program ends The contents stored in the output image area is output to output part when operation processing of a program is finished Output image area refresh p PUE g p g p an The END processing following processing is executed END processin Self diagnosis Change the present values of timer and counter etc Processing data communications between computer link module and communications module Checking the switch for mode setting 5 3 Chapter 5 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 MK80S series can be set to between 0 001 to 6 sec This operation is used to process operation with a constant cycle 3 Event driven interrupt operation method If a situation occurs which is requested to be urgently processed during execution of a PLC program this operatio n method processes immediately the operation which corresponds to interrupt program The signal which informs t he CPU of those urgent conditions is called interrupt signal The MK80S CPU has
89. arge changes of control object due to external conditions b The period of time from when the deviation has occurred to when the MV of D action become the MV of P action is called derivative time and represented as Kd c The D action when a constant deviation occurred is shown as Fig 2 7 Deviation Manipulation quantity in D action Manipulation quantity Fig 2 7 Derivative action with a constant deviation 7 3 0 Chapter 7 Usage of Various Functions d The expression of D action is as following dE MV KpxTd dt e Derivative action is used only in PID action in which P and actions combine with D action d PID action a PID action controls the control object with the manipulation quantity produced by P I D action b PID action when a given deviation has occurred is shown as the following Fig 2 8 Deviation PID action action PI action P action Fig 2 8 PID action with a constant deviation e Forward Reverse action a PID control has two kind of action forward action and reverse action The forward action makes the PV reaches to SV by outputting a positive MV when the PV is less than SV b A diagram in which forward and reverse actions are drawn using MV PV and SV is shown as Fig 2 9 lt Forward action Reverse action TIT Fig 2 9 MV of forward reverse action 7 3 Chapter 7 Usage of Various Functions c Fig 2 10 shows examples of process control b
90. ase unit Master station no 1 G E DR10A Slave station No 31 1 1 built in communication between K80S s This communication cabling map is the same for 3 1 1 Connecting between MK80S s in 8 1 2 System configuration method using built in communication Chapter8 Communication Function 2 Parameter setting 1 Communication Parameter Setting Open a new project file from KGLWIN MK80S must be selected as PLC type After selecting communication parameter from KGLWIN and clicking twice this window comes up Parameter New Projecti Basic___ Interrupt_JComm _PID TUN PID CAL Pulse Out Analou JEnable m Le Jo Head statis of slave RIIE To process 1 1 built in communication between MK80S s must be set Enabled 8 32 Chapter8 Communication Function Set according to the following table Item Contents Station No Sets one of station from 0 to 31 Baud rate Sets one of 1200 2400 4800 9600 19200 38400 57600 bps Data bit Sets one of 7 or 8 Bits Parity bit Sets one of none Even Odd Stop bit Sets one of 1 or 2 Bit s Communication channel e RS232C null modem or RS422 485 can be selected as a communication channel when communication is processed by built in functions of MK80S Base Unit or Cnet I F module G7L CUEC e RS232C dedicated modem can be selected when communication is processed by Cnet I F module G7L CUEC e RS232
91. ature velocity etc to digital value that are the output of A D convert module For example assume that PID control is used for temperature control with Pt100 operation range 0 C 250 C and the goal value is 100 C The equivalent digital output of A D module voltage output range 1 5V is 1600 if the A D module outputs 0 1V with 0 C and 4000 5V with 250 C Therefore the input of SV should be 1600 not 2 Ripple type The MK80S perform auto tuning operation based on the frequency response method PID parameters are obtained by On Off operation during 1 cycle of PV variation The RIPPLE parameter shows at which cycle the CPU module will perform auto tuning operation If 0 is selected the CPU will get PID parameters during the first cycle of PV variation If 1 is selected the second cycle will be used refer Fig 3 1 for detailed information Other choice of RIPPLE parameter is not allowed In general case select 1 for proper auto tuning operation The On Off operation will be occur at the 80 of PV value j nd Perform A T operation at the 13t cycle Peron operation SIR T yale Fig 3 1 The ripple parameter T 3 9 Chapter 7 Usage of Various Functions a Error codes of auto tuning function block PID8AT The following table shows error codes and descriptions of PID8AT instruction Error code STAT output 0 Description Normal operation Countermeasure 1 SV is out of range Chan
92. code Format name Header Station No Command No Hex 2Byte Frame Example ACK H10 H09 H1132 ASCII value H06 H31313332 Explanation When command is one of lower case r only one lower byte of the value resulted by adding 1 Byte each to ASCII values from NAK to ETX is converted into ASCII and added to BCC and sent Hex and 2 bytes ASCII code 4 bytes indicate error type For the details see 8 1 8 Error Error code codes Chapter8 Communication Function 5 Example This example supposes that device M000 of station NO 1 is monitor registered D Computer request Format PC MK80S Base Unit Format name Station No Command Registration Registration Format No Rit Number of Device length blocks Device name Frame check Frame Example RSS H01 H06 MWO000 ASCII value H525353 H3031 H3036 H255457 303030 2 For ACK response after execution of command PC MK80S Base Unit Format name Station No Command Registration No Frame check Frame Example H01 X H01 BCC ASCII value H3031 H3031 3 For NAK response after execution of command PC lt MK80S Base Unit Frame check BCC Header Station No Registration No Error code NAK H01 x H01 Format name Command Error code 2 Frame Example
93. ct the wiring Screw board connector Unit replacement is Check the status of the switch needed 1and 2 Unit replacement is needed Check from the beginning Chapter 11 Troubleshooting 11 25 Troubleshooting flowchart used when a program cannot be written to the CPU part The following flowchart shows the corrective action procedure used when a program cannot be written to the PLC module Program cannot be written to the PC CPU Switch to the remote STOP mode and execute the program write No Is the mode setting switch set the re mote STOP After reading error code by using peripheral Is ERR LED blinking device correct the contents Complete Chapter 11 Troubleshooting 11 3 Troubleshooting Questionnaire When problems have been met during operation of the MK80S series please write down this Questionnaires and contact the service center via telephone or facsimile For errors relating to special or communication modules use the questionnaire included in the User s manual of the unit 1 Telephone amp FAX No Tell FAX 2 Using equipment model 3 Details of using equipment CPU model OS version No ji Serial No KGLWIN version No used to compile programs 4 General description of the device or system used as the control object 5 The kind of the base unit Operation by the mode setting switch Operation by the KGLWIN or communications
94. cy Acceleration Amplitude Y Z axis 10 lt f lt 57Hz 0 035mm 57 lt f lt 150Hz 4 9m s 0 5G Z e Maximum shock acceleration 147 m s 15G 6 Shocks e Duration time 11ms IEC 61131 2 e Pulse wave half sine pulse 3 shocks per axis on X Y Z axis Square wave LGIS Internal Impulse noise 1 500V Standard Electronic IEC 61131 2 discharge Voltage 4 kV Discharge by contact IEC 801 2 Radiated IEC 61131 2 electromagnetic 27 500 MHz 10 V aaa 7 Noise Immunity field hi Rum IEC 801 3 aeo Digital O Fasttransient amp ltem Powersupply bay IEC 61131 2 burst noise Analog VO IEC 801 4 Interface Voltage 2kV 1kV 0 25kV 8 Atmosphere Free of corrosive gases and excessive dust IEC61131 2 9 Altitude Up to 2 000m 10 Pollution degree 2 11 Air cooling Cooling method REMARK 1 IEC International Electrotechnical Commission An international civilian institute who establishes international standards in area of electric and electronics 2 Pollution degree An indicator which indicates pollution degree which determine insulation performance of equipment Pollution degree 2 Normally only non conductive pollution occurs Occasionally however a temporary conductivity caused by condensation shall be expected Chapter 4 Names of Parts Chapter 4 Names of Parts 4 1 Base Unit RS 485 RS 485 a x gen CNET PAU REM alj STOP ROM MODE No Name Indicates powe
95. d terminal Jumper pin of analog input Voltage input Current input CRD Input Input Select Select TT m vo cou vi feos v2 cou oo a uiu Coo Connect left parts Connect right parts by jumper pins by jumper pins External power input terminal gt External voltage 24VDC needs to this terminal Extension cable 8 gt This cable is used to connect while analog input module is used Extension cable connector 6 gt The connector connects extension cable when extended module is used 7 6 0 Chapter 7 Usage of Functions 3 Parameter setting 4 Reading A D conversion value A D conversion value stores special data register as following It is possible to use A D conversion module more than K80S ROM V1 4 A D conversion value of channel 0 stores N Expansion A D D4981 A D conversion value of channel 1 stores f conversion module D4982 A D conversion value of channel 2 stores D4983 A D conversion value of channel 3 stores D4984 A D conversion value of channel 0 stores Expansion A D D4985 A D conversion value of channel 1 stores i conversion module D4986 A D conversion value of channel 2 stores 2 D4987 A D conversion value of channel 3 stores 5 Scaling function The scaling function is the same that of A D D A combination module 7 6 1 Chapter 7 Usage
96. d by the condition of the device executed by the specified scan time 9 Various program execution function Extemal and intemal interrupt program as well as scan program can be executed by setting the execution condition The user can set variously the program execution mode Chapter 1 General 1 3 Terminology The following table gives definition of terms used in this manual Terms Definition Remarks A standard element that has a specified function which configures the sena Module system Devices such as I O board which inserted onto the mother board Power Supply module or base unit I O module A single module or group of modules that perform an independent Unit Operation as a part of PLC system PLC system A system which consists of the PLC and peripheral devices A user program can control the system KGLWIN A peripheral device for the MASTER K series It executes program creation edit compile and debugging A computer software for Windows 95 98 KLD 150S A hand held loader used for program creation edit compile and debugging for MASTER K series I O Image Area Internal memory area of the CPU module which used to hold I O 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 Abbreviation of the word Factory Automation Monitoring S W It is used to EAM call S W packages
97. d the operation of CPU will be stopped To execute an interrupt routine use the El instruction to enable the corresponding interrupt The interrupt routine is not executed if an interrupt factor occurs before execution of an El instruction Once an interrupt is enabled with El instruction it keeps the enabled status until DI instruction is executed to disable the interrupt When a CPU is turned to RUN mode all interrupts are disabled by default When multiple interrupt factors occur simultaneously interrupt routines are executed according to the priority given to the each interrupt If an interrupt factor that has higher priority occurs while other interrupt that has lower priority are executing the interrupt routine of lower priority will be stopped and the interrupt of higher priority will be executed first The following figure shows how a CPU handles multiple interrupts Program starts o Interrupt 2 occurs Stop main program and execute interrupt a outine Ga z Scan Program Interrupt routine 1 Interrupt routine 2 5 12 Chapter 5 CPU Module 1 parameter setting I TDINT 1 INT Edit interrupt 2 Time driven interrupt TDI occurs periodically with the constant interval assigned in parameter setting The interrupt routine of TDI starts with the TDINT instruction and ends with the IRET instruction When multiple interrupt factors occur simultaneously interrupt routines are ex
98. data types of each block must be the same 2 If data type is Bit the data to be written is indicated by bytes of hex Namely if Bit value is 0 it must be indicated by H00 3030 and if 1 by H01 3031 3 Response format ACK response Format name Header Station No Command Command type Frame check Frame Example ACK H20 SS BCC ASCII value H06 H3230 Explanation When command is lowercase r only one lower byte of the value resulted by adding 1 Byte each to ASCII values from ACK to ETX is converted into ASCII and added to BCC and sent 4 Response format NAK response Error code Format name Station No Command Command type Hex 2 Byte Frame Example H20 SS H4252 ASCII value H34323532 Explanation When command is lowercase r only one lower byte of the value resulted by adding 1 Byte BCC each to ASCII values from NAK to ETX is converted into ASCII and added to BCC and sent Hex and 2 bytes ASCIl code 4 bytes indicate error type For the details see 8 1 8 Error Error code codes Chapter8 Communication Function 5 Example This example supposes that HFF is written in M230 of station No 1 and BCC value is checked D Computer request format PC MK80S Base Unit Command Numberof Formatname Header Station No Command Device Length Device Name Data type blocks Frame Example ENQ H01 SS H01 H06 M
99. deficient bit of a byte is filled with 0 An example of sending the above data is as follows Example 1 CD B20E 1B Program IT agri um 1 d E i Itdesignates slave station and function code No of station h11 17 function code h01 2 Address setting Address 0 at MODBUS protocol means address 1 actually So if you want to designate address 20 write address 19 3 Reading number setting Reading number is 37 from 20 to 56 4 Thisis MODBUS Communication instruction Data is sent starting from the low bit by byte unit If the deficient bit of a byte is filled with 0 An example of sending the above data is as follows The data transmission starts lower byte The remnant part of byte is filled with 0 Example 1 CD B20E 1B Stored data at D1000 D1001 D1002 Device Stored data D1000 h CD 6B D1001 h B2 CE Chapter 8 Communication Function D1002 h 00 1B Example program 2 It s supposed that MK80S base unit is the master and it reads Coil Status of the station no 17 a Modicon product The master reads status of the input contact 10197 10218 of the slave station no 17 The input contact of the slave station is supposed to be as follows and the data that are read is saved in M015 The status of input contact 10219 10220 are redundancy Data is sent starting from the low bit by byte unit If the deficien
100. digital input output module G7E DR10A Chapter8 Communication Function 1 Setting communication parameter of the master station and its program D Work on the master station 0 2 Open a new project file and a new program for the master station o gt KGLWIN for Windows Program New Project E EJ New Project K80S B Program Edit program that M000 is increased per 1second Double click parameter item for parameter settings 8 39 Chapter8 Communication Function If you click the Comm button in parameter window in KGLWIN you can see the following window of the communication parameter z Parameter Basic Interrupt JComm PID TUN PID CAL Pulse Out Analoa em Enable z Protocol and Mode i POR TENIS Timeout in Master Mode py ms Station Number jo x Dedicated Baud Rate i200 DataBit 8 zl c Read Status of Slave PLC Parity Bit None Stop Bit List n x C Slave Modbus Communication Channel a bs Master Transmissiom Mods scr RS232C Null Modem or RS422 485 Slave C RS232C Modem Dedicated Line Init Command User Defined C RE232C Dial up Modem ATZ C Master List C Slave Set parameters as the following table Protocol Communication Method and mode Commu m Station no Baud rate Data bit Parity bit Stop bit nication Communication channel Dedicated Enable RS232C
101. e 5 4 Operation Modes The CPU module operates in one of the four modes the RUN STOP PAUSE and DEBUG mode The following descri bes the PLC operation processing in each operation mode 5 41 RUN mode In this mode programs are normally operated The first scan start in the RUN mode Initialize data area according to the preset restart mode Check the program and determine it can be executed or not Execute input refresh Execute programs and tasks Check the availability of expansion units Execute communication and intemal service Execute output refresh No Operation mode is changed Yes Operate with new mode 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 initializati on 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 2 Operation processing contents I O refreshes and program operation are executed 1 Interrupt programs are executed with the detection of their start up conditions 2 Normal or abnormal operation and mounting conditions of the loaded module are checked 3 Communications service or other internal operations are processed 5 15 Chapter 5
102. e Fale 5 24 544 DEBUG mode FRAPE Fra E RS CE AR R NCRU UR RUR RANA EEE NERDE EEEE RIPPERS MEINERS DRP EEE SEIRD URDE RR PEES UR REIR RISRRRE 5 24 545 Operation mode Change Melo XAR Ri ux AN LOK ae CME RAD du C Mee Sedna Melee Mie Mee mma d CR ae hie od 5 25 55 Functions Scab hans dcr XM 5 27 5 5 1 Restart mode eee Heer 5 27 55 2 Self diagnosis OPE OE SLUR SAT HES Dut deen UE IL IDE XC Wied RI ED OPAC RADO CLERICI LEE ZIEL ECCE RIDENS 5 29 5 5 3 Remote function Renee 5 29 554 I O Force On Off function PPP 5 30 5 5 5 Direct I O operation function Xd acd DORT EUER OANE ASAA AAN RR GERE ANEA A DAR 5 31 5 5 6 External device error diagnosis function Atal he CIAR EE Cad RENTE KR ES COPVREEM KU T nE 5 32 5 6 Memory Configuration discedite onc ree dae mcus acie rine acie a ERETTE EEEIEE TETE eeieaGrame ie 5 34 57 O No Allocation Method eee rada egt durat feri Res 5 36 5 8 Built in Flash Memory meme 5 35 5 8 1 Structure ee Henne enne nnne 5 36 58 2 Usage eit Rafa ct a aprecia tranf le Re acc rr utu are Nec ara er aperui Che cal vea estudia 5 37 5 9 External Memory Module hecha sedet Ver nana o a sn Lo aera OD EA ipM P ws Era LN oT 5 39 5 9 1 Structure eee Henne enne 5 39 WE e 5 39 5 10 RTC Module 4 CK IACOERK GEI CREW CK IACTA COGOR C a CLERO CR RR TC ce Sere eee TSC R GER Teer eee eer 5 42 SEE E I aa a ckaa ts 5 42 540 21 sage tse aes sae iar e penati nece Casha oa cir ke eee ask cage ei rui cee 5 42 5 11 Battery Wa S ita alsa Se Atala C A a n
103. e charged in C plus the line voltage are applied across D Max voltage is approx 2y 2 If a resistor is used in this way it does not pose a problem to the output element But it may make the performance of the diode D which is built in the load drop to cause problems Corrective Action Connect registers of tens to hundreds KQ across the load in parallel The load doesn t turn off Leakage current by surge absorbing circuit which is connected to output element in parallel Connect C and R across the load which are of registers of tens KO When the wiring distance from the output module to the load is long there may be a leakage current due to the line capacity ieee ae When the load is C R type timer time constant fluctuates Leakage current by surge absorbing circuit which is connected to output element in parallel 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 contact some timers have half ware rectified internal circuits therefore be cautious T Timer Outpu j The load does not turn off Sneak current due to the use of two different power supplies E1 E2 sneaks E1 is off E2 is on sneaks 11 1 1 Use only one power supply Connect a sneak current prevention diode If the load is the relay etc connect a counter electromotive voltage absorbing code as shown by
104. e device Flag Instruction Step no E rror Zero Carry ME Aes ers AP ose oe ae Bs nb bs F110 F111 F112 n O O PID8 5 O S1 O Flaa Set Error It turns on when designation area is over and F110 the instruction isn t executed Designation area fon Registration No at parameter 0 7 execution status registration area PID8AT PID auto tuning Calculation a Usage e when the condition of execution is on PID auto tuning operation executes only rising edge condition and calculates P I D constant e n is registration No at parameter 0 7 e S1 is execution status and P I D constant registration area b Example program F0093 lt lt a PID8AT 2 D0000 e When the input condition F0093 1second clock is rising edge off gt on PID operation executes at no 2 parameter e PID execution status stores D0000 and the output value of control result stores D0001 and P I D constant sequentially store D003 D004 D005 bF bE bD bC bB bA b9 b8 b7 b6 b5 b4 b3 b2 b1 bO Auto tuning end bit M Done normal execution signal 7 42 Chapter 7 Usage of Various Functions 6 Program Example 1 System configuration K80S Base unit G7F ADHA KGLWIN V2 0 or later MV DC4 20mA RS 232C PV DC4 20mA 15V Signal transforming 1 5V device Temp Sensor Elect
105. e range 0 4 000 When an offset remains after the system is stabilized the PV can be reached to the SV by adding a certain value This value is called as bias value and user can define the bias value 7 27 Chapter 7 Usage of Various Functions Fig 2 2 When the proportional constant Kp is large Fig 2 3 When the proportional constant Kp is small b Integral operation operation a With integral operation the manipulate value MV is increased or decreased continuously in accordance time in order to eliminate the deviation between the SV and PV When the deviation is very small the proportional operation can not produce a proper manipulate value and an offset remains between PV and SV The integral operation can eliminate the offset value even the deviation is very small The period of the time from when the deviation has occurred in action to when the MV of action become that of P action is called Integration time and represented as Ti 7 2 8 Chapter 7 Usage of Various Functions b Integral action when a constant deviation has occurred is shown as the following Fig 2 4 x Deviation MV of P action action Kp E MV of D action Time Fig 2 4 The integral action with constant deviation c The expression of I action is as following K MV Edt Ti As shown in the expression Integral action can be made stronger or weaker by adjus
106. ecuted according to the priority given to the each interrupt If an interrupt factor has higher priority occurs while other interrupt of lower priority is executing the interrupt routine of lower priority will be stopped and the interrupt of higher priority will be executed first Otherwise two interrupts are executed consequently 3 Process driven interrupt Available PDI is P000 P007 8 points assigned in parameter setting PDI occurs when the input status of P000 P007 is changed from Off to On or from On to Off REMARK Total available interrupt points Time driven interrupt process driven interrupt lt 8 points Interrupt signal is ignored when self interrupt occurs more than 2 times during interrupt processing is executing S c Interrupt executing time PLIES LAL PL Interrupt signal ex rising edge 5 13 Chapter 5 CPU Module 5 3 4 Error Handling 1 Error Classification Errors occur due to various causes such as PLC system defect system configuration fault or abnormal ope ration result Errors are classified into fatal error mode which stops system operation for system stability a nd ordinary error mode which continues system operation with informing the user of its error warning The main factors that occurs the PLC system error are given as followings PLC hardware defect System configuration error Operation error during execution of the user programs External device malfunction 2 Operation
107. en the cables and wires T As a measure against very large surge e g due to lightening connect a surge absorber as shown below Surge absorber for lightening Remark 1 Ground the surge absorber E1 and the PLC E2 separately from each other 2 Selecta surge absorber making allowances for power voltage rises 8 Use a insulating transformer or noise filter for protection against noise 9 Twist every input power supply wires as closely as possible Do not allow the transformer or noise filter across the duct Chapter 9 Installation and Wiring 9 2 2 Input and Output Devices Wiring 1 Applicable size of wire to the terminal block connector is 0 18 to 2 mm However it is recommended to use wire of 0 3 mt for convenience 2 Separate the input and output lines 3 I O signal wires must be at least 100 mm 3 94 in away from high voltage and large current circuit wires 4 When the I O signal wires cannot be separated from the main circuit wires and power wires ground on the PLC side with batch shielded cables Under some conditions it may be preferable to ground on the other side Shield cable 5 If wiring has been done with of piping ground the piping 6 Separate the 24VDC I O cables from the 110VAC and 220VAC cables T If wiring over 200 mm 7 88 in or longer distance trouble can be caused by leakage currents due to line capacity Refer to the section 11 4 Example 9 2 3 Grounding 1 This PLC has sufficient protec
108. es and error codes are stored in the special data register 1 Special data register for error history Data area Description D4901 D4904 The latest error information nd i 1 Device D4905 D4908 The 2 aesir information D4961 D4964 The 16t latest error information 2 Description of each word Contents Description D4901 h9905 Year 99 Month 5 D4902 h2812 Date 28 Hour 12 D4903 h3030 Minute 30 Second 30 D4904 h0001 Error code h0001 3 Clear error data Use a data clear function of KGLWIN or KLD 150S 5 23 Chapter 5 CPU Module 5 6 Memory Configuration The CPU module includes two types of memory that are available by the user One is program memory which is used to store the user programs written to implement a system by the user The other is data memory which sto res data during operation Bit Data Area Word Data Area User Program Area 0000 os FFFF P00 D0000 Parameter setting area P13 M000 D4500 Auxiliary relay User Program M189 3 040 points Area M190 TH TOONA l 7ksteps Special auxiliary rela Timer preset value M194 32 points T255 256 words K00 T000 Keep relay Timer elapsed value K31 512 points T255 256 words F00 i C000 Special relay Counter preset value 1 024 point F63 1 024 points re 256 words LOO C000 Link relay Counter elapsed value L63 1 024 points C255 256 words T000 S00 Timer relay 100ms Step Con
109. eset 24V Preset input terminal Common input Common terminal 4 External interface circuit Input warranted voltage stemma dut Terminal Sianal r nternal circui No ignal name Operation 15kQ 14 26 4 V A phase pulse On Input DC24V off 2 5V or lower P00 B phase pulse On 14 264 V Input DC24V Off 2 5V or lower COM input common Preset input 19 264 V DC24V 6V or lower COM input Common 7 2 Chapter 7 Usage of Various Functions 5 Wiring instructions A high speed pulse input is sensitive to the external noise and should be handled with special care When wiring the built in high speed counter of MK80S take the following precautions against wiring noise Be sure to use shielded twisted pair cables Also provide Class 3 grounding 1 2 Do not run a twisted pair cable in parallel with power cables or other I O lines which may generate noise 3 Before applying a power source for pulse generator be sure to use a noise protected power supply 4 For 1 phase input connect the count input signal only to the phase A input for 2 phase input connect to phases A and B 6 Wiring example 1 Voltage output pulse generator 24V Pulse Generator 24V Pulse Generator 7 3 Chapter 7 Usage of Various Functions T Instruction When use the built in high speed counter of K80S the HSC instruction should be used The instr
110. ever the MV keeps the saturated status until the integral term is small enough to cancel the windup of actuator As the result of the windup the actuator will output positive value for a while after the PV reached to the SV and the system show a large overshoot A large initial deviation load disturbance or mis operation of devices can cause windup of actuator 7 3 3 Chapter 7 Usage of Various Functions PV Time Time MV without windup MV with windup Integral term Proportional term There are several methods to avoid the windup of actuator The most popular two methods are adding another feedback system to actuator and using the model of actuator The Fig 2 13 shows the block diagram of the anti windup control system using the actuator model As shown in the Fig 2 13 the anti windup system feedback the multiplication of gain 1 Tt and Es to the input of integral term The Es is obtained as the difference value between actuator output U and manipulation value of PID controller MV The Tt of the feedback gain is tracking time constant and it is in inverse proportion with the resetting speed of integral term Smaller Tt will cancel the windup of actuator faster but too small Tt can cause anti windup operation in derivative operation The Fig 2 14 shows several Tt value and PV in the PI control system 7 3 4 Chapter 7 Usage of Various Functions Actuator model G Actuator E SV PV E
111. everse operation Target velocity 1Kpps Target position 75000 Reverse dir start point Target position 10000 Forward dir Start point Target velodity 1Kpps Velocity Profile F210 turns on while the pulse output is operating 7 22 Chapter 7 Usage of Various Functions 7 1 3 Pulse Catch Function In the base unit 8 points of pulse catch input contact points P000 P007 are internalized Through using this contact point short pulse signal short as 0 2ms can be taken which can not be executed by general digital input 1 Usage When narrow width of pulse signal is input a trouble occurs which can not be detected by general digital input so the operation does not perform as user s intention But in this case through pulse catch function even narrow interval of pulse signal as 0 2ms min can be detected 2 Operating Explanation input signal input image data scan 1 scan 2 scan 3 step executing contents scan1 CPU senses input when pulse signal min 0 2ms is input then saves the status scan2 used to turn on the region of input image scan3 used to turn off the region of input image 3 using method 1 click twice the basic parameter on the project window of KGLMIN 2 Select no to use for pulse catch input of the basic parameter window For details of KGLWIN refers to the manual 7 2 3 Chapter 7 Usage of Various Functions ES p eee ga ju
112. expansion modules to the base unit 1 Open the connector cover of the base unit 2 Insert the connector of the expansion module to the connector of the base unit D Base unit 2 Connector cover 8 expansion module 2 expansion cable 9 7 Chapter 9 Installation and Wiring 9 2 Wiring The followings explains the wiring instructions for use of the system 9 2 1 Power Supply Wiring 1 Use AC 100 240V 50Hz 60Hz as the main power 2 When voltage fluctuations are larger than the specified value connect a constant voltage transformer Use a power supply which generates minimal noise across wire and MK80S and ground when excessive noise Generated connect an insulating transformer MK80S base unit Constant voltage transformer 3 Use a power supply which generates minimal noise across wire and across PLC and ground When excessive noise is generated connect an insulating transformer 4 When wiring separate the PLC power supply from those for I O and power device as shown below Main power PLC power AC100 240V 9 I O power 7 m RET Main circuit I O device Pm x T1 T2 rated voltage transformer Malice MENIGE Chapter 9 Installation and Wirin 5 To minimize voltage drop use the thickest max 2 mn wires possible 6 Do not bundle the 100 VAC and 24VDC cables with main circuit high voltage large current wires or the I O signal wires If possible provide more than 80 mm distance betwe
113. for 10 points modules K7M DR10S K7M DR10S DC K7M DT10S 2 2 2 1 2 Cnet I F system Cnet I F System is used for communication between the main unit and external devices using RS 232C RS 422 Interface The K80S has a built in RS 232C port and has also G7L CUEB for RS 232C G7L CUEC for RS 422 It is possible to construct communications systems on demand 10 points modules include RS 232C and RS 485 ports on the main module and no external communication module is available 1 1 1 Communications system 1 1 1 ratio of an external device computer to main unit using a built in port 2 2 3 RS 232C Communication over a long distance via modem by Cnet I F modules G7L CUEB G7L CUEB S A G7L CUEB 2 1 n Communications system This method can connect between one computer and multiple main units for up to 32 stations Can be connected Max 32 stations RS 232C RS 422 Converter G7L CUEC G7L CUEC RS 2320 RS 422 K7M DR10S K7M OR10S 0C K7M DT 10S Converter 2 3 2 2 Product functional model The following describes functional model of the MASTER K80Sseries 2 2 1 Product Function Block Product function block for the K80Sseries is as follows Base Unit Input power Input signal ES om Input supply DC24V Power M h e j Expansion Modules Input signal Special communicat ions modules Output Built in RS 232C I
114. for process supervision Fnet Fieldbus network Cnet Computer network RS232C RS422 485 RTC Abbreviation of Real Time Clock It is used to call general IC that contains clock function Chapter 1 General Definition Remarks Current flows from the switch to the PLC input terminal if a input signal turns on Sink Input Switch Output Output Sink Output Junction contact A power Source Common Source Output Output Junction Output Chapter 2 System Configuration The MASTER K80Sseries has suitable to configuration of the basic computer link and network systems This chapter describes the configuration and features of each system 2 1 Overall Configuration 2 1 1 Basic system eer expansion main unit module expansion cable Total I O points e 20 80 points Maximum Digital I O module e 2 modules numbers AID DIA e 2 modules of expansion Composite module Total 3 modules modules Analog timer e 3 modules Cnet I F module e 1 module e K7M DR10S K7M DR20S K7M DR30S K7M DR40S K7M DR60S na K7M DR10S DC K7M DR20S DC K7M DR30S DC K7M DR40S DC ain uni K7M DR60S DC K7M DT10S K7M DT20S K7M DT30S K7M DT40S K7M DT60S Items Digital I O module e G7E DR10A A D D A Expansion e G7F ADHA Composite module module Analog timer e G7F AT2A Cnet I F modules e G7L CUEB G7L CUEC 1 Cnet I F module is not available
115. g data size can be set up to 60 WORDs There s no cycle for sending and receiving Setting device area Sending reading device area P M L K T C D S F saving device area P M L K T C D S Receiving reading device area P M L K T C D S F X saving device area P M L K T C D S 8 34 Chapter8 Communication Function 6 This is a window you can change dedicated use 1 setting Private Item Edit Mode Send C Receive Station No uj 0 31 Size Word fi 1 60 Area From D0000 P M L KF T C Area To D0000 P M L K T C Area Station number set the number of the slave or opponent station Mode click send for writing data on the slave station or receive for reading from it Size data size for reading and writing of the master station can be specified up to 60 WORDs Area Item Send mode Receive mode that is in the master station to temporarily that is in the slave station for the data to Area from save the data to be written be read that is in the master station to temporarily Area to thatis in the slave station to write the data save the data to be read Chapter8 Communication Function 3 Flag related with operating status 1 Sending receiving error count for each station total 32 stations Error code is saved following area according to station
116. ge the SV within 0 4000 2 PV is out of range It may caused by fault of A D module Check the A D module 3 S_TIME is out of range Change the S_TIME within 0 100 32 Ripple is out of range 7 4 0 Change the Ripple to 0 Or 1 Chapter 7 Usage of Various Functions 2 instruction 1 PID8 Available device Flag Instruction Step no E rror Zero Carry M Les S T e 2 bs F110 F111 F112 n O O PID8 5 O S1 O Flaa Set Error It turns on when designation area is over and F110 the instruction isn t executed Designation area on Registration No at parameter 0 7 execution status registration area B PID8 PIDCalculation a Usage e when the condition of execution is on PID operation executes only rising edge condition e n is registration No at parameter 0 7 b Example program F0093 p PI 2 D0000 e When the input condition F0093 1second clock is rising edge off gt on PID operation executes at no 2 parameter e PID execution status registrate D0000 and the output value of control result registrate D0001 bF bE bD bC bB bA b9 b8 b7 b6 b5 b4 b3 b2 b bO MV upper limit Done normal execution signal D0000 MV lower limit 4 T 4 Chapter 7 Usage of Various Functions 2 PID8AT Availabl
117. hed 9 1 94 2 Handling Instructions lt i eene nnne nnne eren ereet enetake enne detenti rede 9 4 9 1 3 Connection of expansion module eem 9 7 7110 aR 9 8 9 2 1 Power sUpply Wining ree benennen d edere ek cede iine cue Peir estrante Eis 9 8 92 2 l O devices Wiring tiret inni rennen ten ederent reri hinunter ie 9 10 9 2 3 Grounding d 9 10 9 2 4 Cable Specifications for Wiring seem 9 11 Chapter 10 Maintenance 10 1 Maintenance and InSpectlolfos e eser ed eol eniro e irr cett 10 1 10 2 Daly Inispectlop tinsa eerie adeft renun oni 10 1 10 3 Periodic InSDeCllOpTieenna ternera priv motam romanae ntt isnt tein 10 2 Chapter 11 Trouble Shooting 11 1 Basic Procedures of Troubleshooting miner trennen 11 1 11 2 Troubleshooting mr 11 1 11 2 1 Troubleshooting flowchart used when the power LED turns off eene 11 2 11 2 2 Troubleshooting flowchart used when the error LED is flickering nnn 11 3 11 2 3 Troubleshooting flowchart used when the RUN LED turns off emen 11 4 11 2 4 Troubleshooting flowchart used when the I O devices doesn t operate normally se 11 5 11 2 5 Troubleshooting flowchart used when a program can t be written to the CPU mnn 11 7 11 3 Troubleshooting Questionnaire e m 11 8 11 4 Troubleshooting Examples s eeneniisertiin tribal reti eH ulOH et iEr Ho el evang 11 9 11 4 1 Input circuit troubles and corrective actions sss 11 9 11 4 2 Output circuit troubles and corrective actions sese 11 10 11 5 Error code
118. hin 0 10000 4 TIME is out of range Change the TIME within 0 20000 5 D_TIME is out of range Change the D_TIME within 0 20000 6 S TIME is out of range Change the S TIME within 0 100 7 REF is out of range Change the REF within 0 10 8 TT is out of range Change the TT within 0 1000 9 N is out of range Change the N within 0 1000 10 EN and or EN D is set as 1 Only P Pl and PID controls are available Please when EN P is 0 change the setting of EN P EN I and EN D 1 Please be careful to input 100 times scaled up values for P GAIN and TT 2 TIME D TIME S TIME and REF are 10 times scaled up not 100 times 7 3 8 Chapter 7 Usage of Various Functions b PID8AT instruction parameter setting and explanation a PIDCTUN Item Edit Scantime S TIME is the period of reading data sampling and 10 times scaled up for more precious operation Generally it should be synchronized with external trigger input to perform proper PID operation The range of sampling time is 0 1 10 seconds and actual input range is 0 100 b Control target SV 80 of PV SV setting value the designated value and PV process value present value of MK80S PID operation have the range 0 4000 The range is set with the consideration of the resolution of A D and D A module of MK80S series 12 bits and offset value When setting the SV or PV please be careful convert the analog value of control object temper
119. intenance and Inspection Describes the check items and method for long term normal operation of the PLC system Chapter 11 Troubleshooting Describes various operation errors and corrective actions Appendix1 System Definition Describes parameter setting for basic I O and communications module Appendix 2 Flag List Describes the types and contents of various flags Appendix 3 REMARK Dimensions Shows dimensions of the main uints and expansion modules 1 This manual does not describe the programming method For their own functions refer to the related user s manuals 1 1 Chapter 1 General 1 2 Features 1 MASTRER K808S series features 1 Open network by us of communications protocol in compliance with international standard specifications 2 High speed processing with an operation dedicated processor included 3 Various special modules that enlarge the range of application of the PLC 2 MK80S series is extremely compact to fit a wide range of applications 1 High speed processing High speed processing of 0 5us step with an operation dedicated processor included 2 Various built in functions The main unit can perform many functions without using separate modules It is possible to construct various systems just using the main unit e Fast Processing Applications Pulse catch Allows the main unit to read 4 inputs each having a pulse width as small as 0
120. it means that 5 WORDS should be read 2 Max of MW in number of data can be used up to 64 3 Protocol of RSB doesn t have number of blocks 4 R r SB command of bit devices is not available Explanation When command is lowercase r only one lower byte of the value resulted by adding 1 Byte each to ASCII values from ENQ to EOT is converted into ASCII and added to BCC BCC Device This indicates the number of name s characters that means device which is allowable up to length Name 16 characters This value is one of ASCII converted from hex type and the range is from length of device HO1 ASCII value 3031 to H10 ASCII value 3130 Address to be actually read is entered This must be ASCII value within 16 characters and in Device name this name digits upper lowercase and only are allowable to be entered Chapter8 Communication Function 3 MK80S Base Unit response format MK80S of ACK response Command Number of Number of Format name Header Station No Command data type blocks data Ex of frame ACK H10 SB H01 H02 H1122 ASCII value H06 H3130 H31313232 Item Explanation When command is lowercase r only one lower byte of the value resulted by adding 1 Byte BCC each to ASCII values from ACK to ETX is converted into ASCII and added to BCC and sent It means byte number of hex type and is converted into ASCII This number is determined by
121. izing to the system characteristics Manual MV SV Set Value PID calculation Present Value PV D A converting Control object Automated My module A D converting module lt Figure 1 1 gt Block diagram of PID control system 7 2 6 Chapter 7 Usage of Various Functions 2 Specification 1 Control operation a Proportional operation P operation a P action means a control action that obtain a manipulate value which is proportional to the deviation E the difference between SV and PV b The deviation E is obtained by multiplying a reference value to the actual difference between SV and PV It c prevents the deviation from a sudden change or alteration caused by external disturbance The formula of deviation is as following MV Kpx bxSV PV Kp the proportional constant gain b reference value SV set value PV present value When E happens MV by P operation is like lt Fig 2 1 gt Time Time lt Fig 2 1 gt MV by P operation If the Kp is too large the PV reaches to the SV swiftly but it may causes a bad effect like oscillations shown in the Fig 2 2 If the Kp is too small oscillation will not occur However the PV reaches to the SV slowly and an offset may appear between PV and SV shown in the Fig 2 3 The manipulation value MV varies from 0 to 4 000 User can define the maximum value of MV MV_MAX and minimum value MV_MIN within th
122. k value bit 7 bit 0 1 1 1 1 1 1 1 1 hFF masking value bit 7 bit 0 1 1 0 1 0 0 1 1 AND masking hD3 bit 7 bit 0 1 1 0 1 0 0 1 1 OR masking hFF bit 7 bit 0 0 0 1 0 1 1 0 0 Exclusive OR masking h2C Chapter 8 Communication Function 8 2 3 Instruction Available device Flag Instruction No of Error Zero Carry MIPBI K L F T S D D PEE sec Ft ft F112 1 O SND8 5 O S2 0 0 0 0 O 0O M SND8 Frame no which is designated at parameter Device which the communication status is stored 1 Function When the execution condition is on the communication starts with protocol at parameter which is designated early n D is a frame number at parameter which is designated is a device which the communication status is stored 2 example of program P0020 L EL M SND8 3 M000 When input condition is on the communication starts with protocol at user defined parameter mumber 3 The communication state stores M000 and the format of M000 lis as below bit 15 bit 8 bit bitO Error code Error bit Done bit e Done bit transfer complets normally this bit turns on during 1 scan e Error bit When communication error occurs e Error code When error bit turns on it stores error code 3 Error code
123. lable REMARK Setting range of watchdog 1 6 000ms unit 10ms 5 5 Chapter 5 CPU Module 5 2 5 Timer Processing The MASTER K series uses up count timers There are 5 timer instructions such as on delay TON off delay TOFF integral TMR monostable TMON and re triggerable TRTG timer The measuring time range of 100msec timer is 0 1 6553 5 sec and that of 10msec timer is 0 01 655 35 sec Please refer the MASTER K programming manual for details 1 On delay timer The current value of timer starts to increase from 0 when the input condition of TON instruction turns on When the current value reaches the preset value the timer output relay turns on When the timer input condition is turned off the current value becomes 0 and the timer output relay is turned off Timer input condition E EXE EE Timer output relay Preset value PV Current value 2 Off delay timer The current value of timer set as preset value and the timer output relay is turned on when the input condition of TOFF instruction turns on When the input condition is turned off the current value starts to decrease The timer output relay is turned off when the current value reaches 0 Timer input condition ZEE IESU NER tt Qi B Timer output relay Preset value PV Current value 5 6 Chapter 5 CPU Module 3 Integral timer In general its operation is same as on delay timer Only the difference is the c
124. le converts the analog signal to digital value 0 4000 PID8 instruction will calculate manipulate value MV 0 4000 based on PID parameter settings P_GAIN TIME D TIME etc and PV from A D module Then the calculated MV is output to the channel 0 of D A module D A module will convert the MV 0 4000 to analog signal 4 20mA and output to the actuator power converter Use PID operation with A T function Convert the measured temperature 0 250 C to current signal 4 20mA and input the current signal to the channel 0 of A D module Then the A D module converts the analog signal to digital value 0 4000 A T function block will calculate manipulate value MV 0 4000 based on the SV and PV from A D module Simultaneously the A T module will calculate P and D parameters The END output of A T module will be 1 when the A T operation is completed Then PID module will start operation with PID parameters that are calculated by A T module D A module will convert the MV 0 4000 to analog signal 4 20mA and output to the actuator power converter THES G7F ADHA module is supplied 2channels for A D exchange and 1channel for D A exchange module 7 44 Chapter 7 Usage of Various Functions 4 parameter setting and Program a Incase of using PID function only PID execution completes at 10 second each time At that time bit 0 of D200 turns on and output MV value F095 is 10 second clock
125. lsa flag to indicate whether a user defined frame is received in the order set by the user _ Ifthe received frame is matched with the declared frame in frame list number 3 L003 starts blinking 0 gt 1 0 When frame receiving is done MK80S base unit check if there s any match between the received frame and the declared frame in frame list If there is let the Link relay L n flag blink and save the received data in the assigned area Chapter 8 Communication Function BCC calculation example When frame is set as below the result of calculation is as follow Header jenn O Tane fe al Segrerd 1 Segreni 5 Tyee const 3 24 Type oe lanes C H la fF ASCH Inout mu Bite E un Segen 2 Sepnent Tee woe s mee nost 7 SERERE E D Byte g r Segmen 3 Segen T Tyee HOKE i twe h A aepo E P 5x m r Segmeni 4 Segment Tyee wwe 3 ime phoe lt lt ir e 6b r Tae JIECTIBCCT BCC Satin taa 1 Default setting Data Type ASCII C Hex Check Rule OF C SUMT C SUM2 C X R 1 C XOR2 C MUL 1 C MUL2 Range l ex H 0 T 0 Complement Mask ex FF IFF amp FF Cancel The kinds of The last transmitting frame segment inout The value of sum check BCC Typesetting ASCII Type Hex Type ASCII Input 31 32 33 34 04 CE 05 31 32 33 34 04 43 41 05 31 32 33 3404 CE Hex Input 12 34 04 4A 05 12 34 04 34 41 05 12 34 04
126. m all the data from 2 data to the data before the data marked as BCC and input the Default result to the BCC area SUM 1 BCC method uses sum like defaults but the user can set the BCC area SUM2 BCC method is the same with SUM 1 but it s used when the user masks any value to the last BCC o value Z XOR 1 BCC method is OR Exclusive OR Een 2 XOR2 BCC method is the same with XOR 1 but its used when the user masks any value to the last BCC value MUL 1 BCC method is MULTIPLY that is multiplication MUL 2 BCC method is the same with MUL 1 but its used when the user masks any value to the last BCC value H signifies header S is for segment and T is for tail Range Ex1 When header is set as ENQ STX tail is set as EOT ETX and the range of setting BCC is to be from STX to ETX then set as H 1 T 1 It is to set whether not to take complement number or to take the complement number of 1 or 2 at Complement BCC value If mask setting is done after taking a complement number the user can set any value to do masking Mask Sets any value and method of masking Ex1 When masking by XOR method using a value HFF FF Ex2 When masking by OR method using a value HFF FF When masking by AND method using a value HFF amp FF 3 Keys on Keyboard for setting masking method gt 6 7 Frame size ASCII communication max 128 bytes Hex communication max 256 bytes Link relay L
127. me check Comm Structurized data area or null code ACK number ETX 3 NAK Response frame MK80S base unit gt external communication device when receiving data abnormally max 256 Bytes Header Command Tail Frame check Station Command Error code ASCII 4 Byte 1 Used control codes are as follows Be familiar with the following control codes Because they are importantly used for communication Control codes Hex value Name Contents H05 Enquire Request frame initial code H06 Acknowledge ACK response frame initial code H15 Not Acknowledge NAK response frame initial code H04 End of Text Request frame ending ASCII code H03 End Text Response frame ending ASCII code 8 5 Chapter8 Communication Function 1 The numerical data of all frames are ASCII codes equal to hexadecimal value if there s no clear statement The terms in hexadecimal are as follows e Station No e When the main command is R r or W w and the command type is numerical means a data type e All of the terms indicating size of all data in the Formatted data area Monitoring registration and command registration number of execution commands e All contents of data 1 If itis hexadecimal H is attached in front of the number of frames like H01 H12345 H34 H12 and H89AB 2 Sequence of command frame 1 Sequence of command request frame ENQ Station No
128. mmended value C 0 1 0 47 uF External device R 47 120 Q 1 2W Input signal Or make up another independent display circuit doesn t turn off Leakage current due to line capacity of wiring cable Locate the power supply on the external device side as shown below AC input AC input I L Leakage current s fasi z I e External device Input signal External device doesn t turn off Leakage current of external device Connect an appropriate register which will make Drive by switch with LED indicator the voltage higher than the OFF voltage across the DC input input module terminal and common terminal Leakage current DC input External device Input signal e Sneak current due to the use of two doesn t turn off different power supplies Use only one power supply Connect a sneak current prevention diode DC input DC input Chapter 11 Troubleshooting e E1 gt E2 sneaked 11 1 0 Chapter 11 Troubleshooting 11 4 2 Output circuit troubles and corrective actions The following describes possible troubles with input circuits as well as their corrective actions Condition When the output is off excessive voltage is applied to the load eLoad is half wave rectified inside in some cases it is true of a solenoid When the polarity of the power supply is as shown in QD C is charged When the polarity is as shown in 2 the voltag
129. mmunication ARRAY type must be always set by byte This field is to declare commands and fixed data that will be used in communication frame and constant data to be declared by inputting ASCII input must be done within 10 characters and hex within 20 characters If the number exceeds the limit set the next segment as the same type and continue to input there As an dedicated protocol communication 10RSB0690MW10006 is a frame to execute reading 6 word data from M100 at the slave station no 16 Type const 10RSB06 ic HexInput ASCII Input SIZE Byte Segment 2 me const m1 0006 A C Hexinput ASCII Input sz Byte If the segment is declared as ARRAY type designate transmitting device P M L K F T C D and number of transmitting byte Ex2 If you want to transmit D000 D003 the setting is as below transmitting device D000 number of transmitting 6 bytes It is a radio button to select the input type of commands There re 2 kinds as hex or ASCII value Ms See Ext ASCII 10RSB06 MW100 Ex2 Hex 31 30 52 53 42 30 36 25 57 44 31 30 30 If ARRAY is set it asks whether it would convert data to ASCII to send at send frame or convert to hexadecimal to receive at receive frame Send by ASCII Converting Receive by Hex Converting Size Byte If ARRAY is set the size of area is to be set by byte The unit is a byte Chapter 8 Communication Function
130. mmunication address 0 and the input contact point 1 0001 of Modicon products is marked as communication address 0 in MK80S The size of using data As for data size MK80S base unit supports 128 bytes in ASCII mode and 256 bytes in RTU mode The maximum size of the Modicon products is different from each other kind So refer to Modicon Modbus Protocol Reference Guide Chapter 8 Communication Function 10 Map of wiring Male Type MK80S base unit Pin no Connecting no and direction Quantum 9PIN Pin no Signal Chapter 8 Communication Function 8 3 3 Parameters Setting 1 Setting communication parameter 1 Opena new project file at KGLWIN MK80S should be selected in PLC types Open anew project file for each of the master and the slave 2 Selecta communication parameter at KGLWIN and double click to open the following window If communication mode is ASCII Be sure to set 7bit Chapter 8 Communication Function 3 Set the contents as follows Item Setting contents Station No Set a number between 0 to 31 Don t assign no 0 as broadcasting station lest it may be a cause for mistaken operation Baud Rate Set one from 1200 2400 4800 9600 19200 38400 or 57600 bps Data Bit Set 7 or 8 ASCII mode Set as 7 bits RTU mode Set as 8 bits Parity Bit Set as one of None Even or Odd
131. mple in case of 1000 output at range 4 20 mA current output value before the scaling conversion 1000 x 5 uA 5 mA current output value after the scaling conversion 1000 x 0 8 800 1600 1600x 5A 8 mA 7 5 3 Chapter 7 Usage of Functions 6 Wiring 1 Caution for wiring gt Make sure that external input signal of the mixture module of AC and analog I O is not affected by induction noise or occurs from the AC through using another cable gt Wire is adopted with consideration about peripheral temperature and electric current allowance Thicker than Max size of wire AWG22 0 3 mm is better gt If wire is put near to high temp radiated device or contacted with oil for a long time it may cause of electric leakage so that it gets broken or miss operation during wiring gt Be sure to connect with care of polarity while connecting to external 24V DC power supply gt In case of wiring with high voltage line or generation line it makes induction failure so then it may cause of miss operation and out of order 2 Wiring example a Analog input Voltage input Current input Terminal Terminal b Analog output 1 Be sure to use two core twisted shield wire Be careful to use that analog output is 1 channel 7 5 4 Chapter 7 Usage of Functions 7 VO converstion characteristics 1 Analog input characteristics a Voltage input 4000 2004 7 2008 eene 2002 2000 Digital output value o E
132. n screws Distance between Connecting Visual check Proper clearance Correct terminals conditions Connectors should not be Retighten connector mounting Loose connectors Visual check loose Screws Line voltage check Measure voltage between input terminals 85 264V AC 20 28V DC Change supply power Battery time and battery capac Check total power failure If Battery capacity reduction should n Battery ity life indicated Change the battery capacity time and the ot be indicated battery when specifi reduction specified source ed service life is exceeded If fuse melting disconnection chang Fuse Visual check No melting disconnection e the fuse periodically because a s 10 2 urge current can cause heat Chapter 11 Troubleshooting Chapter 11 Troubleshooting The following explains contents diagnosis and corrective actions for various errors that can occur during system operation 11 1 Basic Procedures of Troubleshooting System reliability not only depends on reliable equipment but also on short downtimes in the event of faults The short discovery and corrective action is needed for speedy operation of system The following shows the basic i nstructions for troubleshooting 1 Visual checks Check the following points Machine operating condition in stop and operating status Power On Off Status of I O devices e Condition of wiring I O wires extension and comm
133. n module 1 D4982 D A conversion value set D4983 A D conversion value of channel 0 stores D4984 A D conversion value of channel 1 stores A D D A combination module 2 D4985 D A conversion value set The table which is shown below is possible to use under the same or more than K80S CPU ROM V1 4 spere ole Explanation Remark register D4980 AID conversion value of channel 0 stores D4981 AID conversion value of channel 1 stores A D D A combination module 1 D4982 D A conversion value stores D4983 unused D4984 A D conversion value of channel 0 stores D4985 AID conversion value of channel 1 stores ND D A combination module 2 D4986 D A conversion value stores D4987 unused 7 5 2 Chapter 7 Usage of Functions 5 Scaling function This function convert automatically range when the inout output range is not matched In case that input output is current this function is useful that external equapment range is not matched each other MK80S series converts range automatically as following 0 20mA lt gt 4 20mA gt Conversion method is as below 1 scaling conversion value A D conversion data of 0 20 mA 800 x 4000 3200 example in case of 8 mA input at range 0 20 mA before the scaling conversion 8 mA 5 uA 1600 after the scaling conversion 1600 800 x 1 25 1000 2 scaling conversion value D A conversion data of 4 20 mA x 3200 4000 800 exa
134. nals Proper clearance should be provided Correct cable PWR LED Check that the LED is ON ON OFF indicates an error See chapter 11 Run LED Check that the LED is ON during Run ON flickering indicates an error See chapter 11 Indica ting ERR LED Check that the LED is OFF during Run OFF ON indicates an error See chapter 11 LED ON when input is ON Input LED Check that the LEO turns ON and OFF Peon so ge See chapter 11 OFF when input is off ON when output is ON tput LED Check that the LEO t N and OFF hapter 11 Outpu Check that the LEO turns ON and O OFF when output is off See chapter Chapter 10 Maintenance 10 3 Periodic Inspection Check the following items once or twice every six months and perform the needed corrective actions Check Items Checking Methods Judgment Corrective Actions Ambient 0 55 C Measure with Ambient temperature A Adjust to general standard ED thermometer and Environme Ambient Humidity 5 95 RH Internal environmental standard of l hygrometer measure Bickel i Ambiance corrosive gas There should be no corrosiv Control section e gases The module should be move t The module should be mounted Looseness Ingress PLC he unit securely T Retighten screws Conditions dust or r i Visual check No dust or foreign material foreign material Loose terminal Re tighten screws Screws should not be loose Retighte
135. nication supports Modbus the Modicon product s communication protocol It supports ASCII mode using ASCII data and RTU mode using Hex data Function code used in Modbus is supported by instruction and especially function code 01 02 03 04 05 06 15 and 16 Refer to Modicon Modbus Protocol Reference Guide http www modicon com techpubs toc7 html 8 3 2 Basic Specification 1 ASCII mode 1 It communicates using ASCII data 2 Each frame uses colon H3AJ for header CRLF Carriage Return Line Feed HOD HOA for tail 3 It allows Max 1 second interval between characters 4 It checks errors using LRC 5 Frame structure ASCII data I Co Item Header Address Funcion coe Data Size 1 byte 2 bytes 2 bytes 2 RTUmode 1 It communicates using hex data 2 There s no header and tail It starts with address and finishes frame with CRC wo It has at least 3 5 character times between two frames Itignores the current frame when 1 5 character times elapse between characters EN It checks errors using 16 bit CRC Frame structure hex data QD Ol REMARK 1 The size constituting 1 letter is 1 character So 1 character is 8 bits that is 1 byte 2 1 character time means the time lapsed for sending 1 character Ex Calculation of 1 character time at 1200 bps 1200 bps means that it takes 1 sec to send 1200 bits To send 1 bit 1 sec 1200 bits 0 83 ms Therefore 1
136. nsion A T module 1 D4969 A T conversion value of channel 4 stores Expansion A T module 1 D4970 A T conversion value of channel 1 stores Expansion A T module 2 D4971 A T conversion value of channel 2 stores Expansion A T module 2 D4972 A T conversion value of channel 3 stores Expansion A T module 2 D4973 A T conversion value of channel 4 stores Expansion A T module 2 D4974 A T conversion value of channel 1 stores Expansion A T module 3 D4975 A T conversion value of channel 2 stores Expansion A T module 3 D4976 A T conversion value of channel 3 stores Expansion A T module 3 D4977 A T conversion value of channel 4 stores Expansion A T module 3 4 Program example 1 Program explanation Program which controls on delay time of output contact point within 0 to 20 sec By analog timer module 2 System configuration Base Unit Analog timer module AIT conversion data is moved D000 always 7 6 6 Chapter8 Communication Function Chapter 8 Communication Function 8 1 Dedicated Protocol Communication 8 1 1 Introduction MK808 s built in Cnet communication uses only MK80S base unit for a dedicated communication That is it doesn t need a separate Cnet I F module to facilitate the user intended communication system by utilizing reading or writing of any area in CPU and monitoring function MK80S base unit serves as follows e Individual continuous reading of device e Individual continuous writing
137. nter Program RAM 0005h error Stop PGM RAM Error Program RAM is defected Contact the service center Defect of dedicated LSI for sequence 0006h Gate array error Stop G A Error instruction processing Contact the service center Sub rack power Stop Sub Power Error Extension Rack Power down or Error Check the power of the 0007h down error extension rack Turn the power off and 0008h OS WDT error Stop OS WDT Error CPU OS watch dog error restart the system Contact the service center 0009h LA RAM Stop Common RAM Error Common RAM interface error Contact the service center Continue Break of fuse used in output units or Check MME USE LED Orne 000Ah Fuse break error 1 0 Fuse Error unit Turn the power off stop Mixed I O and replace the fuse 000Bh Inouet or coe Stop OP Code Error jnstructions unreadable by the SRM Contact the service center error are included during execution Flash memory F 000Ch error during Stop User Memory Error Read to Write from the inserted Flash Check and replace the memory is not performed flash memory execution apna Turn the power off and ngog Teste unt imb and 0010h I O slot error Stop 1 0 Slot Error g 0p restart the system I O unit defect or extension cable Replace the I O unit or defect extension cable Points of mounted I O units overrun 0011h Maximum VO Stop MAX I O Error TIE Wien 19 points FMM Replace the I O unit error mounting number over error MINI_MAP ove
138. nverted value of this is 31 32 33 34 35 36 37 38 and this contents is entered in data area Name directly highest value is entered first lowest value last 1 If data type is Bit data read is indicated by bytes of hex Namely if Bit value is 0 it indicated by HOO and if 1 by H01 4 Response format NAK response Error code Format name Header Station No Command Command type Frame check Hex 2 Byte Ex of frame NAK H20 SS H1132 BCC ASCII value H15 H31313332 Explanation When command is lowercase r only one lower byte of the value resulted by adding 1 BCC Byte each to ASCII values from NAK to ETX is converted into ASCII and added to BCC Hex and 2 bytes ASCII code 4 bytes indicate error type For the details see 8 1 8 Error Error code codes Chapter8 Communication Function 5 Example Format name Header Station No Command K80S base unit This example supposes when 1 WORD from M20 and 1 WORD from P001 address of station No 1 are read and BCC value is checked Also it is supposed that H1234 is entered in M20 and data of H5678 is entered in P001 Computer request format PC gt MK80S Base Unit Command Number of Variable Format Devicelength Format name type blocks length name Ex of fram e ENQ H01 SS H02 H05 MW20 H06 PWO001 H254D57 H25505730 A
139. of Functions 6 Wiring 1 Caution for wiring gt Make sure that external input signal of the mixture module of AC and analog I O is not affected by induction noise or occurs from the AC through using another cable gt Wire is adopted with consideration about peripheral temperature and electric current allowance Thicker than Max size of wire AWG22 0 3 mm is better gt If wire is put near to high temp radiated device or contacted with oil for a long time it may cause of electric leakage so that it gets broken or miss operation during wiring gt Be sure to connect with care of polarity while connecting to external 24V DC power supply gt In case of wiring with high voltage line or generation line it makes induction failure so then it may cause of miss operation and out of order 2 Wiring Voltage Terminal Current Terminal Be sure to use two core twisted shield wire Chapter 7 Usage of Functions 7 Analog Digital conversion characteristics 1 Analog input characteristics a Voltage input 4000 2004 OQ ernest 2009 aeee 2000 o 2 s gt x 5 a 2 5 o E 2 2 a p Digital Output Value Svea yer 5V gt Voltage Input Analog Input Voltage AID Conversion Characteristics Voltage Input In voltage input digital amount 0 is output by OV input and 4 000 is output by 10V input Therefore input 2 5mV equals to digital amount 1 but value less than 2 5mV c
140. of device e Reading CPU status Monitor devices registration e Executing monitoring e 1 1 connection link between MASTER K s system configuration MK80S base unit RS 232C MK80S built in communication function supports Cnet communication without any separate Cnet module It must be used under the following instructions 1 MK80S base unit supports 1 1 communication only for 1 N system having master slave Format use MK80S base unit with G7L CUEC module connected G7L CUEC module supports RS 422 485 protocol 10 point main unit includes RS 485 communication terminal so 1 N system can be configured without G7L CUEC module 2 RS 232C communication cable for MK80S base unit is different from RS 232C cable for KGL_WIN in pin arrangement and from the cable for Cnet module too The cable can t be used without any treatment For the detailed wiring method refer to 8 1 2 3 It s possible to set baud rate type and M area size in KGL_WIN For the detailed information refer to the appendix or KGLWIN manual Chapter8 Communication Function 8 1 2 System configuration method According to the method of connection the system using MK80S built in communication can be composed 1 Connecting system configuration link between MASTER K s 1 1 1 connection with general PC a Communication program made by C or BASE computer language on the user s computer or utility program like MMI software can be used K80S base unit
141. on 1 operational pattern No operation pattern No is each pulse out pattern No Max 40 patterns can be set 2 Output pulse count It sets output pulse number The setting range 0 42944967295 3 Max speed It sets operational speed at normal section The setting range 50 2000pps 50multiflier only 4 Acceleration Deceleration mode Acceleration Deceleration mode is designation of increasing decreasing velocity operation Disable uniform velocity operation enable increasing decreasing velocity operation 5 Acceleration deceleration slop Acceleration slop is available in case that acceleration deceleration mode is enable This is slop that pulse frequency reach to maximum pulse frequency from 0 pulse only integer 6 Bit device set 8 Direction contact signal setting of contact for direction signal output 7 15 Chapter 7 Usage of Various Functions b continuous operation setting of contact for infinitive operation c emergency stop setting of contact for emergency stop 7 The number of acceleration pulse Automatically calculate at KGL WIN if the maximum pulse and slop are set by user Calculation method is as below The number of acceleration pulse maximum pulse 50 50 maximum pulse 100 50 eeeses 100 50 50 50 x acceleration slop x 2 ex maximum pulse 1000pps acceleration slop 1 The number of acceleration pulse 1000 50 50 900 50 50
142. ontact point designation 05 No output contact point where is designated to the direction output Output contact point designation 7 2 0 Chapter 7 Usage of Various Functions 9 Output Direction Input type of servo motor driver or stepping motor driver is subdivided into 2 Output direction of control can be selected in the pulse output parameter 1 Selecting method of output direction a When driver gets input forward direction pulse and reverse direction pulse contact point and the forward reverse direction signals one levels Output pulse P50 Output dir P51 Forward direction output Reverse direction output velocity Set velocity 1Kpps i decelerationslop acceleration slop 1 1 Initial position Set position 5000 velocity Profile Parameter setting Example of a program When the M000 is on direction contact P51 is set and pulse outputs at pattern O forward direction output When the M001 is on direction contact P51 is reset and pulse outputs at pattern O reverse direction output Be careful If direction bit use another purpose pulse output operates abnormally T 2 Chapter 7 Usage of Various Functions b Driver gets input forward direction pulse and reverse direction pulse through different contact points Forward direction P50 Reverse direction P51 Forward direction Reverse direction Parameter setting Forward operation R
143. ow In general control system is required to be adaptable to various external internal changes Especially it should shows a stable transient response with the sudden change of the SV to be robust to load disturbances and or measurement noise PV Time Figure 2 11 The PI control with several reference values Integral windup All devices to be controlled actuator has limitation of operation The motor has speed limit the valve can not flow over the maximum value When the control system has wide PV range the PV can be over the maximum output value of actuator At this time the actuator keeps the maximum output regardless the change of PV while the PV is over the maximum output value of actuator It can shorten the lifetime of actuator When the control action is used the deviation term is integrated continuously It makes the output of control action very large especially when the response characteristic of system is slow This situation that the output of actuator is saturated is called as windup It takes a long time that the actuator returns to normal operating state after the windup was occurred The Fig 2 12 shows the PV and MV of PI control system when the windup occurs As shown as the Fig 2 12 the actuator is saturated because of the large initial deviation The integral term increase until the PV reaches to the SV deviation 0 and then start to decrease while the PV is larger than SV deviation lt 0 How
144. r 0012h Special card Stop Special I F Error Special Card Interface error Contact the service center interface error 0013h FMM 0 I F error Stop FMM 0 I F Error FMM 0 I F Error Contact the service center 0014h FMM 1 I F error Stop FMM 1 I F Error FMM 1 I F Error Contact the service center 0015h FMM 2 I F error Stop FMM 2 I F Error FMM 2 I F Error Contact the service center 0016h FMM 3 I F error Stop FMM 3 I F Error FMM 3 I F Error Contact the service center O020h Parameter Error Stop Parameter Error A written parameter has changed or Correct the content of the checksum error parameter When the power is applied or RUN I O Parameter Stop starts I O unit reservation information Correct the content of the 0021h I O Parameter Error parameter or reallocate or Error continue differs from the types of real loaded replace the I O unit I O units The point of the reserved I O 0022h aie Vo Stop I O PARA Error information or real loaded I O units Pore cine Content orne ver parameter overruns the maximum I O point 0023h p 0 Farameter Stop FMM 0 PARA Error FMM 0 Parameter Error Correct the parameter 0024h As 1 Parameter Stop FMM 1 PARA Error FMM 1 Parameter Error Correct the parameter 0025h p Ann Stop FMM 2 PARA Error FMM 2 Parameter Error Correct the parameter 11 13 Chapter 11 Troubleshooting continued Error Code Error CPU state Message Cause Corrective Ac
145. r supply to the system PWR LED e On When the supply is normal e Off When the supply is abnormal Indicates base unit operation e On Indicates local key switch or remote running mode CPU Off with the following led gets off 1 oe RUNLED gt Without normal power supply to the base unit Indication gt While key switch is stopped gt Detecting an error makes operation stop Indicates Base Units operation ERR LED On Off of led self inspected error Off CPU is normally working 2 I O LED Indicates I O operating status Folder for battery Folder for back up battery installation installation Chapter 4 Names of Parts No Name Key switch mode creation Indicates base units drive mode RUN Indicates program operation STOP Stopped program operation e PAU REM usage of each modules are as follows gt PAUSE temporary stopping program operation gt REMOTE Indicates remote drive Dip switch memory operation See Chapter 5 RS 232C connector 9 pin DIN connector to connect with external devices like KGLWIN Expansion connector cover Connector cover to connect with expansion unit Terminal block cover Protection cover for wiring of terminal block Private hook DIN rail Private part hook for DIN rail RS 485 communication terminal Only available with 10 points modules K7M DR10S K7M DR10S DC K7M DT10S Chapter 4 Names of
146. rame Ex is hex value and H is unnecessary during preparing real frame 2 Device data type of each must be same If data type of the first block is WORD and the second block is BIT error occurs 3 Response format ACK response Station Command Number of Number Format name Header Command data No type blocks of data Ex of frame ACK SS H01 H02 HA9F3 ASCII value H06 H3031 H3032 H41394633 p 1 block max 16 blocks possible Explanation When command is lowercase r only one lower byte of the value resulted by adding 1 Byte each to ASCII values from ACK to ETX is converted into ASCII and added to BCC and sent Number of data means byte number of hex type and is converted into ASCII This number is determined according to data type X W included in device name of computer request Format Number of data Number of data in accordance with its data type is as follows Data type Available variable Number of data Bitl X P M L K T C F X 1 Word W P M L K T C D S F W 2 e n data area there are the values of hex data converted to ASCII code saved Ex 1 The fact that number of data is HO4 ASCII code value H3034 means that there is hex data of 4 bytes in data Hex data of 4 bytes is converted into ASCII code in data Chapter8 Communication Function Ex 2 If number of data is H04 and the data is H12345678 ASCII code co
147. ration time 380ms sais Pulses 4 620 Decelerating pulses 190 Accelerating pulses 190 velocity gt i 2 0 step st step a Acceleration step 19 Deceleration example when acceleration is 1 7 17 Chapter 7 Usage of Various Functions Condition 2 Set up as acceleration slop 2 max frequency 1000 no of pulse out 5000 QD If I D velocity inclination is 2 2 pulses are output on the 1st step velocity 50pps Pulse velocity is 50pps So time consuming is 40ms 4 pulses are output on the 2nd step velocity 100pps and time consumes 20ms amp By calculation in the same way the time to reach to 1000pps is 40ms 20 1 760ms and the no of output pulses are 2 4 6 36 38 380 units Decreasing velocity inclination is 2 thus 380 units of pulses are needed The no of pulses in the uniform velocity region are 5000 380 380 4 240 units Whole spent time is 57 600ms Acceleration Uniform velocity Deceleration Time 760ms Time 4 240ms Time 760ms Pulses 380 Pulses 4 240 l Pulses 380 velocity 24 step 1st step Acceleration step 19 Deceleration If the acceleration slop goes bigger the increasing time and pulse go bigger by direct proportion to inclination Then be careful of an occurring of the instruction error when the no of a d pulse becomes bigger than the no of whole pulse 7 1 8 Chapter 7 Usage of Various Functions
148. re You can see dip switches as shown when you open I O terminal block cover BUILT_IN CNET Terminal block cover ROM MODE 5 26 Chapter 5__CPU Module 5 8 2 Usage Set the base unit to the STOP mode Select the Flash memory of on line menu the following window shows 1 read read the program and parameter to CPU memory from fresh memory 2 write write the program and parameter to fresh memory from CPU memory 3 verify verify the program and parameter between CPU memory and fresh memory 5 27 Chapter 5 CPU Module 4 dip switch for operating flash memory Dip switch position Description upper switch is for Cnet ON OFF When power is on the program saved in the flash memory operates ROM MODE Upper switch is for Cnet CPU recognizes that there is no program in the flash memory and starts to ON OFF drive program from RAM ROM MODE REMARKS 1 The flag for flash memory operation is F00A Dip switch for flash memory operation is placed in deep place to prevent a mistaken operation caused by terminal block cover etc Use a small driver to operate it Driver Terminal block cover 5 28 Chapter 5__CPU Module 5 9 External Memory Module MK80S series supplies external memory module for the user to save programs safely or download a program on the system and use it in case of a program is damaged 5 9 1 Structure Installation connector
149. ric oven 0 200 C Heater Transformer 2 Initial setting a o e PID operation parameters Auto Manual operation setting Auto Forward Reverse operation Forward SV setting 960 60 C 1120 70 C 1280 80 C 1600 100 C Current value setting DA980 AD conversion value of AD module Ch BIAS setting 0 If only P control is used input proper value other 0 EN P EN I EN D setting EN_P 1 EN I71 EN Dz71 PID operation REF 10 TT 50 N21 MV_MAX MV_MIN MVMAN MV_MAX 4000 MC_MIN 0 MAMAN 2000 S TIME S_TIME 100 sampling time 10 seconds Auto tuning parameters gt PV setting 960 60 C 1120 70 C 1280 80 C 1600 100 C gt S TIME S_TIME 100 sampling time 10 seconds gt Current value setting D4980 AD conversion value of AD module Ch1 gt wave select designation value 1 VVVVVVVVY A D module setting gt Channel setting use channel 1 gt input range setting DC 4 20 mA gt A D conversion data registration area D4980 gt Output data type 48 4047 D A module setting gt output range setting DC 4 20 mA gt D A conversion data registration area D4982 7 4 3 Chapter 7 Usage of Various Functions 3 a Program Explanation Use only PID operation without A T function Convert the measured temperature 0 250 C to current signal 4 20mA and input the current signal to the channel 1 of A D module Then the A D modu
150. rom M000 of station No 10 is read and BCC value is checked Also it is supposed that data in M000 and in M001 is as follow M000 H1234 M001 H5678 D Computer request format PC MK80S Base Unit Command y i Format name Header Station No Command Device length Devicename Number of data type Frame Example ENQ HOA SB H06 MW000 H02 H254D5730 ASCII value H05 H3041 H3036 H3032 3030 2 For ACK response after execution of command PC lt MK80S Base Unit Command Number of Format name Station No Command Data type data Frame Example HOA SB H04 12345678 ASCII value H3041 H3034 H3132333435363738 3 For NAK response after execution of command PC lt MK80S Base Unit Format name Station No gt Command Command type Error code Frame Example H0A r SB Error code 2Byte ASCII value H3041 H72 Error code 4Byte Chapter8 Communication Function 3 Individual writing of device W w SS 1 Introduction This is a function that writes the PLC device memory directly specified in accord with memory data type 2 PC request format Command Number of Device Format name Station No Command Device Name Data type blocks Length Frame Example H20 SS H01 H06 MW100 HOOE2 ASCIl H254D5731 H30304 value 3030 532 Be es 1 block setting can be repeated up to max
151. ror The JMP JME instruction error Correct the JMP JME instruction error instruction oo45h The FOR NEXT Stop FOR NEXTEmor The FOR NEXT instruction error Correct the FOR NEXT instruction error instruction The MCS MCS MCSCLR 7 Correct the MCS 0046h MCSCLR Stop Error The MCS MCSCLR instruction error MCSCLR instruction instruction error The MPUSH 0047h MPOP instruction Stop MPUSH S MEQE The MPUSH MPOP instruction error Correct the MPUSH s error Error MPOP instruction 0048h Dual coil error Stop DUAL COIL Error Timer or counter has been duplicated Correct timer counter Input condition error or too much use Check and correct the 0049h Syntax error Stop Syntax Error of LOAD or AND OR LOAD program Replace the battery under 0050h Battery error Continue Battery Error Backup battery voltage error the present condition 11 14 Appendix 1 System Definitions Appendix 1 System Definitions 1 Option 1 Connect Option You should set the communication port COM1 4 to communicate with PLC Select the Project Option Connect Option in menu Default Connection is RS 232C interface For the detail information about Connect Option refer to KGLWIN Manual e BIEMet App1 1 Appendix 1 System Definitions 2 Editor option Monitor display type Select the desired type in the monitor display type 4 types click the O K button You can select a one type Source
152. rules REMARK 1 All numerical data can use hexadecimal decimal and binary type If we convert decimal 7 and 10 into each type Hexadecimal H07 HOA or 16807 16 0A Decimal 7 10 Binary 280111 241010 8 69 Chapter 8 Communication Function 7 Function code types and memory mapping 8 Code Function code name a E Remark 01 Read Coil Status OXXXX bitoutput Read bits 02 Read Input Status 1XXXX bit input Read bits 03 Read Holding Registers 4XXXX word outpul Read words 04 Read Input Registers 3XXXX word input Read words 05 Force Single Coil OXXXX bit output Write bit 06 Preset Single Register AXXXX word output Write word 15 Force Multiple Coils OXXXX bitoutput Write bits 16 Preset Multiple Registers 4XXXX word output Write words MASTER K Mapping Bit area Word area Address Data area Address Data area h0000 P area h0000 P area h1000 Marea h1000 Marea h2000 L area h2000 L area h3000 Karea h3000 Karea h4000 F area h4000 F area h5000 Tarea h5000 T area current value area h6000 C area h6000 C area current value area h7000 S area h8000 D area Modbus addressing rules MK80S base unit starts its address from 0 and matches with 1 of Modicon products data address So MK80S s address n matches n 1 of Modicon products address This means that the output contact point 1 0001 of Modicon products is marked as co
153. s 1 Tt Fig 2 143 The block diagram of anti windup control system Fig 2 14 The PV output characteristics with different Tt values 2 Realization of PID control on the PLC In this chapter it will described that how to get the digitized formula of the P I and D terms Then the pseudo code of PID control will be shown a P control The digitized formula of P control is as following P n Kb xSV n PV n n sampling number K proportional gain constant b reference value SV set value PV present value b l control The continuous formula of control is as following K rt I t f e s ds Wt integral term 119 K proportional gain constant Ti integral time e s deviation value By deviation about t we can obtain 7 3 5 Chapter 7 Usage of Various Functions dl K e e SV PV deviation value dt Ti The digitized formula is as following I n l I n K gt n 5 e n h sampling period GDA E aos Ti c D control The continuous formula of derivative term is as following Td d d T x pcDe kn 2 N dt dt N high frequency noise depression ration y the object to be controlled PV The digitized formula is as following Use Tustin approximation method 21d hN 2KTdN D n _ __D n 1 _ n xn 2Td hN 2Td hN d Pseudo code of PID control The pseudo code of PID control is as following Step 1 Get constants that are used for PID operation h Bi
154. s ASCII code 4 bytes indicate error type For the details see 8 1 8 Error codes Error code Chapter8 Communication Function 5 Example This example supposes that 2 byte HAA15 is written in D000 of station No 1 and BCC value is checked D Computer request Format PC MK80S Base Unit Station Command Device Formatname Header Command Number of Device Data No type Length data Frame Example ENQ SB H06 DW0000 H01 HAA15056F H414131353 ASCII value H05 H3036 H254457303030 H3031 0353646 2 For ACK response after execution of command PC lt MK80S Base Unit Format name Header Station No Command Command type Frame Example ACK H01 W SB Frame check BCC ASCII value H06 H3031 3 For NAK response after execution of command PC lt MK80S Base Unit Format name Station No Command Command type Error code Frame Example 01 W SB Error code 2 ASCII value Error code 4 8 21 Chapter8 Communication Function 5 Monitor register X 1 Introduction Monitor register can separately register up to 10 in combination with actual variable reading command and carries out the registered one through monitor command after registration 2 PC request Format Format name Header Station No Command Registration No Registration Format Frame Example
155. s in the process RUN LED is off Turn the power unit off and on No Yes Contact the nearest service center Complete Chapter 11 Troubleshooting 11 24 Troubleshooting flowchart used when the I O part doesn t operate normally The following flowchart explains corrective action procedure used when the I O module doesn t operate normally When the I O module doesn t work normally Is the indicator LED of the P40 on Measure the voltage of power E E Replace the connector of the Check the status of P40 by supply in P40 7 terminal board KGLWIN No ls the Yes terminal connector it normal condition connector appropriate Is the output voltage of power supply for load wiring correct Yes Separate the external wiring than check the condition of output module Yes 4 ls it normal condition Check the status of P40 Replace the Unit Chapter 11 Troubleshooting Are the indicator LED of the Switch 1 and 2 on Check the status of the switch tand 2 Check the status of the switch 1and2 ls the terminal screw tighten securely Is input wiring correct Is input wiring correct Yes Is the condition of the terminal board connector appropriate Is input wiring correct Separate the external wiring witch then check the status by forced input Correct wiring Retighten the terminal Replace the terminal Corre
156. se Unit Format name Station No Command Registration No Error code Frame check Frame Example H01 y H01 Error code 2 BCC ASCII value H3031 H3031 Error code 4 8 27 Chapter8 Communication Function 7 Reading PLC Status RST 1 Introduction This is a function that reads flag list including operating status of PLC and error information 2 PC request Format Format name Header Station No Command Command type Frame check Frame Example ENQ HOA ST BCC ASCII value H05 H3041 Explanation When command is lowercase r only one lower byte of the value resulted by adding 1 Byte each to ASCII values from ENQ to EOT is converted into ASCII and added to BCC 3 Response Format ACK response Command PLC status data type Hex 20 Byte Frame Example H0A ST Status data Format Format name Station No Command ASCII value H3041 gt Explanation When command is lowercase r only one lower byte of the value resulted by adding 1 Byte each to ASCII values from ACK to ETX is converted into ASCII and added to BCC and sent 4 Response Format NAK response Error code Format name Header Station No Command Command type Frame check Hex 2 Byte Frame Example HOA ST H1132 BCC ASCII value 3041 31313332 Explanation When command is one of lower case r only one lower byte of the value
157. t bit of a byte is filled with 0 An example of sending the above data is as follows Example 1 AC DB 35 Program LL hil roz Dooo0 Higi p z LLE n n m m W DBUIS et a O 07 d i J E i D Itdesignates slave station and function code No of station h11 17 function code h02 2 Address setting Address 0 at MODBUS protocol means address 1 actually So if you want to designate address 10197 write address 10196 3 Reading number setting Reading number is 22 from 10197 to 10220 4 Thisis MODBUS Communication instruction The data transmission starts lower byte The remnant part of byte is filled with 0 Example 2 AC DB 35 Stored data at D200 D201 Device Stored data D200 h AC DB D201 h 00 35 Chapter 9 Installation and Wiring Chapter 9 Installation and wiring 9 1 Installation 9 1 4 Installation Environment This unit has high reliability regardless of its installation environment but be sure to check the following for system reliability 1 Environment requirements Avoid installing this unit in locations which are subjected or exposed to 1 Water leakage and dust Continuous shocks or vibrations Direct sunlight Dew condensation due to rapid temperature change Higher or lower temperatures outside the range of 0 to 55 C Relative humidity outside the range of 5 to 95 C Corrosive or flammable gases 2 3 4 5
158. tched on the new data in D4990 D4993 K1000S D9990 D9993 will be moved to F53 F56 After data is moved M1904 has to be switched off immediately because current data will be updated every scan while M1904 is on Example program P000 MOV h9901 D4990 1999 January Start switch MOV h1711 D4991 17th 11 o clock h5324 D4992 53min 24sec h1900 D4993 1999 Sunday D M1904 Changing enable Other Program 5 32 Chapter 5 CPU Module 5 11 Battery 1 Specifications Item Specifications Normal voltage DC 3 0V Warranty life time Application 5 years Programs and data backup and RTC runs in power failure Specifications Lithium Battery 3V External dimension mm 9 14 5 X 26 2 Handling Instructions 1 Don t heat or solder its terminals 2 Don t measure its voltage with a tester or short circuit 3 Don t disassemble 3 Battery Replacement Backup battery needs periodic exchange In case of battery replacement at power off the built in super capacitor backup the program and retain variables about 30 minutes However it is recommended to complete the battery replacement as soon as possible or turn on the base unit during battery replacement Battery replacement Open the cover of the CPU module Release the existing battery from the holder and disconnect the connector Insert a new battery into the holder in the exact direction and connect the
159. te ried insane Fed io Ern sees 7 50 7 2 2 Analogue Timer ee 7 59 8 1 Direct Protocol Communication 8 1 Gel IntrodUetionese ose eee es aligns ties age hegeenes eee stash Cro con iere une ben tic Godless tas the 8 1 8 1 2 System Configuration method em 8 2 8 1 3 Frame Structure eese eni aset iege etit eed E ier piterne IR ne eijerra MESS 8 5 8 1 4 Eistot Commands o rennen emereteeee tnnc erste deesse cemere prie itid tee set end 8 7 8 d9 Data Type LE 8 8 8 1 6 Execution of Commands see 8 9 8 1 7 1 1 Built in Communication between GM7 s nnne 8 31 8 1 8 Error Codes Vire e ties crat ordi kae si p COD RR T ELECTA 18 debat ua enda Sula Hear need a 8 45 8 2 User Defined Protocol Communication 3 erties 8 47 92 T Introductions eeeaserernrren med esent isi uke Fnit cade Fil Fo rr redde nes 8 47 8 22 Paramelter Selling rente dne Fete Hii ueni ridi cuiu sang 8 48 82 3 F hction BlOCKs sss Fiere eiaeaen Fe predrcueedered Hii coe il rii dit cuin Enea 8 57 8 2 4 Example of Use sssstetrescteretsnetieest tesnttsescstntsr netics ss aaatesresetarten etere rtrt itani 8 58 8 3 Modbus Protocol Communication nnn nemen 8 68 8 3 1 Introduction Pee eee eee eee eee ee eee eee eee eee eee eee ree eee eee eee 8 68 SRS et ciee a OC rudi 8 68 8 3 3 Parameter Setting een 8 72 8 3 4 FUNCTION BloCkze a a a a a siete 8 74 9 14 Installation HH mmm 9 1 91 1 Installation Environment eee rnnt nsnm nnn tepnnenin ct crier eerie tender nent ee s
160. ter 10 Maintenance Be sure to perform daily and periodic maintenance and inspection in order to maintain the PLC in the best conditions 10 1 Maintenance and Inspection The I O module mainly consist of semiconductor devices and its service life is semi permanent However periodic inspection is requested for ambient environment may cause damage to the devices When inspecting one or two times per six months check the following items Check Items Judgment Corrective Actions Temperature 0 55 C Adjust the operating temperature and humidity Ambient Humidity 5 959 RH with the defined range airone RA Use vibration resisting rubber or the vibration Vibration No vibration prevention method Play of modules No play allowed Securely enrage the hook Connecting conditions of g No loose allowed Retighten terminal screws terminal screws Change rate of input voltage 15 to 10 Hold it with the allowable range Check the number of Spare parts Spare parts and their Cover the shortage and improve the conditions Store conditions 10 2 Daily Inspection The following table shows the inspection and items which are to be checked daily Corrective Check Items Check Points Judgement Actions Connecting conditions of terminal check for loose mounting screws Screws should not be loose Retighten Screws block or extension Check the distance between solderless termi
161. the dot line Chapter 11 Troubleshooting Output circuit troubles and corrective actions continued Condition Corrective actions The load off Over current at off state The large solenoid current Insert a small L R magnetic contact and drive the load response time fluidic load L R is large such as is directly driven with using the same contact is long the transistor output The off response time can be delayed by one or more second as some loads make the current flow across the diode at the off time of the transistor output Output Surge current of the white lamp To suppress the surge current make the dark current transistor is of 1 3 to 1 5 rated current flow destroyed Output A surge current of 10 times or more when turned on Source type transistor output 11 1 2 Chapter 11 Troubleshooting 11 5 Error code list Error Code Message CPU state Message Cause Corrective Actions Internal system Fault of some area of operating ROM 0001h error Stop System Error or H W defect Contact the service center 0002h OS ROM error Stop OS ROM Error Internal system ROM is defected Contact the service center 0003h OS RAM error Stop OS RAM Error Internal system RAM is defected Contact the service center 0004h Data RAM error Stop DATA RAM Error Data RAM is defected Contact the service ce
162. the week F0570 to F058F Unused F0590 to F059F Storing error step Stores the error step of the program F0600 to FO60F Storing FMM step If a FMM related error has occurred its occurrence information is stored F0610 to FO63F Unused App2 5 Appendix 4 External Dimensions Appendix 3 External Dimensions unit mm 1 Base unit A B 10points 85 95 20points 135 145 30points 135 145 40points 165 175 60points 215 225 2 Extension Option module App4 1
163. ting integration time Ki in action That is the more the integration time the longer the integration time as shown in Fig 2 5 the lesser the quantity added to or subtracted from the MV and the longer the time needed for the PV to reach the SV As shown in Fig 2 6 when the integration time given is short the PV will approach the SV in short time since the quantity added or subtracted become increased But If the integration time is too short then oscillations occur therefore the proper P and value is requested d Integral action is used in either PI action in which P action combines with action or PID action in which P and D actions combine with action Fig 2 5 The system response when a long integration time given 7 2 9 Chapter 7 Usage of Various Functions Fig 2 6 The system response when a short integration time given c Derivative operation D action a When a deviation occurs due to alteration of SV or external disturbances D action restrains the changes of the deviation by producing MV which is proportioned with the change velocity a velocity whose deviation changes at every constant interval in order to eliminate the deviation gt D action gives quick response to control action and has an effect to reduce swiftly the deviation by applying a large control action in the direction that the deviation will be eliminated at the earlier time that the deviation occurs gt D action can prevent the l
164. tion velocity time Infinite operation Operate infinitely without an increasing decreasing operation until meet the emergency stop command velocity time 7 1 1 Chapter 7 Usage of Various Functions 2 Functional Specification Item Specification No of output 1 point Output type Pulse Output velocity Max 2Kpps Min 50pps Output pulse 0 2147483647 Execution type of the increasing decreasing velocity Designation of acceleration Type of the direction designation Right opposite direction pulse output Load power supply DC 12V 24V Usable range of the load power supply DC10 2 26 4V Maximum load current 150mA Initiative electric current Less than 0 4A 10ms Maximum power dropdown under On Less than DC 0 5V Electric current leakage under Off Less than 0 1mA On delayed time Less than 1ms Off delayed time Less than 1ms 1 Several points can be used for the pulse output point if they are not output at the same time Thus it is possible that right direction pulse is output as P040 opposite direction pulse is output as P041 7 12 Chapter 7 Usage of Various Functions 3 Names of parts Stepping motor AC100 240V P41 P4 ENS COMO COM1 COM2 eere Teo 2 ADDO Motor driver l Output direction Output pulse JUUL Terminal No Names Usage P40 Pulse output Pulse output termin
165. tion 1 2 or 4 with 2 phase counter 2 phase pulse input multiplied by one Counts the pulse at the leading edge of A phase 2 phase pulse input multiplied by two Counts the pulse at the leading falling edge of A phase 2 phase pulse input multiplied by four Counts the pulse at the leading falling edge of A phase and B 1 Performance Specifications Items Specifications Types A phase B phase Preset Input signal Rated level 24VDC 15mA Signal type Voltage input Counting range 0 16 777 215 Binary 24 bits Max counting speed 1 phase 16kHz 2 phase 8kHz Up Down 1 phase Sequence program or B phase input selection 2 phase Auto select by phase difference of A phase and B Multiplication 1 2 0r4 Preset input Sequence program or external preset input 2 Input specification Items Specifications Rated input 24VDC 15mA A B phase On voltage 14VDC or higher Off voltage 2 5VDC or lower Rated input 24VDC 15mA On voltage 19VDC or higher Preset input Off voltage 6V or lower On delay time Less than 1 5ms Off delay time Less than 2ms 7 1 Chapter 7 Usage of Various Functions 3 Names of wiring terminals Counter input VS UE SEU es Preset input BUILT_IN CNET ew Poo px poa os Trofeo Terminal No Names P00 A 24V A Phase input terminal ROM MODE P01 o B 24V B Phase input terminal P02 Pr
166. tion against noise so it can be used without grounding except for special much noise However when grounding it should be done conforming to below items 2 Ground the PLC as independently as possible Class 3 grounding should be used grounding resistance 8022 or less 3 When independent grounding is impossible use the joint grounding method as shown in the figure below B Class 3 grounding Class 3 grounding A Independent grounding Best B Joint grounding Good C Joint grounding Not allowed 4 Use 2 mr 14AWG or thicker grounding wire Grounding point should be as near as possible to the PLC to minimize the distance of grounding cable 9 1 0 Chapter 9 Installation and Wiring 9 2 4 Cable Specifications for wiring The specifications for wiring is as follows Kinds of external connection ee Minimum Maximum Digital Input 0 18 AWG24 1 5 AWG16 Digital Output 0 18 AWG24 2 0 AWG14 Analog Input Output 0 18 AWG24 1 5 AWG16 Communication 0 18 AWG24 1 5 AWG16 Main power 1 5 AWG16 2 5 AWG12 Grounding 1 5 AWG16 2 5 AWG12 e Be sure to use solderless terminal for power supply and I O wiring Be sure to use M3 type as terminal screw e Make sure that terminal screw is connected by 6 9 kg cm torque Be sure to use fork shaped terminal screw as shown below cable solderness terminal fork shaped 6 2mm less t 9 1 1 Chapter 10 Maintenance Chap
167. tion isn t allowed Slave Device Failure Error status of the slave station Acknowledge It s a responding code of the slave station for the master station to prevent the master station time out error when request command processing takes time The master station marks an error code and waits for a certain time without making any second request Slave Device Busy Error when request command processing takes too much time The master should request again Time Out Error when exceeds the time limit of the communication parameter as it communicates Number Error Errors when data is 0 or more than 256 bytes Parameter Error Error of setting parameters mode master slave Station Error Error when the station number of itself and the station number set by the S1 of instruction are the same 8 75 Chapter 8 Communication Function Example program 1 It s supposed that MK80S base unit is the master and it reads Coil Status of the station no 17 a Modicon product The master reads status of the Coil 00020 00056 of the slave station no 17 The Coil of the slave station is supposed to be as follows and the data that are read is saved in D1000 Status Hex Data status of the Modicon product s Coil 00020 00059 The status of Coil 57 58 59 are redundancy Data is sent starting from the low bit by byte unit If the
168. tion time of a user program in order to supervisor its normal or abnormal operation Setting range is 1ms 6000ms 4 Input setting set the input filter constant and input catch contact point 5 Remote access enable setting This parameter enables remote access authority App2 2 Appendix 2 Flag List Appendix 2 Flag List 1 Special relay F This flag is useful to edit user program Relay Function Description F0000 RUN mode Turns on when the CPU in the RUN mode F0001 Program mode Turns on when the CPU in the Program mode F0002 Pause mode Turns on when the CPU in the Pause mode F0003 Debug mode Turns on when the CPU in the Debug mode F0006 Remote mode Turns on when the CPU in the Remote mode F0007 User memory installation Turns on when a user memory is installed F0008 and F0009 Unused F000A User memory operation Turns on when a user memory is being operated F000B to F000E Unused FOOOF Execution of the STOP instruction Turns on when the STOP instruction is being operated F0010 Always On Always On F0011 Always Off Always Off F0012 1 Scan On 1 Scan On F0013 1 Scan Off 1 Scan Off F0014 Scan toggle Scan toggle F0015 to F001F Unused F0020 1 step run Turns on when the 1 step run is operated in the Debug mode F0021 Breakpoint run Tums on when the breakpoint run is operated in the Debug mode F0022 Scan run Turns on
169. tions 0026h dus uiu Stop FMM 3 PARA Error FMM 3 Parameter Error Correct the parameter A digit of other than 0 to 9 has met during BCD conversion 0030h Operation Error Stop Operation Error 2 Correct the content of the e An operand value is outside the error step defined operand range Pon Check the maximum scan ontinue i i 0031h WDT Over WDT Over Error Scan time has overrun the watch dog time of the program and stop time modify the program or insert programs Program replacement has Error of Program An error has occurred at program not been completed during 0032h Change during Stop PGM Change Error change during run NO SBRT JME run JMP JME FOR run and END NEXT CALLx and SBRTx 0033h de Check Continue Code Check Error An error has occurred while checking Correct the error rror a program 0040h Code Check Error Stop Code Check Error SUM unreadable Dy OP Correct the error step Missing the END Insert the END instruction 0041h instruction in the Stop Miss END Error eae does NOthave Me END at the bottom of the program program Missing the RET Insert the END instruction 0042h instruction in the Stop Miss RET Error The subroutine does riot hasithe RET at the bottom of the instruction at its bottom program program Missing the SBRT 0043h instruction in the Stop Miss SBRT Error The subroutine does not has the Insert the SBRT subroutine SBRT instruction instruction program oo44n TPEJMP JME Stop JMP E Er
170. tput In current output digital amount 0 exchanges to OmA and 4 000 does 20mA Analog amount of digital input 1 equals to 5 uh 7 5 6 Chapter 7 Usage of Functions 8 Program example 1 Distinction program of A D conversion value a Program explanation When digital value of channel 0 is less than 2000 P090 is on when digital value of channel 0 is more than 3000 P091 is on When digital value of channel 0 is more or same than 2000 or lesser than 3000 P092 is on b System configuration Base Unit AlD D A mixture module Expansion unit output 1 0 allocation Base unit input P000 PO3F Base unit output P050 PO7F A D D A mixture module P080 PO8F Expansion unit output P090 PO9F c Program 7 57 Chapter 7 Usage of Functions 2 Program which controls speed of inverter by analog output voltage of 5 steps a Program explanation When P80 becomes On 2000 5V is output When P81 becomes On 2400 6V is output When P82 becomes On 2800 7V is output When P83 becomes On 3200 8V is output When P84 becomes On 3600 9V is output b System configuration Base Unit A D D A mixture module Digital extended module c Program 7 5 8 Chapter 7 Usage of Functions 7 2 2 AID Conversion module 1 Performance specifications The performance specifications of the analog input module are following Item Specifications Voltage 0 10VDC input resistance more than 1 M9
171. troller T191 192 points S99 100 x 100 steps T192 00 00 S99 99 Timer relay 10ms T255 64 points C000 Counter relay C255 256 points 5 24 Chapter 5 CPU Module 5 7 I O No Allocation Method I O No allocation means to give an address to each module in order to read data from input modules and output data to output modules Max 3 expansion module is available Mounting module No of module can be mounted remark Expansion I O module 2 A D conversion module 2 Analog timer module 3 Communication module 1 1 0 No allocation method module area remark Main Input P000 PO3F Fixed 64 points Output P040 PO7F Fixed 64 points Expansion 1 Input P080 PO8F Fixed 16 points Output P090 PO9F Fixed 16 points Expansion 2 Input P100 P10F Fixed 16 points Output P110 P11F Fixed 16 points Expansion 3 Special None A D A T Communication Basically I O allocation is fixed point method the area which is not used can be used internal relay The special module is not allocated 5 25 Chapter 5 CPU Module 5 8 Built in Flash Memory MK80S series includes a built in flash memory to store user program Also user can set the PLC automatically executes the user program of flash memory when the PLC is turned on It is similar with the ROM operation of other PLCs but it is different that no external memory is required 5 8 1 Structu
172. uction format of HSC is as following When the value of operation mode D4999 PV or SV is not proper the instruction error flag F110 turns on and the HSC instruction is not executed Operation mode Input terminal Tod r Multiplication Description D4999 A phase B phase Preset wae Pulse U D Set by sequence program input PR Set by sequence program U D Set by sequence program h1010 Pulse Preset input din e input PR Set by preset input s UID Set by UID input Se inpu n1100 Puise UD input ped input PR Set by sequence program U D Set by U D input nito PSE Wp input Preset input k ead input PR Set by preset input h2001 A phase B phase PR Set by sequence program input input 1 multiplication x PR Set by sequence program h2002 A phase B phase 2 ae q prog input input 2 multiplication PR Set by sequence program h2004 A phase B phase _ 4 ce q prog input input 4 multiplication PR Set by preset input Se reset inpu n2014 Phase B phase preset input ROM input input 1 multiplication PR Set by preset input h2012 Phase B phase Preset input 2 G input input 2 multiplication PR Set by preset input h2014 Phase B phase preset input 4 uin D input input 4 multiplication Remark The U D and PR input of sequence program must be programmed with dummy input e
173. uilt in communication and Cnet I F module G7L CUEC RS232C Modem Dedicated Line It s to be selected for the communication using an dedicated modem with Cnet I F module G7L CUEB RS232C Dial Up Modem It s to be selected for the general communication connecting through the telephone line by dial up modem and Cnet I F module G7L CUEB Footnote Using Cnet I F module G7L CUEB supporting RS232C RS232C dedicated or dial up modem communication can be done but not through Cnet I F module G7L CUEC supporting RS422 485 Timeout in Master Mode It s the time waiting a responding frame since the master MK80S base unit sends a request frame The default value is 500ms It must be set in consideration of the max periodical time for sending receiving of the master PLC _Ifits set smaller than the max send receive periodical time it may cause communication error User Define Master Slave If it is set as the master it s the subject in the communication system If it s set as the slave it only responds to the request frame of the master 8 48 Chapter 8 Communication Function 2 Setting frame 1 Select one out of user defined terms of protocol and mode in communication parameter registration List button is activated E us oi 2 Click List button to activate the following window 3 Select one of 1 15 in frame list to open the following window Chapter 8 Comm
174. unication Function D Frame specification Header Used in Header type Possible characters as headers are 1 alphabet letter 1 numeric number or control characters as below Control character Available Control Code NUL h00 STX h02 ETX h03 EOT h04 ACK h06 NAK h15 SOH h01 ENQ h05 BEL h07 BS h08 HT h09 LF h0A VT h0B FF hOC CR hOD SO hOE 1 h0F DLE h10 DC1 h18 DC2 h12 DC3 h13 DC4 h14 SYN h16 ETB h17 CAN h18 EM h19 SUB h1A ESC h1B FS h1C GS h1D RS h1E US h1F Del H7F Example 1 NUL ENQ 1 A Possible Example 2 NUL ENQ 12 ABC impossible tisallowed to be only 3 consecutive characters Example 1 ENQ STX NUL Possible Example 2 AJ NUL ENQ STX impossible Send Receive Not defined It is the initial value that doesn t declare a frame format Send It is that declares send frame Receive It is that declares receive frame When Frame 0 window is activated Tx Rx term is set as Not defined and all the segments are not in activation Chapter 8 Communication Function Segment 1 8 Enter segment by segment to separate fixed sending data area CONSTANT and device area Array To set a segment type there re NONE not defined CONST fixed data area ARRAY Device area CONST declares commands and fixed data that are used for communication frame and ARRAY is used to input and save the data needed for interactive co
175. unications cables Display states of various indicators such as POWER LED RUN LED ERR LED and I O LED Afte r checking them connect peripheral devices and check the operation status of the PLC and the prog ram contents 2 Trouble Check Observe any change in the error conditions during the following Switch to the STOP position and then turn the power on and off 3 Narrow down the possible causes of the trouble where the fault lies i e e Inside or outside of the PLC e O module or another module e PLC program 11 2 Troubleshooting This section explains the procedure for determining the cause of troubles as well as the errors and corrective actions 5 Flowchart used when the POWER LED is turned OFF 5 Flowchart used when the ERR LED is flickering p Flowchart used when the RUN turned OFF Flowchart used when the output load of the output module perly doesn t turn on Program cannot be written E Flowchart used when a program can t be written to the PLC 11 1 Chapter 11 Troubleshooting 11 2 1 Troubleshooting flowchart used when the POWER LED turns OFF The following flowchart explains corrective action procedure used when the power is supplied or the power led tums off during operation Power LED is turned OFF Is the power supply operating Supply the power Does the power led turn on See the power supply be within AC 110 240 V Does the power led turn on Is the fuse blown
176. upt The TDI programs are executed with a constant time interval specified with program TDI parameter setting Process driven interrupt program PDI Subroutine program The PDI programs are executed only external interrupt input is applied and the corresponding interrupt routine is enabled by EI instruction The subroutine programs are executed when they are called by the scan program with a CALL instruction 5 3 2 Processing method The following diagram shows that how the CPU module process programs when the CPU module is powered on or switched to RUN mode Start operation Subroutine program PDI program Scan program TDI program END processing 5 11 Chapter 5 CPU Module 5 3 3 Interrupt function When an interrupt occurs the CPU module will stop the current operation and execute the corresponding interrupt routine After finish the interrupt routine the CPU resume the sequence program from the stopped step MASTER K series provides 2 types of interrupt The TDI Time driven interrupt occurs with the constant period and PDI Process driven interrupt occurs with the status of external input Before to use interrupt function in sequence program the parameter setting should be done properly Then the corresponding interrupt routine should be written after END instruction Refer chapter 4 for details If interrupt routines are not matched with parameter settings an error occurs an
177. urrent value will not be clear when the input condition of TMR instruction is turned off It keeps the elapsed value and restart to increase when the input condition is turned on again When the current value reaches preset value the timer output relay is turned on The current value can be cleared by the RST instruction only Timer input condition UEM eee Timer output relay Timer reset input Preset value PV PT t1 t2 t3 Current value 4 Monostable timer In general its operation is same as off delay timer However the change of input condition is ignored while the timer is operating decreasing Timer input condition Timer output relay Preset value PV Current value Chapter 5 CPU Module 5 Retriggerable timer The operation of retriggerable timer is same as that of monostable timer Only difference is that the retriggerable timer is not ignore the input condition of TRTG instruction while the timer is operating decreasing The current value of retriggerable timer will be set as preset value whenever the input condition of TRTG instruction is turned on Timer input condition Timer output relay Preset value PV Current value REMARK The accuracy of timer The Maximum timing error of timers of MASTER K series is 2 scan time 1 scan time Refer the programming manual for details 5 8 Chapter 5 CPU Module 5 2 5 Counter Processing The counter counts the
178. ut refresh is executed 2 Operation processing contents 1 I O refresh is executed by one time every scan 2 Communications service or other internal operations are processed 5 16 Chapter 5 CPU Module 3 Debug operation conditions Two or more of the following four operation conditions can be simultaneously specified Operation conditions Description Executed by the one step operation Executes just an operation unit one step Executed to the ine l Executes user program until the specified step break point specified breakpoint Executed according to Execute user program until a device bit or word assigned is changed to the specified status the device status Executed by the specified scan numbe Execute user program for specified number of scans r 4 Operation method 1 Execute the operation after the debug operation conditions have been set in the KGLWIN 2 In interrupt programs each task can be specified to operation enable disable For detailed operation method refer to the KGL WIN Users Manual Chapter 9 Debugging 5 4 5 Operation mode change 1 Operation mode change methods The following method is used to change the operation mode 1 Change by the mode setting switch of CPU module 2 3 4 Change by the STOP instruction during program execution Change by the KGLWIN connected with the CPU module communications port 1 2 3 Change by the KGLWIN connected to
179. ven they are set as external input When the PR and or U D is set as external input the input conditions of sequence program is ignored 7 4 Chapter 7 Usage of Various Functions 1 EN input Counter enable When the EN input turns on the counter starts counting pulse When the EN is off the counting is stopped and the current value of high speed counter is cleared as 0 2 UID input Up down When the U D input is off the high speed counter operates as up counter When the U D is off it operates as down counter 3 PR input Preset When the PR input is on the current value of high speed counted is replaced with the preset value PV 4 Output relay F0170 The F070 bit will be turn on when the current value of high speed counter F18 lower word F19 upper word is equal of greater than the set value SV 5 Carry flag F0171 The carry flag turns on when the current value of high speed counter is underflow 0 gt 16 777 215 during down counting or overflow 16 777 215 gt 0 during up counting 6 Current value The current value of high speed counter is stored at two words F18 and F19 The lower word is stored at F18 and upper word is stored at F19 7 5 Chapter 7 Usage of Various Functions 8 example program 1 1 phase operation mode U D by program D4999 h1010 U D set by sequence program M001 PR set by external PR input Ladder diagram F12 L3 MOV h1010 D4999 m 3
180. ward reverse operation control Master K exclusive protocol support MODBUS protocol support User s protocol support Capacity 1 phase 16 kHz 1 channel 2 phase 8 kHz 1 channel It has 3diffferant counter function as following 1 phase up down by program 1 phase up down by B phase input 2 phase up down by phase difference function function preset value Minimum pulse width 0 2msec 8 points Pulse output External interrupt 8points 0 4ms Input filter Weight g K7M DR10S K7M DR20S K7M DR30S K7M DR40S K7M DR60S G7E DR10A 2khz 0 5 2 Common use with KGLWIN port Transistor output onl Chapter 5 CPU Module 5 2 Operation Processing 5 2 1 Operation Processing Method 1 Cyclic operation A PLC program is sequentially executed from the first step to the last step which is called scan This sequential processing is called cyclic operation Cyclic operation of the PLC continues as long as conditions do not change fo r interrupt processing during program execution This processing is classified into the following stages Processing Operation Start Stage for the start of a scan processing it is executed only o ne time when the power is applied or reset is executed It exe Initialization cutes the following processing gt I O reset gt Execution of self diagnosis gt Data cle
181. when the scan run is operated in the Debug mode F0023 Coincident junction value run Turns on when the coincident junction run is operated in the Debug mode F0024 Coincident word value run Turns on when the coincident word run is operated in the Debug mode F0025 to F002F Unused F0030 Fatal error Turns on when a fatal error has occurred F0031 Ordinary error Turns on when an ordinary error has occurred F0032 WDT Error Turns on when a watch dog timer error has occurred F0033 l O combination error Turns on when an I O error has occurred When one or more bit s of F0040 to FOOSF turns on F0034 Battery voltage error Turns on when the battery voltage has fallen below the defined value F0035 Fuse error Tums on when a fuse of output modules has been disconnected F0036 to F0038 Unused F0039 Normal backup operation Turns on when the data backup is normal F003A RTC data error Turns on when the RTC data setting error has occurred F003B During program edit Turns on during program edit while running the program F003C Program edit error i a program edit error has occurred while running F003D to F003F Unused App2 3 Appendix 2 Flag List Continued Relay Function Description When the reserved I O module set by the parameter differs F0040 to FOOSF I O error from the real loaded I O module or a I O module has been mounted or dismounted
182. y forward and reverse actions respectively temperature time Reverse action for Cooling Forward action for Heating Fig 2 10 PV of forward reverse action Reference value In general feedback control system shown as the Figure 2 10 the deviation value is obtained by the difference of PV and SV P I and D operations are performed based on this deviation value However each of P and D operations use different deviation values according to the characteristics of each control actions The expression of PID control is as following lo x dEd MV K i Eis ds Ta Za MV Manipulate value K Proportional gain Ti Integral time Td Derivative time Ep Deviation value for proportional action Ei Deviation value for integral action Ed Deviation value for derivative action The deviation values of P I and D action is described as following equations Ep bx SV PV Ei SV PV Ed PV The b of the first equation is called as reference value It can be varied according to the load disturbance of measurement noise SV MV PV PID m Process Fig 2 411 Diagram of simple feedback system 7 3 2 Chapter 7 Usage of Various Functions 9 The figure 2 11 shows the variation of PV according to the several different reference values b As shown in the Fig 2 11 the small reference value produces small deviation value and it makes the control system response be sl
183. y part Approximately 70 of the power supply module current is converted into power 35 of that 65 dissipated as heat i e 3 5 6 5 of the output power is actually used e Wow 3 5 6 5 lv x 5 laav x 24 W where l5v 5VDC circuit current consumption of each part 124v 24VDC circuit average current consumption of output part with points simultaneously switched ON Not for 24VDC power supplied from external or power supply part that has no 24VDC output 2 Total 5VDC power consumption The total power consumption of all modules is the power of the 5VDC output circuit of the power supply part eWsvzlvx 5 W 3 Average DC24V power consumption with points simultaneously switched ON The total power consumption of all modules is the average power of the DC24V output circuit of the power supply part e Wav lav X 24 W 4 Average power consumption by voltage drop of output part with points simultaneously switched ON Wout lout X Varop 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 9 Installation and Wiring 5 Average power consumption of input parts with points simultaneously ON e Win lin x E x inputpoints x the rate of points switched on simultaneously W E input current effective value for AC A E input voltage actual operating voltage V 6 Power consumption of the speci
184. ytes Built in function High speed counter Phase1 16 kHz phase2 8 kHz 1channel pulse output 1 x 2kHz pulse catch pulse width 0 2ms 4 points external contact point interrupt 0 4ms 8points input filter 0 15ms all input PID control function RS 232C communication K7M DR30S K7M DR30S DC K7M DT30S O Points 18 DC inputs 12 relay outputs K7M DR30S K7M DR30S DC 18 DC inputs 12 TR outputs K7M DT30S Program capacity 48 kbytes Built in function High speed counter Phase1 16 kHz phase2 8 kHz 1channel pulse output 1 x 2kHz pulse catch pulse width 0 2ms 4 points external contact point interrupt 0 4ms 8points input filter 0 15ms all input PID control function RS 232C communication 2 6 Section Items Models Description Remark Basic Base Unit K7M DR40S K7M DR40S DC K7M DT40S O Points 24 DC inputs 16 relay outputs K7M DR40S K7M DR40S DC 24 DC inputs 16 TR outputs K7M DT40S Program capacity 48 kbytes Built in function High speed counter Phase1 16 kHz phase2 8 kHz 1channel pulse output 1 x 2kHz pulse catch pulse width 0 2ms 4 points external contact point interrupt 0 4ms 8points input filter 0 15ms all input PID control function RS 232C communication K7M DR60S K7M DR60S DC K7M DT60S 1 0 Points 36 DC inputs 24 relay outputs K7M DR60S K7M DR60S DC 36 DC inputs 24

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