MASTER-K120S

Programmable Logic Controller

Read this manual carefully installing,operating, wiring, servicing inspecting this equipment. Keep this manual within easy reach for quick reference.

before or

SAFETY INSTRUCTIONS
To Prevent injury and property damage, follow these instructions. Incorrect operation due to ignoring instructions will cause harm or damage, the seriousness of which is indicated by the following symbols
.

This WARNING symbol indicates the possibility of death or serious injury

CAUTIONThis symbol indicates the possibility of injury or damage to property.

The meaning of each symbol in this manual and on your equipment is follows as This is the safety alert symbol. Read and follow instructions carefully to avoid dangerous situation.
.

This symbol alerts the user to the presence of dangerous voltage inside the product that might cause harm or electric shock.

SAFETY INSTRUCTIONS Design Precautions Warning

Install a safety circuit external to the PLC that keeps the entire system safe even when there are problems with the external power supply or the PLC module. Otherwise, serious trouble could result from erroneous output or erroneous operation.
- Outside the PLC, construct mechanical damage preventing interlock circuits such as emergency stop, protective circuits, positioning upper and lower limits switches and interlocking forward/reverse operation. When the PLC detects the following problems, it will stop calculation and turn off all output in the case of watchdog timer error, module interface error, or other hardware errors. However, one or more outputs could be turned on when there are problems that the PLC CPU cannot detect, such as malfunction of output device (relay, transistor, etc.) itself or I/O controller. Build a fail safe circuit exterior to the PLC that will make sure the equipment operates safely at such times. Also, build an external monitoring circuit that will monitor any single outputs that could cause serious trouble.

Make sure all external load connected to output does NOT exceed the rating of output module.
Overcurrent exceeding the rating of output module could cause fire, damage or erroneous operation.

Build a circuit that turns on the external power supply when the PLC main module power is turned on.
If the external power supply is turned on first, it could result in erroneous output or erroneous operation.

SAFETY INSTRUCTIONS Design Precautions Caution

Do not bunch the control wires or communication cables with the main circuit or power wires, or install them close to each other. They should be installed 100mm (3.94inch) or more from each other.
Not doing so could result in noise that would cause erroneous operation.

Installation Precautions Caution

Use the PLC in an environment that meets the general specification contained in this manual or datasheet.
Using the PLC in an environment outside the range of the general specifications could result in electric shock, fire, erroneous operation, and damage to or deterioration of the product.

Completely turn off the power supply before loading or unloading the module.
Not doing so could result in electric shock or damage to the product.

Make sure all modules are loaded correctly and securely.

Not doing so could cause a malfunction, failure or drop.

Make sure I/O and extension connector are installed correctly.

Poor connection could cause an input or output failure.

When install the PLC in environment of much vibration, be sure to insulate the PLC from direct vibration.
Not doing so could cause electric shock, fire, and erroneous operation.

Be sure to there are no foreign substances such as conductive debris inside the module.
Conductive debris could cause fires, damage, or erroneous operation.

SAFETY INSTRUCTIONS Wiring Precautions Warning

Completely turn off the external power supply when installing or placing wiring.
Not doing so could cause electric shock or damage to the product.

Make sure that all terminal covers are correctly attached.

Not attaching the terminal cover could result in electric shock.

Caution
Be sure that wiring is done correctly be checking the products rated voltage and the terminal layout.
Incorrect wiring could result in fire, damage, or erroneous operation.

Tighten the terminal screws with the specified torque.

If the terminal screws are loose, it could result in short circuits, fire, or erroneous operation.

Be sure to ground the FG or LG terminal to the protective ground conductor.

Not doing so could result in erroneous operation.

Be sure there are no foreign substances such as sawdust or wiring debris inside the module.
Such debris could cause fire, damage, or erroneous operation.

SAFETY INSTRUCTIONS Startup and Maintenance Precautions Warning

Do not touch the terminals while power is on.
Doing so could cause electric shock or erroneous operation.

Switch all phases of the external power supply off when cleaning the module or retightening the terminal or module mounting screws.
Not doing so could result in electric shock or erroneous operation.

Do not charge, disassemble, heat, place in fire, short circuit, or solder the battery.
Mishandling of battery can cause overheating or cracks which could result in injury and fires.

Caution
Do not disassemble or modify the modules.
Doing so could cause trouble, erroneous operation, injury, or fire.

Switch all phases of the external power supply off before mounting or removing the module.
Not doing so could cause failure or malfunction of the module.

Use a cellular phone or walky-talky more than 30cm (11.81 inch) away from the PLC
Not doing malfunction. so can cause a

Disposal Precaution Caution

When disposing of this product, treat it as industrial waste.
Not doing so could cause poisonous pollution or explosion.

Revision History
Date Code Revision history 2002.7. 10310000380 First edition is published 2003.5. 10310000380 A revised edition is published Main unit and expansion modules are added Built-in function are upgraded 2003.9 10310000380 A revised edition is published. Main units are added Built-in functions are upgraded.

Contents
Chapter 1. General 1.1 Guide to Use This Manual 1.2 Features 1.3 Terminology Chapter 2. System Configuration 2.1 Overall Configuration
1-1 1-2 1-3

2-1 2-1 2-2 2-4 2-4 2-5

2.1.1 Basic System 2.1.2 Cnet I/F System

2.2 Product Functional Model 2.2.1 Product Functional

Block 2.2.2 MASTER-K120S Series System Equipment Product

Chapter 3. General Specifications 3.1 General Specifications Chapter 4. Names of Parts 4.1 Main Unit
4.1.1 60 (Standard) 4.1.2 40 Points Points Points Points Points Points Points Points Main Main Main Main Main Main Main Main (Standard) 4.1.3 30 (Standard) 4.1.4 20 (Standard) 4.1.5 30 (Economic) 4.1.6 20 (Economic) 4.1.7 14 (Economic) 4.1.8 10 (Economic) 3-1

4-1 4-2 4 -3 4-4 4-5 4-6 4 -7 4-7 4-7 4-8 4-8 4-8 4-9 4 - 10 4 - 10 4 - 11 4 - 11 4 - 12 4 - 12

Unit Unit Unit Unit Unit Unit Unit Unit

4.2 Expansion I/O Module 4.2.1 20 Point I/O Module

4.2.2 10 Point I/O Module 4.2.3 8 Point I/O Module

4.3 Special Module 4.3.1 A/DD/A Combination

Module 4.3.2 D/A Conversion Module 4.3.3 A/D Conversion Module Analog 4.3.4 Timer Module 4.3.5 RTD Input Module

4.4 Communication I/F Module 4.4.1 Cnet I/F Module

4.4.2 Fnet I/F Module 4.4.3 Pnet I/F Module 4.4.4 DeviceNet Module I/F

4 - 13 4 - 13 4 - 13 4 - 14 4 - 14 4 - 14

4.5 Option Module Chapter 5. Power Supply / CPU 5.1 Power Supply Specifications 5.1.1 Standard 5.2 CPU Specifications
5.2.1 Type 5.2.2 Type Type 5.3.2 Type Economic

5-1 5-1 5-1 5-2 5-2 5-4 5 -6 5-6 5-7 5-8 5-8 5-9 5 - 12 5 - 14 5 - 14 5 - 14 5 - 15 5 - 17 5 - 19 5 - 19 5 - 20 5 - 20 5 - 20 5 - 21 5 - 23 5 - 23 5 - 24 5 - 27 5 - 27 5 - 28 5 - 29 5 - 30 5 - 30

Standard

Economic

5.3 Operation Processing

5.3.1 Operation Processing Method 5.3.2 Operation Processing at Momentary Power Failure OccurrenceTime 5.3.3 Scan 5.3.4 Timer 5.3.5 Scan Watchdog Timer Counter

5.4 Program 5.4.1Classifications of

Program 5.4.2 Program Execution Procedure 5.4.3 Interrupt

Processing 5.3.6 Processing

5.5 Operation Modes

Programs 5.4.4 Handling

Error

5.5.1 RUN ModeSTOP Mode 5.5.2 5.5.3 PAUSE Mode DEBUG Mode(Standard Type 5.5.4 Only) 5.5.5 Operation Mode Change

5.6 Function Self- 5.6.1

diagnosis 5.6.2 I/O Force On/Off function 5.6.3 Direct I/O Operation function System 5.6.4 error

5.7 Memory Configuration 5.8 I/O Address Allocation 5.9 Built-in Cnet Selection switch 5.9.1
Structure

history

 5.10 External Memory Module 5.10.1 5.11 RTC Module 5.11.1

Structure 5.11.2 Usage Structure 5.10.2 Usage

5.9.2 Usage

5 - 30 5 - 32 5 - 32 5 - 32 5 - 34 5 - 34 5 34

Chapter 6. Input and Output Modules 6.1 Input / Output Specifications 6.2 Digital Input Specifications 6.2.1 Main Unit 6.3 Digital Output Specification 6.3.1 Main Unit (Relay
Output) 6.3.2 Main Unit (Tr Output :DRT/DT Type Only) 6.3.3 Expansion Module 6.2.2 Module Expansion

6-1 6-2 6-2 6-5 6-6 6-6 6-9 6 - 11

Chapter 7. Usage of Various Functions 7.1 Built-in Functions

7-1 7-1 7 - 14 7 - 16 7 - 17 7 - 19 7 - 39 7 - 40 7 - 49 7 - 55 7 - 61 7 - 63 7 - 69 7 - 69 7 - 72 7 - 85 7 - 91 7 - 100 7 - 104

7.1.1 High Speed Counter Function Pulse 7.1.2 Catch Function Filter Function 7.1.3 Input 7.1.4 External Interrupt Function 7.1.5 PID Control Function(Standard Type Only) 7.2.1 A/DD/A Combination Module 7.2.2 A/D Conversion Module D/A 7.2.3 Conversion Module 7.2.4 Analogue Timer RTD 7.2.5 input Module

7.2 Special Module

7.3 Positioning Function(DRT /DTtype only) 7.3.1

Specification 7.3.2 Positioning Function 7.3.3 Positioning parameter and Operation Data 7.3.4 Instructions 7.3.5 Flag list and Error code 7.3.6 Wiring with servo and stepping motor driver

Chapter 8. Communication Function 8.1 Dedicated Protocol Communication 8.1.1

Introduction 8.1.2 System configuration method 8.1.3 Frame Structure 8.1.4 Lists of Commands 8.1.5 Data Type 8.1.6 Execution of Commands 1:n Built-in Communication between MASTER8.1.7 1:1,

8-1 8-1 8-2 8-5 8-7 8-8 8-9 8 - 28 8 - 38 8 - 39 8 - 39 8 - 39 8 - 47 8 - 48 8 - 57 8 - 57 8 - 57 8 - 60 8 - 62 8 - 67 8 - 67 8 - 68 8 - 69 8 - 71 8 - 73 8 - 73 8 - 76

8.2 User Defined Protocol Communication

8.2.1 Introduction Parameter 8.2.2 Setting 8.2.3 Instruction 8.2.4 Example of

K120Ss 8.1.8 Codes

Error

8.3 Modbus Protocol Communication 8.3.1

Introduction 8.3.2 Basic Specifications 8.3.3 Parameter

usage

8.4 No Protocol Communication 8.4.1

Introduction 8.4.2 Parameter Setting 8.4.3

Setting 8.3.4 Instruction examples

and

8.5 Remote Connection and Communication I/F module

8.5.1 Remote Connection 8.5.2 Communication I/F Module

Instructions 8.4.4 Examples

Chapter 9. Installation and Wiring 9.1 Installation

9.1.1 Environment 9.1.2 Instructions 9.1.3 Connection Module of

9-1 9-1 9-3 9-6 9-7 9-7 9-8 9-9 9-9

Installation Expansion

Handling

9.2 Wiring

9.2.1 Power Supply Wiring Input and Output Devices 9.2.2 Wiring 9.2.3 Grounding 9.2.4 Cable Specifications for wiring

Chapter 10. Maintenance 10.1 Maintenance and Inspection 10.2 Daily Inspection 10.3 Periodic Inspection Chapter 11. Troubleshooting 11.1 Basic Procedure of Troubleshooting 11.2 Troubleshooting 11.2.1 Troubleshooting flowchart used when the power LED turns
off 11.2.2 Troubleshooting flowchart used when the error LED is flickering 11.2.3 Troubleshooting flowchart used when the RUN LED turns off 11.2.4 Troubleshooting flowchart used when the I/O devices doesnt operate

10 - 1 10 - 1 10 - 2

11 - 1 11 - 1 11 - 2 11 - 3 11 - 4 11 - 5 11 - 7 11 - 8 11 - 9 11 - 9 11 - 10 11 - 12

11.3 Troubleshooting Questionnaire 11.4 Troubleshooting Examples 11.4.1 Input circuit troubles and corrective 11.5 Error code list

normally 11.2.5 Troubleshooting flowchart used when a program cant be written to the CPU

actions Output circuit troubles and corrective 11.4.2 actions

Appendix Appendix 1 System Definitions Appendix 2 Flag Lists Appendix 3 Dimensions

App11 App21 App31

Chapter 1 General

Chapter 1. General
1.1 Guide to Use This Manual

This manual includes specifications, functions and handling instructions for the MASTER-K120S series PLC. This manual is divided up into chapters as follows: No. Contents Title

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-K120S series. Chapter 3 General Specification Describes general specifications of units used in the MASTER-K120S series. Chapter 4 Names of Parts Describes each kind of manufacturing goods, titles, and main functions Chapter 5 Power Supply / CPU Chapter 6 Input and Output Chapter 7 Usage of Various Functions Describes each kind of manufactured goods' usage

Chapter 8 Communication Function Describes built-in communication functions

Chapter 9 Installation and Wiring Describes installation, wiring and handling instructions for reliability of the PLC system Describes the check items and method for long-term normal operation of the PLC system.

Chapter 10 Maintenance

Chapter 11 Troubleshooting Describes various operation errors and corrective actions. Appendix 1 System Definitions Describes parameter setting for basic I/O and communications module Appendix 2 Flag List Describes the types and contents of various flags. Appendix 3 Dimensions Shows dimensions of the main units and expansion modules

REMAR K -. This manual does not describes the programming method. For their own functions, refer to the related user's manuals.

1-1

Chapter 1 General

1.2. Features
1) MASTER-K120S series is extremely compact, to fit a wide range of applications and have following features. (1) High speed processing High speed processing ofs/step with an general purpose processor 0.1~0.9 included . (2) Various built-in functions The main unit can perform many functions without using separate modules. Therefore, It is possible to construct various systems just using the main unit. Fast Processing Applications - Pulse catch: Allows the main unit to read a pulse which has width as small as 10 . - High speed counter(Economic): Support high-speed counting up to 100(10)kHz for 1 phase, 50(5)kHz for 2 phase. - External interrupts : Using in applications that have a high-priority event which requires immediate responses. The input filter function help reduce the possibility of false input conditions from external noise, such as signal chattering. The filter time can be programmed from 0 to 1000ms. Using RS-232C and RS-485 built-in port, MASTER-K120S can connects with external devices, such as personal computers or monitoring devices and communicate 1:N with MASTER-K120S system. Using built-in PID control function, PID control system can be constructed without using separate PID module. Using built-in Positioning function, position control system can be constructed without using separate position control module.(only DRT/DT type has built-in positioning function) (3) Batteryless The users program can be saved permanently, because it is stored to EEPROM. (4) When program is edited during processing, it is stored to EEPROM automatically (5) Open network by use of communication protocols in compliance with international standard specifications. (6) Various special modules that enlarge the range of application of the PLC (7) It can easily do On/Off of the system, using RUN/STOP switch. (8) It can easily save the user program in EEPROM by simple manipulation in KGLWIN without using external memory. (9) Strong self-diagnostic functions It can detect the cause of errors with more detailed error codes. (10) It can prevent unintentional reading and writing, using password. (11 Debugging function(Standard ) type) On-line debugging is available when the PLC Operation mode is set to debug mode. executed by one command. executed by break-point settings. executed by the condition of the device executed by the specified scan time. (12) Various program execution function External and internal interrupt program as well as scan program can be executed by setting the execution condition. Therefore, user can set variously program execution mode. 1-2

Chapter 1 General

1.3 Terminology
The following table gives definition of terms used in this manual. Terms Remarks Modul e Definition A standard element that has a specified function which configures the system. Devices such as I/O board, which inserted onto the mother board unit. or base Example ) CPU module Power Supply module I/O module Example ) Main unit

Unit A single module or group of modules that perform an Operation as a part of PLC independent system. PLC system A system which consists of the PLC and peripheral devices. A user can control the program system. KGLWIN A program and debugging tool for the MASTER-K series. It program creation, edit, compile and debugging(A computer executes software). KLD-150S debugging A hand-held loader used for program creation, edit, compile and 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 program is not completed within the pre-set if a time. FAM Abbreviation of the word Factory Automation Monitoring S/W. It is used call S/W packages for process to supervision. Fnet network Fieldbus

Cnet Computer 422/485)

network(RS-232C,

RS-

RTC Abbreviation of Real Time Clock. It is used to call general IC contains clock that function.

1-3

Chapter 1 General

Terms Remarks

Definition Current flows from the switch to the PLC input terminal if a input signal turns on.

Sink Input

Current flows from the PLC input terminal to the switch after a input signal turns on.

Sourc eInput

Current flows from the load to the output terminal and the PLC output turn on.
Output Contact

Sink Output

Current flows from the output terminal to the load and the PLC output turn on.

Sourc e utput O

Output Contact

1-4

Chapter 2 Configuration

System

Chapter 2. Configuration

System

The MASTER-K120S series has suitable to configuration of the basic, computer link and network systems. This chapter describes the configuration and features of each system.

2.1 Overall Configuration

2.1.1 Basic system
Main expansion unit module

expansio nabl c e Total points Maximum number of expansion modules I/O Digital module I/O 10-120 points 3 modules 3 modules 3 modules 1 module

Standard Economic

2 modules 2 modules 2 modules 1 modules

A/D-D/A module Analog timer Cnet I/F module Economi c unit Digital I/O module Analog I/O module Analog timer Resistance Temperature Detactor Cnet I/F modules DeviceNet I/F module FieldBus I/F module Profibus Module RTC I/F

Main Standard

Expansio n module Items Communic ation I/F module Option module Memory

K7MDR10/14/20/30UE K7MDR//DRT/DT20/30/40/60U G7E-DR10A, G7E-DR20A, G7E-TR10A, G7E-DC08A, G7ERY08A G7F-ADHA, G7F-ADHB, G7F-AD2A, G7F-DA2I, G7FDA2V G7FAT2A G7FRD2A G7L-CUEB, G7LCUEC G7LDBEA G7LFUEA G7LPBEA G7ERTCA G7MM256B 2-1

Chapter 2 Configuration 2.1.2 Cnet system

System

I/F

Cnet I/F System is used for communication between the main unit and external devices using RS-232C/RS-422 Interface. The MK120S has a built-in RS-232C port, RS-485 port and has also G7L-CUEB for RS-232C, G7L-CUEC for RS-422. It is possible to construct communication systems on demand. 1) 1:1 system Communications

(1) 1:1 ratio of an external device (computer) to main unit using a built-in port MASTERK120S

RS-232C

Monitoring Device

RS-485

(2) 1:1 ratio of an external device (monitoring unit) to main unit using a built-in RS-485 port

RS-485 MASTER-K120S K120S MASTER-

Monitoring Device RS-232C

2-2

Chapter 2 Configuration

System

(3) RS-232C Communication over a long distance via modem by Cnet I/F modules MASTER-K120S G7L-CUEB MASTERK120S CUEB G7L-

Modem Modem

MASTERK120S

G7LCUEB

Modem

Modem

2) 1:n Communications system This method can connect between one computer and multiple main units for up to 32 stations

Can be connected Max. 32 stations

RS-232C Converter

RS-422

G7LCUEC

G7LCUEC

MASTER-K120S

MASTER-K120S

MASTER-K120S

RS-232C

RS-485

Converter Built-in RS-485 Built-in RS-485 Built-in RS-485

* Refer details.

to

chapter 8. communication function for 2-3

Chapter 2 Configuration

System

2.2 Product Functional Model

The following describes functional model of the MASTERK120Sseries.

2.2.1 Product Functional Block

Product function block for the K120S series is as follows. Main Unit Modules Power supply Expansion

Input signal

Input signal

Powe r supply
DC24V
Power supply

Input

Input

CPU

Special/communicatio n modules

Comm. I/F

Output

Output

Built-in RS-485

Built-in RS-232C I/F

Output signal

Output signal

Sub-system Description CPU

Input

Output

Power Supply Communicatio n Interfac e

Signal processing function -. Operating system function -. Application program storage / memory function -. Data storage / memory function -. Application program execution function The input signals obtained from the machine/process to appropriate signal levels for processin g The output signals obtained from the signal processing function to appropriate signal levels to drive actuators and/or displays Provides for conversion and isolation of the PLC system power from the main supply Provides the data exchange with other systems or PADT, such as KGLWIN, personal computer s

2-4

Chapter 2 Configuration 2.2.2 K120S Product

System

Series

System

Equipment

1) Main Unit Standard type Items Models I/O Point & Power Supply Remark Built-in Function

K7MDR20U K7MDR30U K7MDR40U K7MDR60U K7M DRT/DT20 U K7M DRT/DT30 U K7M DRT/DT40 U

12 DC inputs(24VDC) 8 relay outputs 85~264 VAC 18 DC inputs(24VDC) 12 relay outputs 85~264 VAC 24 DC inputs(24VDC) 16 relay outputs 85~264 VAC 36 DC inputs(24VDC) 24 relay outputs 85~264 VAC 12 DC inputs(24VDC) 4/0 relay outputs 4/8 TR outputs 85~264 VAC 18 DC inputs(24VDC) 8/0 relay outputs 4/12 TR outputs 85~264 VAC 24 DC inputs(24VDC) 12/0 relay outputs 4/16 TR outputs 85~264 VAC

Program capacity : 10 k steps Max. expansion : 3 modules High-speed counter : - 1 Phase : 100 kHz 1channel, 20 kHz 2channel. - 2 Phase : 50 kHz 1channel, 10 kHz 1channel. Pulse catch : pulse width 10 2 points, 50 6 points, External interrupt: : 10 2 points, 50 6 points Input filter: 0 ~ 1000ms (can be designated with groups) PID control function RS-232C communication, RS-485 communication Program capacity : 10 k steps Max. expansion : 3 modules High-speed counter : - 1 Phase : 100 kHz 1channel, 20 kHz 2channel. - 2 Phase : 50 kHz 1channel, 10 kHz 1channel. Pulse catch : pulse width 10 - 2 points, 50 - 6 points, External interrupt: : 10 - 2 points, 50 - 6 points Input filter: 0 ~ 1000ms (can be designated with groups) PID control function RS-232C communication, RS-485 communication Positioning function - 2axes 100 kpps - Absolute / Incremental positioning method - Single / Repeat operation method - End / Keep / Continuous mode - Return to origin, JOG, PWM, velocity control

Main Unit

36 DC inputs(24VDC)

K7M DRT/DT60 U

20/0 relay outputs 4/24 TR outputs 85~264 VAC

2) Main Unit Economic type Items Models I/O Point & Power Supply Remark Built-in Function

K7MDR10UE K7MDR14UE K7MDR20UE K7MDR30UE

6 DC inputs(24VDC) 4 relay outputs 85~264 VAC 8 DC inputs(24VDC) 6 relay outputs 85~264 VAC

Program capacity : 2 k steps Max. expansion : 2 modules Pulse catch : pulse width 50 4 points, High-speed counter : - 1 Phase : 10 kHz 2channel. - 2 Phase : 5 kHz 1channel. External interrupt: : 50 4 points Input filter: 0 ~ 1000ms (can be designated with groups) RS-232C communication RS-485 communication(K7M-DR10/14UE only) Built-in analog timer(K7M-DR10/14UE only)

Main Unit

12 DC inputs(24VDC) 8 relay outputs 85~264 VAC 18 DC inputs(24VDC) 12 relay outputs 85~264 VAC

2-5

Chapter 2 Configuration
3) Modules Section Remark Expansion Items

System

Models

Description G7EDR10A G7EDR20A 6 DC inputs / 4 relay outputs 12 DC inputs / 8 relay outputs 8 DC inputs Slim Type 10 outputs Transistor Slim

Expansio n module module

Digital

I/O

G7EDC08A G7ETR10A G7ERY08A G7EDR08A

8 relay outputs Type

4 DC Input, 4 Relay output A/D : 2 channel , D/A : 1 channel A/D : 2 channel , D/A : 2 channel Typ Slim e A/D : 4 channel D/A : output) 4 channel(current

A/DD/A Combination ADHB

module

G7FADHA G7F-

A/D conversion module AD2A D/A module conversion

G7FG7FDA2I G7FDA2V G7F-

Analog timermodule AT2A Specia l module RTD module RD2A G7F-

D/A : 4 channel(voltage output) Slim Points : 4points Digital output range : 0~200 Resistance temperature detactor 4 channel(Pt100, JPt100) RS-232C channel RS-422 channel DeviceNet (Slave) : I/F : 1 module 1

Typ e Slim Typ e Standar d only type

G7LCUEB G7LCUEC Communication module I/F G7LDBEA G7LFUEA G7LPBEA RTC module RTCA G7E-

FieldBus I/F module Profibus (Slave) I/F module Clock

Standar d only type

Real Time module

External Memory G7MExternal Memory M256B module * External memory G7M-M256 isnt supported in K120S series. Only G7M-M256B is available for . K120S series

2-6

Chapter 3 General Specifications

Chapter 3. General Specifications

3.1 General Specifications
The following table shows the general specifications of the MASTER-K120S series. No. Item References Specifications
C - 25 ~+70 C

1 Operating ambient Temperature 0 ~ 55 2 Storage ambient Temperature

3 Operating ambient Humidity 5 ~ 95%RH, non-condensing 4 Storage ambient Humidity 5 ~ 95%RH, non-condensing Occasional vibration Frequency Acceleration Amplitude Sweep count 10 =f <57Hz - 0.075mm 2 {1G} 57 =f =150Hz 9.8m/s Continuous vibration Frequency Acceleration Amplitude 10 =f <57Hz - 0.035mm 2 {0.5G} 57 =f =150Hz 4.9m/s -

5 Vibrations

10 times for each X, Y, Z axis

IEC 61131-2

6 Shocks

2 {15G} Maximum shock acceleration: 147 m/s Duration time: 11ms Pulse wave: half sine pulse ( 3 shocks per axis, on X, Y, Z axis )

IEC 61131-2 LGIS Internal Standard IEC 1000-4-2 IEC 1000-4-3 Digital I/O (less than24V) Analog I/O Interfac e

Square wave Impulse noise

1,500 V

Electronic discharge Voltage: 4 kV ( Discharge by contact ) IEC 61131-2, Radiated electromagnetic field noise Fast transient & burst noise 27 ~ 500 MHz, 10 V/m IEC 61131-2,

7 Noise Immunity

Item Power supply Digital I/O (24V and up) Voltage 2kV 1kV 0.25kV

IEC 61131-2 IEC 1000-4-4

8 Atmosphere Free of corrosive gases and excessive dust 9 Altitude Up to 2,000m 10 Pollution degree 2 11 Cooling method Air-cooling

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.

3-1

Chapter 4 Parts

Names of

Chapter 4. Names of Parts

4.1 Main Unit

BUILT_IN CNET RUN PAU/REM STOP ON OFF ROM MODE

-+
RS-485

No. Description

Name Indicates status of power supply to the PWR LED system : When the supplied power is On normal Off : When the supplied power is abnormal Indicates operating status of main unit On : Indicates local key switch or remote running mode Off : with the followings, LED turns RUN off LED - When the supplied power to the main unit is abnormal. - While key switch is on stop mode - Detecting an error which makes operation stop Indicates operating status of CPU ERR LED Flickering : self-inspected error Off: CPU is working normal. 4 -1

CPU Condition LED

Chapter 4 Parts

Names of

No Name Description I/O LED Indicates operating status of I/O Built-in RS-485 (Except K7M-DR10/14UE) connector communications. 2-pin connector for built-in RS-485

Key switch for mode economic creation.(Except type)

Dip-switch for Cnet I/F RS-232C connector Expansion cover Terminal cover connector

Designates main units operation mode RUN : Run program operation STOP: Stop program operation PAU / REM: usage of each modules are as follows: - PAUSE : temporary stopping program operation - REMOTE : designates remote driving See Chapter 5. 9-pin DIN connector to connect with external devices like KGLWIN Connector cover to connect with expansion unit Protection cover for wiring of terminal block

block

Private hook DIN rail Private part hook for DIN rail

4.1.1 (Standard)
1) K7MDR60U

60-points

main

unit

4 -2

Chapter 4 Parts
2) K7MDRT60U

Names of

3) K7MDT60U

4.1.2 (Standard)
1) K7MDR40U

40-points

main

unit

4 -3

Chapter 4 Parts
2) K7MDRT40U

Names of

3) K7MDT40U

4.1.3 (Standard)
1) K7MDR30U

30-points

main

unit

4 -4

Chapter 4 Parts
2) K7MDRT30U

Names of

3) K7MDT30U

4.1.4 (Standard)
1) K7MDR20U

20-points

main

unit

4 -5

Chapter 4 Parts
2) K7MDRT20U

Names of

3) K7MDT20U

4.1.5

30-points main unit (Economic)

1) K7MDR30UE

4 -6

Chapter 4 Parts 4.1.6

Names of

20-points main unit (Economic)

1) K7MDR20UE

4.1.7

14-points main unit (Economic)

1) K7MDR14UE

4.1.8

10-points main unit (Economic)

1) K7MDR10UE

4 -7

Chapter 4 Parts

Names of

4.2 Expansion I/O Module

4.2.1 20points I/O Module
1) G7EDR20A No. Names Input LED Output LED Input contact Input common terminal Output contact Output common terminal Expansion cable Expansion Terminal Cable Connecting

4.2.2 10points I/O Module

1) G7EDR10A No. Names Input LED Output LED Input contact Input common terminal Output contact Output common terminal Expansion cable Expansion Terminal 1) G7ETR10A No. Names Output LED Output contact Output common terminal External Power Supply (DC24V) Expansion cable Expansion Terminal Cable Cable Connecting

Terminal

Connecting

4 -8

Chapter 4 Parts

Names of

4.2.3 8points I/O Module

1) G7EDC08A

No. Names Input LED Input contact Input common terminal Expansion cable Expansion Terminal Cable Connecting

2) G7ERY08A

No. Names Output LED Output contact Output common terminal Expansion cable Expansion Terminal Cable Connecting

4 -9

Chapter 4 Parts

Names of

4.3 Special Module

4.3.1 A/D D/A Module
1) G7FADHA

Combination

No. Names RUN LED Analog Output Terminal Analog Input (Voltage/current) selecting jumper pin Analog Input Terminal External Power Supply Terminal (DC24V) Expansion Cable Expansion Terminal Cable Connecting

2) G7FADHB No. Names RUN LED Analog Input Terminal Analog Output Terminal External Power Supply (DC24V) Expansion Cable Expansion Terminal Cable

Terminal

Connecting

4 -10

Chapter 4 Parts

Names of

4.3.2 D/A Conversion Module

1) G7FDA2I No. Names RUN LED Analog Output Terminal Expansion Cable Expansion Cable Terminal External Power (DC24V) Connecting Supply Terminal

2) G7FDA2V

No. Names RUN LED Analog Output Terminal Expansion Cable Expansion Cable Connecting Terminal External Power Supply Terminal (DC24V)

4.3.3 A/D Module

Conversion

No. Names
24 V 2 4 G
I np u t

In p u t Se le ct CH3 CH2 CH1 CH0

CH 0 C H1 CH 2 C H3 V0 C OM V1 C OM 2 C OMV3 C OM V I 0 I1 I2 I3

RUN LED Analog Input Terminal Analog Input (Voltage/current) jumper pin External Power (DC24V) Expansion Cable Expansion Terminal 4 -11 Cable Supply

selecting

Terminal

Connecting

Chapter 4 Parts

Names of

4.3.4 Analog timer Module

No. Names RUN LED Analog Timer Resistor Expansion Cable Expansion Terminal

Volume

Control

Cable

Connecting

4.3.5 RTD Module

Input

No. Names RUN LED Analog Timer Resistor Expansion Cable Expansion Terminal

Volume

Control

Cable

Connecting

4 -12

Chapter 4 Parts

Names of

4.4 Communication I/F Module

4.4.1 Cnet Module
1) CUEB G7L-

I/F

No. Names RS-232C connector Communication LED Expansion cable Expansion cable terminal TM/TC selecting switch

status

connecting dip

2) G7LCUEC

No. Names RS-422/485 connector Power supply/Communication LED Expansion cable Expansion terminal cable

status

connecting

4.4.2 Fnet I/F Module

1) G7LFUEA No. Names Station No. selecting switch Fnet cable connector 1 and 2 Expansion cable Expansion cable connecting terminal Communication status LED

4 -13

Chapter 4 Parts

Names of

4.4.3 Pnet I/F Module

1) PBEA G7L-

No. Names Station No. selecting switch Pnet cable connector Expansion cable Expansion cable connecting terminal Communication status LED

4.4.4 DeviceNet I/F Module

1) DBEA G7LNo. Names Station No. switch(NA) DeviceNet connector Expansion cable

selecting cable

Expansion cable connecting terminal Baud rate selecting switch Power supply/Communication status LED

4.5 Option Module

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. MASTER-K120S series have two option modules External memory module and RTC module.

No. Names Option module Connecto r

4 -14

Chapter 5 CPU

Power Supply /

Chapter 5. Power Supply / CPU

5.1 Power Supply Specifications
5.1.1. Standard Type
Items K7M Rated voltage Rated frequency Rated current Inrush current Efficienc y Input fuse Permitted Momentary power failure Output DR/DRT/DT20 U
85 ~ 264 VAC

K7M DR/DRT/DT30 U

K7M DR/DRT/DT40 U

K7M DR/DRT/DT60 U

50 / 60 Hz (47 ~ 63 Hz) 0.5A(110VAC)/0.25A(220VAC) 0.6A(110VAC)/0.3A(220VAC) Up to 30A Up to 60A

Input

65% min.(rated input/maximum load) 2A/AC250V (Time Lag Type) 10 ms DC 5V 1.2A 2A DC 24V 0.2A

Output(1 )

voltage Output current Output Output(2 voltage Output ) current Power supply indication

status

PWR LED On when power supply is normal

5.1.2. Economic Type

Items K7M DR10UE K7M DR14UE K7M DR20UE K7M DR30UE Rated 85 ~ 264 VAC voltage Rated 50 / 60 Hz (47 ~ 63 Hz) frequency Rated 0.3A(110VAC) / 0.15A(220VAC) 0.5A(110VAC) / 0.25A(220VAC) current Inrush Up to 30A current Efficienc 65% min.(rated input/maximum load) y Input 2A/AC250V (Time Lag Type) fuse Permitted Momentary power failure Output Output voltage Output Output voltage status
10 ms DC 5V 0.5A 1.2A DC 24V 0.2A PWR LED On when power supply is normal

Input

Output(1) current Output(2) current

Power supply indication

5-1

Chapter 5 CPU

Power Supply /

5.2 CPU Specifications

The following table shows the general specifications of the MASTER-K120S series

5.2.1. Standard Type

Specification s K7M-DR/DRT/DT30U

Items K7M-DR/DRT/DT20U DR/DR`T/DT60U

Remark K7M-DR/DRT/DT40U s K7M-

Program control method Cyclic execution of stored program, Time-driven interrupt, Process-driven interrupt I/O control method Indirect mode(Refresh method), Direct by program command Program language Instruction list, Ladder diagram Numbers of instructions Basic : 30, Application : 277 Processing 0.1 Program 10ksteps speed capacity s/step

I/O points 20 30 40 60 P P000 ~ P63F M M000 ~ M191F K K000 K31F ~ I/O relay,TR. Auxiliary relay Keep relay Link relay Special relay

L L000 ~ L63F F F000 ~ F63F Memor y devic e 100msec : T000 ~ T191 (192 points) 10msec : T192 ~ T250 (59 points) T 1msec : T251 ~ T255 (5 points) -. Adjustable by parameter setting C C000 ~ C255 S S00.00 ~ S99.99 D D0000 D4999 ~

Time r

Counte r Step controller Data register

Operation modes RUN, STOP, PAUSE, DEBUG Self-diagnosis functions Detects errors of scan time, memory, I/O and power supply Data back-up method Latch area backup Up to 3 level Max. expansion (External memory or RTC module can be connected as 4th expansion level module) 5-2

Chapter 5 CPU
(continued )

Power Supply /

Items

PID function

control

Cnet I/F Function

Remark K7M-DR/DRT/DT20U K7M-DR/DRT/DT40U s K7MDR/DRT/DT60U Controlled by commands, Relay and PRC auto tuning, PWM output, manual output, adjustable operation scan time, Anti-windup, SV-Ramp, Delta MV, Position and Velocity algorithm Dedicated protocol support MODBUS protocol support RS-232C 1port User defined protocol support RS-485 - 1 port No protocol support

Specification s K7M-DR/DRT/DT30U

Capacity 1 phase : 100 kHz-2 channel, 20 kHz-2 2 phase : 50 kHz-1 channel, 10 kHz-1 channel channel 4 different counter modes as following; -. 1 phase operation mode. High- Counter -. 2 phase CW/CCW function mode. spee -. 2 phase Pulse + Direction d mode. counte -. 2 phase Multiplication r mode(MUL4) Internal/External preset function Additiona Latch Counter l function Built-in functio RPM function n Function Comparison Output function N0. of control axis : 2 Axis Operatio Control method : Point-to-Point, Speed n Control Specificatio Control unit : Pulse n Positioning data : 20 data / axis(Operation step N0. 1 ~ 20) Positioning method : Absolute / Incremental Operation method : Single / Repeat PositionOperation mode : End / Keep / Positioning Continuous ing Address range : -2,147,483,648 ~ 2,147,483,647 Speed : Max. 100kpps(setting range 5 ~ 100,000) Acceleration / Deceleration method : trapezoidal method Origin detection when approximate origin turns off Return to Origin detection after deceleration when approximate origin turns Origin on. Origin detection by approximate origin. JOG Setting range : 5~100,000 ( High / Low speed) Pulse catch Minimum pulse width : 10 ( 2 points) and 50 (6 points) External interrupt 10 (2 points) and 50 (6 points) Input filter 0~1000ms(Adjustable) Weight (g) 520 540 660 850

DRT / DT Type Only

5-3

Chapter 5 CPU

Power Supply /

5.2.2. Economic Type

Specification s K7M-DR10UE DR30UE K7M-DR14UE K7M-DR20UE K7M-

Items

Remark s

Program control method Cyclic execution of stored program, Time-driven interrupt, Process-driven interrupt I/O control method Indirect mode(Refresh method), Direct by program command Program language Instruction list, Ladder diagram Numbers of instructions Basic : 30, Application : 269 Processing 0.4 Program 2ksteps speed capacity s/step

I/O points 10 14 20 30 P P000 ~ P63F M M000 ~ M191F K K000 K31F ~ I/O relay Auxiliary relay Keep relay Link relay Special relay

L L000 ~ L63F F F000 ~ F63F Memor y devic e 100msec : T000 ~ T191 (192 points) 10msec : T192 ~ T250 (59 points) T 1msec : T251 ~ T255 (5 points) -. Adjustable by parameter setting C C000 ~ C255 S S00.00 ~ S99.99 D D0000 D4999 ~

Time r

Counte r Step controller Data register

Operation modes RUN, STOP, PAUSE Self-diagnosis functions Detects errors of scan time, memory, I/O and power supply Data back-up method Latch area backup Up to 2 level Max. expansion (External memory or RTC module can be connected as 3th expansion level module)

5-4

Chapter 5 CPU
(continued )

Power Supply /

Items

Cnet I/F Function

K7M-DR10UE DR30UE Dedicated protocol support MODBUS protocol support 1port User defined protocol support port No protocol support

Specification s K7M-DR14UE K7M-DR20UE K7M-

Remark s
RS-485 is available on K7M-DR10/14UE only

RS-232C RS-485 - 1

Capacity channel

HighFunction speed counte r

Built-in

Counte r functio n

Additiona l functio n

1 phase : 10 kHz-2 2 phase : 5 kHz-1 channel 4 different counter modes as following; -. 1 phase operation mode. -. 2 phase CW/CCW mode. -. 1 phase Pulse + Direction mode. -. 2 phase Multiplication mode(MUL4) Internal/External preset function Latch Counter function RPM function

Pulse catch points) External interrupt 50 (4 points) Input filter 0 1000ms(Adjustable) Weight (g) 360 370 500 510

Comparison Output function Minimum pulse width : 50 (4

5-5

Chapter 5 CPU

Power Supply /

5.3 Operation Processing

5.3.1 Operation Processing Method
1) operation Cyclic

A PLC program is sequentially executed from the first step to the last step, which is called scan. This sequential processing is called cyclic operation. Cyclic operation of the PLC continues as long as conditions do not change for interrupt processing during program execution. This processing is classified into the following stages: Stages Processing Operation Start -

Initializatio n

Stage for the start of a scan processing. it is executed only one time when the power is applied or reset is executed. It executes the following processing.. I/O reset Execution of self-diagnosis Data clear Allocating I/O address and type Input conditions are read and stored into the input image area before starts processing.

Input image refresh Program processing Program starts ~ Program ends

area

Program is sequentially executed from the first step to the last step

operation

Program operation processing

The contents stored in the output image area is output to output part

Output refresh

image

area

when operation processing of a program is finished.

Stage for return processing after the CPU part has finished 1 scan.

END processing

The END processing following processing is executed. 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.

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Chapter 5 CPU
2) Interrupt method

Power Supply /

operation

If a situation occurs which is requested to be urgently processed during execution of a PLC program, this opera tion method processes immediately the operation, which corresponds to interrupt program. The signal, which infor ms the CPU of those urgent conditions is called interrupt signal. The MASTER-K120S CPU has three kind of int errupt operation methods, which are internal, external and high speed counter interrupt signal methods.

5.3.2 Operation Processing at Momentary Power Failure Occurrence

The momentary power failure occurs when the input line voltage to the power supply falls down below the rated voltage. When momentary power failure within 10ms occurs, the CPU maintain operation processing. But If is exceeds 10ms, CPU stop processing and all output turns off. And The re-start process is executed as the power is reapplied. 1) Momentary power failure within 10 ms

The operation processing is maintained Input power

Momentary power failure within 1Oms

2) Momentary power failure exceeding 10 ms

The re-start process is executed as the power is re-applied. Input power

Power failure exceeding 1Oms

REMAR K 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).

5-7

Chapter 5 CPU

Power Supply /

5.3.3 Scan Time

The processing time from a 0 step to the 0 step of next scan is called scan time. 1) Expression for scan time Scan time is the sum of the processing time of scan program that the user has written, of the task program processing time and the PLC internal processing time. (1) Scan time = Scan program processing time + Interrupt program processing time + PLC internal processing time Scan program processing time = The processing time used to process a user program that is not specified to a task program. Interrupt program processing time = Total of the processing times of interrupt programs executed during one scan. PLC internal processing time = Self-diagnosis time + I/O refresh time + Internal data processing time + Communications service processing time (2) Scan time differs in accordance with the execution or non-execution of interrupt programs and communications processing, etc. 2) Flags 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)

5.3.4 Scan Watchdog Timer

1) Watchdog timer is used to detect a delay which is attributable to abnormal operation of sequence program (Watchdog time is set in menu of basic parameter of KGLWIN.) 2) When watchdog timer detects an exceeding of preset watchdog time, the operation of PLC is stopped immediately and all output is off. 3) If an exceeding of preset watchdog time is expected in sequence program, use WDT instruction. 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 available.

REMAR K -. Setting range of watchdog : 10 ~ 6,000ms(unit : 10ms)

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Chapter 5 CPU

Power Supply /

5.3.5 Timer Processing

The MASTER-K series use up count timer. There are 5 timer instructions such as on-delay (TON), off-delay (TOFF), integral (TMR), monostable (TMON), and re-triggerable (TRTG) timer. The measuring range of 100msec timer is 0.1 ~ 6553.5 seconds, 10msec timer is 0.01 ~ 655.35 seconds, and that of 1msec timer is 0.001 ~ 65.53 seconds. Please refer to the MASTER-K programming manual for details.

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.
input condition Output relay
t0+PT t4+PT t5

Preset value Timer relay Timer type

output

t0

t1 t2 t3 t4 t5

Pre value Current value

t0 t1 t2 t3 t4 t5

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 t0 t2 t4 t1 Timer output relay PT Preset value t3 t5

t1 + PT PT

t5 + PT

Current value

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Chapter 5 CPU

Power Supply /

3) Integral timer In general, its operation is same as on-delay timer. Only the difference is the current value will not be clear when the input condition of TMR instruction is turned off. It keeps the elapsed value and restart to increase when the input condition is turned on again. When the current value reaches preset value, the timer output relay is turned on. The current value can be cleared by the RST instruction only.

Timer input condition

t0 t2 t1 t4 t5

Timer output relay Preset value

PT = (t1-t0)+(t3-t2)

Current value
t0 t2 t1 t3 t5 t5+PT

Timer reset input

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). When current value reaches preset value the timer output relay is turned off and current value is cleared .

Timer input condition

t0 t1 t2 t3 t4

Timer output relay

t0 t0+PT t2 t2+PT t4 t4+PT

Preset value

Current value
t0 t1 t2 t4

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Chapter 5 CPU

Power Supply /

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 PT Timer output relay

Preset value (PV) (On operation) Current value

REMAR K The Maximum timing error of timers of MASTER-K series is 1 scan time + the time from 0 step to timer instruction

5 - 11

Chapter 5 CPU

Power Supply /

5.3.6 Counter Processing

The counter counts the rising edges of pulses driving its input signal and counts once only when the input signal is switched from off to on. MASTER-K series have 4 counter instructions such as CTU, CTD, CTUD, and CTR. The followings shows brief information for counter operation. Refer to the MASTER-K Instruction Manual for details. 1) Up counter (CTU) -. The counter output relay is turned on when the current value reaches the preset value. -. When the reset input is turned on, the counter output relay and current value is cleared as 0.

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.

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 otherwise off.

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Chapter 5 CPU

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4) Ring counter -. The current value is increased with the rising edge of the counter input signal, and the counter output relay is turned on when the current value reaches the preset value. Then the current value and counter output relay is cleared as 0 when the next counter input signal is applied.

5) Maximum counting speed (1) The maximum counting speed of counter is determined by the length of scan time. Counting is possible only when the on/off switching time of the counter input signal is longer than scan time. Maximum countin g spee d (C m a x) = n 100 1 ts ( times/sec ) where, n : duty (%), t
s

: scan time

(2) Duty Duty is the ratio of the input signals on time to off time as a percentage.

T1 T2 OFF ON OFF If T1 =T2,

n (% = T1 T1 + T2 T2 T1 + T2 100 )

If T1 > T2,

n (% =

100

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Chapter 5 CPU

Power Supply /

5.4 Program
5.4.1 Classifications of Program
All functional elements need to execute a certain control process are called as a program. In MASTER-K120 series, a program is stored in the EEPROM mounted on a CPU module or flash memory of a external memory module. The following table shows the classification of the program. Program type Description Scan program The scan program is executed regularly in every scan Time-driven interrupt program (TDI) The TDI programs are executed with a constant time interval specified with parameter setting. Process driven The PDI programs are executed when external interrupt input is applied and the interrupt corresponding program interrupt routine is enabled by EI (PDI) instruction. High speed counter This interrupt programs are executed when comparison task signal is driven applied. interrupt (Standard Type program(HSCDI) only) Subroutine program The subroutine programs are executed when they are called by the scan program with a instruction. CALL

5.4.2 Program Execution Procedure

The following diagram shows that how the CPU module process programs when the CPU module is powered on or switched to RUN mode.

Start processing

Subroutine program PDI program TDI program HSCDI program END processing

Scan program

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Chapter 5 CPU

Power Supply /

1) Scan program -. The scan program is executed regularly in every scan from 0 step to last step. -. When interrupts has occurred, CPU pauses scan program and executes corresponding interrupt program first. -. When this interrupt program finished, scan program is to resume. 2) Interrupt program -. When an interrupt occurs, the CPU module will stop the current operation and execute the corresponding interrupt routine first. After finish the interrupt routine, the CPU resume the sequence program from the stopped step. -. MASTER-K102S series provides 3 types of interrupt. The TDI (Time driven interrupt) occurs with the constant period The PDI (Process driven interrupt) occurs with the status of external input. The HSCDI(High speed counter driven interrupt) occur with comparison task signal from high speed counter. (Standard type only)

5.4.3 Interrupt Programs

1) Usage program of interrupt

(1) Before to use interrupt function in sequence program, the parameter setting should be done properly. Then the corresponding interrupt routine should be written after END instruction. (Refer chapter 4 for details) If interrupt routines are not matched with parameter settings, an error occurs and the operation of CPU will be stopped. (2) To execute an interrupt routine, use the EI instruction to enable the corresponding interrupt. The interrupt routine is not executed if an interrupt factor occurs before execution of an EI instruction. Once an interrupt is enabled with EI instruction.

(3) 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. Following figure show how CPU handles multiple interrupts

Scan Program

1 2 7 2

Program starts Interrupt 2 occurs Stop main program and execute interrupt routine 2 occurs (higher

Interrupt routine 1 Interrupt routine 2

3

4 6

5 - 15

Interrupt 1 priority) 5 Stop routine 2 1 6 Finish routine routine2 7 Finish routine program
4

and run routine 1 and return to 2 and return to main

Chapter 5 CPU
2) setting

Power Supply /

parameter

3) Time driven interrupt TDI occurs periodically with the constant interval assigned in parameter setting. The interrupt routine of TDI starts with the TDINT instruction and ends with the IRET instruction. When multiple interrupt factors occur simultaneously, interrupt routines are executed according to the priority given to the each interrupt. 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. In standard types of MK120S series, Available TDI is P000 ~ P007 (8 points) assigned in parameter setting and period can be designated for each other. In economic types, Available TDI is P000 ~ P003 (4 points) . 4) Process driven interrupt In standard types of MK120S series, Available PDI is P000 ~ P007 (8 points) assigned in parameter setting. In the parameter setting window, TDINT indicates time driven interrupt and INT indicates process driven interrupt. PDI occurs when the input status of P000 ~ P007 is changed from Off to On or from On to Off or both. In economic types of MK120S series, Available PDI is P000 ~ P003 (4 points), and occurs when the input status of P000 ~ P003 is changed from Off to On. It isnt occurs falling edge of input condition. 5) HSC driven interrupt HSCDI occurs when comparison task of HSC occurs and Available HSCDI is Ch0 ~ Ch4 (4 points) .

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Chapter 5 CPU

Power Supply /

REMAR K Total available interrupt points is 8(In standard type). -. Time driven interrupt + process driven interrupt + high speed counter driven interrupt = 8 points Interrupt signal is ignored when self-interrupt occurs more than 2 times during interrupt processing is executing.

ignore d

Interrupt time

executing

Interrupt signal (ex : rising edge)

5.4.4 Error Handling

1) Error Classification Errors occur due to various causes such as PLC system defect, system configuration fault or abnormal operation result. Errors are classified into fatal error mode, which stops system operation for system stability, and ordinary error mode, which continues system operation with informing the user of its error warning. The main factors that occurs the PLC system error are given as followings. PLC hardware defect System configuration error Operation error during execution of the user programs External device malfunction 2) Operation mode at error occurrence In case of error occurrence, the PLC system write the error contents the corresponding flags and stops or conti nues 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 operation error has occurred. (2) System configuration error This error occurs when the PLC hardware configuration differs from the configuration defined in the K120S 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 program, its contents are marked on the error flags and the system continues its operation. If operation time overruns the watchdog time or I/O modules loaded are not normally controlled, the system enters into the STOP state.

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Chapter 5 CPU

Power Supply /

(4) External device malfunction The PLC user program detects malfunctions of external devices. If a fatal error is detected the system ent ers into the STOP state, and if an ordinary error is detected the system continues its operation. REMAR K 1) In occurrence of a error, the state is to be stored in the representative system error flag F006. 2) For details of flags, refer to Chapter 11. Troubleshooting.

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Chapter 5 CPU

Power Supply /

5.5 Operation Modes

The CPU operates in one of the four modes - RUN, STOP, PAUSE and DEBUG mode. The following describes ope ration processing in each operation mode.

5.5.1 Mode

RUN

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 internal service

Execute output refresh

No Operation mode is changed? Yes Operate with new mode

1) Processing when the operation mode is changed. Initialization of data area is executed when the first scan starts and The possibility of execution of the program is decided with effectiveness. 2) Operation contents check on its

processing

I/O Refresh and program operation are executed. (1) Interrupt programs are executed with the detection of their start-up conditions. or abnormal operation and mounting conditions of the loaded module are (2) Normal checked. (3) Communications service or other internal operations are processed.

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Chapter 5 CPU

Power Supply /

5.5.2 STOP mode

In this mode, programs are not operated. 1) Processing when the operation mode is changed. The output image area is cleared and output refresh is executed. 2) Operation processing contents (1) I/O refresh is executed. (2) Normal or abnormal operation and mounting conditions of the loaded module are checked. (3) Communications service or other internal operations are processed.

5.5.3 PAUSE mode

In this mode, the program operation is temporarily stopped. If it returns to the RUN mode, the operation continu es from the state before the stop. 1) Processing when the operation mode changes Data registers and input image areas are not cleared and the operating conditions just before the mode chang e is maintained. 2) Operation processing contents (1) I/O refresh is executed. (2) Normal or abnormal operation and mounting conditions of the loaded module are checked. (3) Communications service or other internal operations are processed.

5.5.4 DEBUG only)

mode(Standard type

In this mode, errors of a program are searched and the operation sequence is traced. Changing into this mode is only possible from the STOP mode. In this mode, a program can be checked with examination on its executi on state and contents of each data. 1) Processing when the operation mode changes (1) Data area is initialized at the starting time of the mode change complying with the restart mode, which has been set on the parameters. (2) The output image area is cleared and input refresh is executed. 2) Operation processing contents (1) I/O refresh is executed. (2) Debugging process is executed complying with setting. I (3) I/O refresh is executed after debugging process has executed to end of the program (4) Normal or abnormal operation and mounting conditions of the loaded module are checked. (5) Communications service or other internal operations are processed

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Chapter 5 CPU

Power Supply /

3) Debug operation conditions following four operation conditions can be specified. Operation conditions Description executed by one command. When executed, Stop operation after executing one instruction executed by breakpoint settings. When executed, Stop operation at designated breakpoint executed by the condition of the device When executed, Stop operation by condition of designated devices status executed by the specified scan time When executed, Operates specified scan time. 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 KGLWIN Users Manual Chapter 9.

5.5.5 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.(Standard type only) (2) Change by the KGLWIN connected with the CPU module communications port. (3) Change by the KGLWIN connected to the remote CPU module through Cnet I/F (4) Change by the STOP instruction, during program execution. (5) Change by the KGLWIN connected to the remote CPU module through Fnet(Standard type only) 2) Operation mode change by the mode-setting switch of CPU module.(Standard type only) The following shows the operation mode change by the mode-setting switch of CPU module. Mode setting switch position Operation mode RUN Local STOP STOP PAU / REM RUN PAU / REM PAU / REM Remote STOP RUN *1 Local RUN PAU / REM * 2 Local PAUSE STOP Local STOP RUN Local STOP

REMAR K -. If the operation mode changes from RUN mode to local RUN mode by the mode setting switch, the PLC operates continuously without stopping.

5 - 21

Chapter 5 CPU

Power Supply /

3) Mode change Remote operation Remote operation mode change is available only when the operation mode is set to the remote STOP mode (i.e., the mode setting switch position is in the STOP PAU/REM). Mode setting switch position Mode Change Mode change by the Remote STOP Remote RUN Remote STOP Remote PAUSE X X Remote STOP DEBUG Remote RUN Remote PAUSE Remote RUN Remote STOP Remote RUN DEBUG X PAU / REM X Remote PAUSE Remote RUN Remote PAUSE Remote STOP Remote PAUSE Remote DEBUG X X DEBUG Remote STOP DEBUG Remote RUN X X DEBUG Remote PAUSE X X Mode change using FAM or Cnet I/F, etc.

KGLWI N

5 - 22

Chapter 5 CPU

Power Supply /

5.6 Functions
5.6.1 Self-diagnosis
1) Functions (1) The self-diagnosis function permits the CPU module to detect its own errors. (2) Self-diagnosis is carried out when an error occurs during PLC power supply is turned on or operating process. If an error is detected, the system stops operation to prevent faulty PLC operation. 2) WDT (Watch dog timer) function The watch dog timer is an internal timer of a PLC to detect the error of hardware and a sequence program. it is changeable with 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 delay 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 flickers. (RUN LED will be turned OFF) Therefore, when use FOR ~ NEXT or CALL instruction, insert WDT instruction to reset the watch dog timer. Refer the MASTER-K programming manual for details on the parameter setting.

WDT

END

END

WDT Reset Reset

WDT Reset

WDT

3) I/O module check function Mounting conditions of the loaded module are checked 4) Error history When error occurs, Corresponding error code is stored in special relay F006.

5 - 23

Chapter 5 CPU

Power Supply /

5.6.2 I/O function

Force

On/Off

It is possible to input/output a designated data regardless of the program operation results. When used with OUTOFF instruction simultaneously, OUTOFF is prior to I/O Force On/Off. 1) Forced I/O setting method. -. I/O Force on/off setting is applied to input area and output area. -. I/O Force on/off should be set for each input and output, the setting operates from the time that Force I/O setting enable is set. -. This setting can be done when I/O modules are not really loaded. -. Select the set forced I/O from KGLWIN

Click

-. Select the I/O area and then double click.

5 - 24

Chapter 5 CPU

Power Supply /

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 - 25

Chapter 5 CPU

Power Supply /

2) Special data register for forced I/O The contents of forced I/O setting is registered to special data register as below. It is possible to use forced I/O function to program. Items Special Device All Forced I/O enable M1910 Forced I/O enable by bit D4700 ~ D4763 Forced I/O set data D4800 ~ D4863 3) Force on/ off Processing timing and method (1) Forced Input After data have been read from input modules, at the time of input refresh the data of the junctions which have been set to force on/off will be replaced with force setting data to change the input image area. And then, the user program will be executed with real input data and force setting data. (2) Forced output When a user program has finished its execution the output image area has the operation results. At the time of output refresh the data of the junctions which have been set to force on/off will be replaced with force se tting data and the replaced data will be output. However, the force on/off setting does not change the output image area data while it changes the input image area data. (3) Precautions Turning the power off and on, changes of the operation mode or operation by reset switch does not change the previous force on/off setting data. They remain within the CPU module and operation is executed with the same data. Forced I/O data will not be cleared even in the STOP mode. When setting new data, disable every I/O settings using the setting data clear function and set the new data. REMAR K -. For detailed operation, refer to the KGLWIN users Manual Chapter 7 Force I/O setting.

5 - 26

Chapter 5 CPU 5.6.3 function

Power Supply / Direct I/O Operation

This function is useful when reads an input relays state directly during execution of a program and uses in the operation, or write the operation result directly to an output relay. Direct input/output is executed by the IORF instruction. If this instruction is used, the input/output image area will be directly updated and applied to the continuing operations. REMAR K -. For detailed operation, refer to the MASTER-K Manual for instruction.

5.6.4 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 times and error codes are stored in the special data register. 1) Special data register for error history Data Description area D4901 ~ D4904 The 1 D4905 ~ D4908 The 2 :: D4961 ~ D4964 16 2) Description of each word Data area Contents Description D4900 H0001 Error occurred point D4901 H0305 Year : 03, Month : 5 D4902 h2812 Date : 28, D4903 h3030 Minute : 30, D4904 (h0001) 3) Clear error data Use a data KGLWIN. h0001 Hour : 12 Second : 30 The error information, 17 n derror information
st

The :

th

error information

Devic e

th

error information

Error code

clear

function

of

REMAR K Refer to the KGLWIN users Manual Chapter 7, for details.

5 - 27

Chapter 5 CPU

Power Supply /

5.7 Memory Configuration

The CPU module includes two types of memory that are available by the user. One is program memory, which is used to store the user programs written to implement a system by the user. The other is data memory, which sto res data during operation. Bit Data Area Word Data Area User Program Area 0 P00
I/O relay

F 0000

FFFF D0000 Data Register D

Reserved for special usage

P63 M000

P
Auxiliary relay

D4500 D4999

Wor d

Parameter area

setting

M189 M190 M191 K00

(3,040 points) M Special auxiliary relay (32 points) Keep relay

T000
Timer preset value

User Program Area (10ksteps ) (economic type 2ksteps)

T255 T000

(256 words)

Timer elapsed value

K31 F00

(512 points) Special relay

T255 C000

(256 words) Counter preset value

F63 L00

(1,024 points) Link relay

C255 C000 C255

(256 words) Counter elapsed value

L63

(1,024 points)

(256 words)

T000
Timer (100ms)

S00
192 points Timer (10ms)

Step Controller

T191 T192

S99

(100 steps)

100

S S00.00~S99.99

T250 T251

59 points Timer (1ms)

T255 C000

5 points

Counter

C255

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Chapter 5 CPU

Power Supply /

5.8 I/O Address Allocation

I/O No. allocation means to give an address to each module in order to read data from input modules and output data to output modules.

Max. 3 expansion module is available in standard type. Mounting module Max. module can be mounted remark Expansion I/O module 3 2 modules in economic type A/D, D/A conversion module 3 Analog timer module 3 Not available on economic type Communication module 1 1) I/O No. allocation method -. 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. Module Remark Main I/O Allocation Input P000 ~ P03F Fixed 64 points Output P040 ~ P07F Fixed 64 points Input P080 ~ P08F Fixed 16 points Output P090 ~ P09F Fixed 16 points Input P100 ~ P10F Fixed 16 points Output P110 ~ P11F Fixed 16 points Input P120 ~ P12F Fixed 16 points Output P130 ~ P13F Fixed 16 points None

Expansion #1 Expansion #2 Expansion #3

Special A/D,A/T,Communication

5 - 29

Chapter 5 CPU

Power Supply /

5.9 Built-in Cnet Selection Switch

5.9.1 Structure
You can see dip switches as shown when you open I/O terminal block cover.

BUILT_IN CNET ON ROM MODE OFF

Terminal cover

block

5.9.2 Usage

Dip switch position Description upper switch is for Cnet. ON OFF ROM MODE Upper switch is for Cnet. ON ROM MODE * OFF

Turn upper switch communication

on

to

use

built-in

RS-232C

Turn upper off switch to use external communication modules.

The lower switch is for O/S download setting. Dont handle this . switch

5 - 30

Chapter 5 CPU

Power Supply /

Dip switch for Built-in Cnet is placed in deep place to prevent a mistaken operation caused by terminal block cover, etc. Use a small driver to operate it.

Drive r

Dip switch Terminal cover block

5 - 31

Chapter 5 CPU

Power Supply /

5.10 External Memory Module

MK120S series supplies external memory module for the user to save programs safely or download a program on the system and use it in case of a program is damaged.

5.10.1 Structure

Installation connector

5.10.2 Usage
1) Saving the users program on the external memory module. (1) Turn the power of the base unit off. (2) Install the memory module. -. When only main unit is used : Connect to the expansion connector of the basic unit. -. When expansion units are used : Connect to the expansion connector of the last connected expansion unit. (3) Turn the power of the main unit on. (4) Connect KGLWIN and PLC. (5) Online Read Information I/O menu, and the following message box will in Select Information displayed

5 - 32

Chapter 5 CPU
(6) Select

Power Supply /

Online Flash memory Write to external in menu, and the following message box will memory displayed.

(7) Turn the power of the main unit off. (8) Remove the external memory module. Through the above steps a user can save a program into the external memory module. 2) Run the PLC with a program of external memory module (1) Turn the power of the main unit off. (2) Install the memory module - When only main unit is used, connect to the expansion connector of the main unit And when expansion unit is used, connect to the expansion connector of the last connected expansion unit. (3) Turn on the power of the main unit. Through the above steps the user can operate the PLC with program stored in the external memory module.
REMARK

1) When the PLC restarts, it always operated with the external memory module automatically if external memory is connected 2) .Remove after writing is finished.

5 - 33

Chapter 5 CPU

Power Supply /

5.11 RTC Module

MK120S series supplies RTC(Real Time Clock) module for the time-scheduling control. To use RTC function with K120S series, the RTC operation module should be attached to the expansion slot of main unit or expansion module. Clock operation by the RTC function is continued with a super capacitor when the CPU is powered off.

5.11.1 Structure

Installation connector

5.11.2 Usage
1) Read RTC data (1) Read RTC data from KGLWIN -. Select Online Write Information Set PLCin menu. Clock

-. Following displayed

message

box

will

be

5 - 34

Chapter 5 CPU

Power Supply /

(2) Read RTC data from special register Special Area (Word) byte register Upper byte Lower Descriptio n Month Dat a (BCD format)

F053 Lower 2 digits of year H0207 F054 Day Hour H2313 F055 Minute Second H5020 F056 Higher 2 digits of year H2002 Example : 2002. 07. 23. 13:50:20, Tuesday 2) Write RTC data

Date

There is two ways to write new RTC data to the CPU. The first one is using a graphic loader (KGLWIN). For detailed information, refer the users manual of KGLWIN. The second one is write sequence program. By switching a special bit on, user can replace the current RTC data with the reset data stored in a specified memory area. The followings are the memory address of preset data and an example program . Descriptio Data register n Area (Word) Upper byte Lower byte D4992 Lower 2 digits of year Month D4993 Day Hour H1011 D4994 Minute Second D4995 Example : 2002. 7. 10. 11:53:24, Monday * M1904 : RTC data change bit When the M1904 bit is switched on, the new data in D4993 ~ D4996 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. Dat a (BCD format) H0207

H5324

Higher 2 digits of year Date H2001

3) expression

Date

Number 0 1 2 3 4 5 6 Date Sunday Monday Tuesday Wednesday Thursday Friday Saturday REMAR K 1) If RTC stops or error occurs, write new data to the RTC then error is called off. 2) There is no written clock data in the RTC when shipped. 3) Before using RTC module, write clock data to the RTC first

5 - 35

Chapter 6 Specification

Input

and

Output

Chapter 6 Specification

Input

and

Output

6.1 Input / Output Specifications

Digital input that offers to MASTER-K120S series are made to use both of electric current sink and electric current source. To keep use coil load as an output module, maximum opening and shutting frequency is 1 second on and 1 second off. The following diagram shows maximum life relay for relay output.

100

50 30 20

10

AC r/load DC r/load AC r/load

125V 30V 250V

0.5

5 of

10 electric

100(A )

Opening/shutting current

6-1

Chapter 6 Specification

Input

and

Output

6.2 Digital Input Specification

6.2.1 Main unit
1) Specification Model Specificatio n
K7M-DR10UE K7M-DR14UE

Main unit
K7MDR/DRT/DT20U K7M-DR20UE K7MDR/DRT/DT30U K7M-DR30UE K7MDR/DRT/DT40U K7M-DRT40U K7MDR/DRT/DT60U K7M-DRT60U

Number of input points 6 points 8 points 12 points 18 points 24 points 36 points Insulation method Photo coupler Rated input voltage DC 24V Rated input current 7 mA (Standard Type P0~P3:9mA, Economic Type P0,P1:9mA) Operating voltage range DC20.4 ~ 28.8V (ripple: less than 5%) Max. simultaneous input points 100% simultaneously On On voltage / On current DC19V or higher / 5.7 mA or higher Off voltage / Off current DC6V or lower / 1.8 mA or lower Input impedance Approx.3.3 k Off Response time On (Standard Type P0~P3:2.7 k , Economic Type P0,P1:2.7 k)

On 0,1,2,5,10,20,50,100,200,500,1000ms (Default : 10ms) Off 0,1,2,5,10,20,50,100,200,500,1000ms (Default : 10ms)

Common terminal 6 points / COM 8 points/COM 12 points/COM 18 points/ COM 12points/COM 18points/COM Operating indicator LED turns on at ON state of input

2) diagram

Circuit

R COM R C Internal circui t Standard Type P000 ~ P001 Economic Type None

R COM R Internal circui t

Standard Type P002 ~ Economic Type P000 ~

6-2

Chapter 6 Specification

Input

and

Output

3) Input wiring Main units wiring method is as follows. DC input specifications offered by MASTER-K120S is to be used for both electric current sink and electric current source. (1) unit Main

DC24 V

DC24 V

6-3

Chapter 6 Specification

Input

and

Output

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 Input

device

Relay IN 7mA COM

Sensor

+
O ut p ut

Po we r f or se n so r

IN

0V

7mA

COM +

Same power for sensor and input +

Co n st a nt ] cu r re n t Output

IN 7mA
Power for sensor

0V

COM

+
Output

Power for sensor IN

0V

7mA

COM

+ COM +
Output

IN
0V

Power for sensor

6-4

Chapter 6 Specification

Input

and

Output

6.2.2 Expansion Module

1) Specifications Model Specificatio n
Insulation method Photo coupler Rated input voltage DC 24V Rated input current 7 mA Operating voltage range DC 20.4 ~ 28.8V (ripple: less than 5%) Max. Simultaneous input points 100% simultaneously On On voltage / On current DC19V or higher/ 5.7 mA or higher Off voltage / Off current DC6V or lower / 1.8 mA or lower Input impedance Approx. 3.3 k Response time Off On On 0,1,2,5,10,20,50,100,200,500,1000ms Off 0,1,2,5,10,20,50,100,200,500,1000ms (Default : 10ms) (Default : 10ms)

G7E-DR10A

Expansion Module

G7E-DC08A

G7E-DR20A

Number of input points 6 points 8 points 12 points

Common terminal 6 points / com 4 points / com 12 points / com Operating indicator LED turns on at ON state of input

2) Circuit diagram Its the same with the one for the main unit. 3) wiring Input DC24 V DC24 V

6-5

Chapter 6 Specification

Input

and

Output

6.3 Digital Output Specification

6.3.1 Main Output)
1) Specification (1) type Standard Model Specifications DR20U K7M(K7MDRT20U) K7MDR30U (K7MDRT30U) Main Unit K7MDR40U (K7MDRT40U) K7MDR60U (K7MDRT60U)

unit

(Relay

Output point 8 points(4 points) 12 points(8 points) 16 points(12 points) 24 points(20 points) Insulation method Relay insulation Rated load voltage/current DC24V / 2A (r/load), AC220V / 2A (COS = 1)/1 point , 5A / 1COM Min. load Voltage/current DC5V / 1mA Max. load voltage/current AC250V, DC110V Current leakage when off 0.1mA (AC220V, 60Hz) Max. On/off frequency 1,200 times/hr Surge Absorber None Mechanical More than 20,000,000 Rated on/off voltage/current load 100,000 or more Life Electrical AC200V / 1.5A, AC240V / 1A (COS0.7) 100,000 or more = AC200V / 1A, AC240V / 0.5A (COS0.35) 100,000 or more = DC24V / 1A, DC100V / 0.1A (L / R = 7ms) 100,000 or more Response time On Off On 10 ms or lower Off 12 ms or lower

Operation indication LED is on at on status of output

6-6

Chapter 6 Specification
(2) type Economic Model Specifications DR30UE

Input

and

Output

Main Unit K7M-DR10UE K7M-DR14UE K7M-DR20UE K7M-

Output point 4 points 6 points 8 points 12 points Insulation method Relay insulation Rated load voltage/current DC24V / 2A (r/load), AC220V / 2A (COS = 1)/1 point , 5A / 1COM Min. load Voltage/current DC5V / 1mA Max. load voltage/current AC250V, DC110V Current leakage when off 0.1mA (AC220V, 60Hz) Max. On/off frequency 1,200 times/hr Surge Absorber None Mechanical More than 20,000,000 Rated on/off voltage/current load 100,000 or more Life Electrical AC200V / 1.5A, AC240V / 1A (COS0.7) 100,000 or more = AC200V / 1A, AC240V / 0.5A (COS0.35) 100,000 or more = DC24V / 1A, DC100V / 0.1A (L / R = 7ms) 100,000 or more Response time On Off On 10 ms or lower Off 12 ms or lower

Operation indication LED is on at on status of output

2) Circuit

L Interna l circui t

Relay COM

6-7

Chapter 6 Specification
3) wiring (1) unit Output

Input

and

Output

Main

L L

L L

L L

L L

L L

L L

L L

L L

L L

L L

L L

DC5V DC24V

DC24V

AC110/220V

DC24 V

6-8

Chapter 6 Specification

Input

and

Output

6.3.2 Main unit (TR Output : DRT/DT type only)

1) Specification Model Specifications DRT/DT60U K7M-DRT/DT20U Main Unit K7M-DRT/DT30U K7M-DRT/DT40U K7M-

Output point 4 points / 8 point 4 points / 12 point 4 points / 16 point 4 points / 24 point Insulation method Photo coupler insulation Rated load voltage DC12/24V Operation load Voltage DC10.2 ~ 26.4V Max. load current 0.5A/1 point (DRT Type P40~P43: 0.1A/1point, DT Type P40~P41 0.1A/1point) Current leakage when off Less than 0.1mA Voltage drop when on Less than DC0.3V Surge Absorber Zener diode Inrush current Less than 4A, 10ms Response time On Off On 0.2 ms or lower Off 0.2 ms or lower

Operation indication LED is on at on status of output

P40,P41 24V

Interna l Circuit R2

TR1

R 3

P42,P43 24V P/C Interna l Circuit R2 R 3 TR1

REMARK 1) Output TR P000 ~ P003 of DRT Type(K7M-DRT20/30/40/60U) are for positioning function. 2) They also can be used as general transistor output, but cant be used for AC load. When used for AC loads, they can be destroyed.

6-9

Chapter 6 Specification
2) wiring Output

Input

and

Output

AC100-240V FG

P40

P41

P42 COM2 P43

P COM3

COM0 COM1

LLLL DC12V/24 V

6-10

Chapter 6 Specification

Input

and

Output

6.3.3 Expansion Module

1) Specifications Model Specifications DR20A Expansion Module G7E-

G7E-DR10A

G7E-DR08A

G7E-RY08A

Output point 4 points 8 points Insulation method Relay insulation Rated load Voltage/current DC24V / 2A (Resistive load), AC220V / 2A (COS 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 times/hr Surge Absorber None Mechanical More than 20,000,000 Rated on/off voltage/current load 100,000 or more Life Electrical AC200V / 1.5A, AC240V / 1A (COS0.7) 100,000 or more = AC200V / 1A, AC240V / 0.5A (COS0.35) 100,000 or more = DC24V / 1A, DC100V / 0.1A (L / R = 7ms) 100,000 or more Off On 10 ms or lower Response time On Off 12 ms or lower Operation indication LED is on at on status of output = 1) / 1 point 5A / 1COM

2) Circuit Its the same with the output circuit of the main unit. 3) wiring Output

L L L L L L

DC5V DC24V AC110/220V

DC5V/24V AC110/220V

6-11

Chapter 6 Specification
Model Specification s

Input

and

Output

Expansion Module G7ETR10A

Output point 10 points Insulation method Photo coupler insulation Rated load Voltage/current DC12V/24V Operating load voltage range DC10.2 ~ 26.4V

Max. load current 0.5A/1 point, 4A/1COM Current leakage when off 0.1mA or lower Max. inrush current 4A/10ms or lower Max. Voltage drop when on DC 1.5V or lower Surge Absorber Clamp diode Response time Off On 2 ms or lower On Off 2 ms or lower

Common method 10 points/ 1COM, Operation indication LED is on at on status of output

DC12/24 V

L L L L L L L L L L

REMAR K 1) Refer to 7.2 Special Functions for the special modules

6-12

Chapter 7 Functions

Usage of Various

Chapter 7. Functions

Usage

of

Various

7.1 Built-in Functions

7.1.1 High-speed function counter

This chapter describes the specification, handling, and programming of built-in high speed counter of MASTER-K120S. The built-in high speed counter of MASTER-K120S(hereafter called HSC) has the following features; Linear counter : Up/Down counter. Counting range is from -2,147,483,648 to 2,147,483,647 Ring counter : Counter value rotates from 0 to (set value1) counter 4 functions as followings operation 1-phase mode pulse + direction mode : Up / down is selected by direction 1-phase Counter pulse CW/CCW mode : Up / down is selected by CW or CCW pulse 2-phase mode input multiplication mode : Up / down is automatically selected by the 2-phase phase difference between A-phase and B.(multiplied by 4) Preset function Change current value to preset value. counter Latch Latches current Additiona value. Comparison output When current value is equal to comparison value, turns on the output contact l functio points or executes interrupt n program RPM function Calculate the RPM(Rotates Per Minute) of input pulse Counter format 1) Performance Specifications Items Specifications Standard Type Economic Points 1 phase : 4 points, 2 Phase : 2 points 1 phase : 2 points, 2 Phase : 1 points Type 1-phase 10kHz/ Max. counting speed 1-phase 100kHz/ 2-phase 50kHz ( Ch0, 5kHz Ch1) 1-phase 20kHz/ 2-phase 10kHz ( Ch2, ( Ch0, Ch1) Input types A-Phase, Ch3) B-Phase, Preset input Counting ranges from -2,147,483,648 to 2,147,483,647(Binary 32 bits) 1-phase Up counter 1-phase Pulse + direction input A-Phase : Input pulse, B-Phase : Direction Up / Down pulse 2selectio phase CW/CCW mode A-Phase : Up counting pulse, B-Phase : Down counting n pulse2 phase multiplication mode Auto-select by phase difference of A-phase and AdditionalBfunction Ring counter, Latch counter, Preset, Comparison output, RPM function 2) specification Input Function Description

2-phase

Items Specifications Items Specifications Rated input 24VDC (7mA) Rated input 24VDC (7mA) On voltage 20.4 ~ 28.8VDC On voltage 20.4 ~ 28.8VDC Off voltage 6VDC or A / B phase Preset lower input On delay time 200 or Off voltage 6VDC or lower lower Off delay time 200 or lower 7-1

Chapter 7 Functions
3) Names terminals of

Usage of Various

wiring

Input pulse Preset input

BUILT_IN CNET

ON

OFF

ROM MODE

P00

P02

P04

P06

P08 P23

P10 P0F

COM0

COM1

P01

P03

P05 P07

P11

P22 24G 24V

Names No. Usage 1Phase 2Phase 1Phase Terminal No. 2Phase P00 Ch0 Input Ch0 A Phase Input Counter input terminal terminal P01 Ch1 Input Ch0 B Phase Input Counter input terminal terminal P02 Ch2 Input Ch2 A Phase Input Counter input terminal terminal P03 Ch3 Input Ch2 B Phase Input Counter input terminal terminal P04 Ch0 Preset 24V Ch0 Preset 24V Preset input terminal terminal P05 Ch1 Preset 24V - Preset input terminal P06 Ch2 Preset 24V Ch2 Preset 24V Preset input terminal terminal P07 Ch3 Preset 24V - Preset input terminal COM0 Input Common Input common terminal < Standard Type >

A Phase Input B Phase Input A Phase Input B Phase Input Preset input

Preset input

Names No. No. 1Phase 2Phase Usage 1Phase Terminal 2Phase P00 Ch0 Input Ch0 A Phase Input Counter input terminal A Phase Input terminal P01 Ch1 Input Ch0 B Phase Input Counter input terminal B Phase Input terminal P02 Ch0 Preset 24V Ch0 Preset 24V Preset input terminal Preset input terminal P03 Ch1 Preset 24V - Preset input terminal < Econnomic Type >

7-2

Chapter 7 Functions
4) External circuit I/O circuit

Usage of Various

interface Term i nal No.

3.3 k

Internal

Signal name 1Phase 2Phase Ch0 Input pulse Ch1 Input pulse Ch2 Input pulse Ch3 Input pulse

Operat i on

P00

3.3 k

P01

Input

3.3 k

P02

P03
3.3 k

Ch0 A Phase Input lower Ch0 B Phase Input lower Ch2 A Phase Input lower Ch2 B Phase Input lower

Input warranted voltag e On 20.4~28.8V 6V or On 20.4~28.8V

Off

Off

6V or On 20.4~28.8V

Off

6V or On 20.4~28.8V

Off

6V or

CO M0 Common
3.3 k

P04

Ch0 Prese tinput Ch1 Prese tinput Ch2 Prese tinput Ch3 Prese tinput

Ch0 Prese tinput lower Ch2 Prese tinput lower -

On 20.4~28.8V Off 6V or On 20.4~28.8V Off 6V or lower On 20.4~28.8V Off 6V or On 20.4~28.8V Off lower 6V or

3.3 k

P05

Input

3.3 k

P06

3.3 k

P07

CO M0 Common

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 MASTER-K120S, take the following precautions against wiring noise. (1) Be sure to use shielded twisted pair cables. Also provide Class 3 grounding. (2) Do not run a twisted pair cable in parallel with power 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.

7-3

Chapter 7 Functions
6) example Wiring

Usage of Various

(1) Voltage generator

output

pulse

Pulse Pulse Generator Generator

24V

CHSC
A

B COM

24VG

(2) Open generator

collector

output

pulse
24V

CHSC Pulse Pulse Generator Generator

COM A

24VG

7-4

Chapter 7 Functions
7) Instruction(HSCST) HSCAST counter Instructio n S SV CV

Usage of Various

High

speed Available Flag device

#D

No. of integer steps Error (F110) Zero (F111) Carry (F112)

MPKLFTCSD

7/9

Flag set

Designation S Channel which is designated at parameter(0~3)

Error (F110)

Error flag turns on when designating area is over

SV

Set value (binary 32 bits) Range : (-2,147,483,648 ~ 2,147,483,647)

CV Current value of HSC stored area

HSCST S SV CV (1) Functions When input condition turns on, corresponding high speed counter is enabled. When input condition turns off, high speed counter stop counting and turns output point off . The current value is retained. The high speed counter can counts from -2,147,483,648 to 2,147,483,647(binary 32bits). When current value is greater than set value, output point F17*(* is channel number) turns on and it turns off when current value is less than set value. If current value is greater than 2,147,483,647, carry flag F18* turns on and and it turns off when input condition turns off. If HSC designated as ring counter, carry flag is set when current value reaches set value. If current value is smaller than -2,147,483,648, borrow flag F19* turns on and and turns off when input condition turns off If designated as ring counter, if current value is 0, borrow flag is set at next pulses rising edge and current value goes set value 1(in down counter mode) (2) Error code Code Error Actions Corrective

H10 Mode setting error When Ch0 is set as 2-Phase, Ch 1 cant be used and Ch3 cant be used if Ch2 is set to 2-Phase. H11 Ring counter setting error Adjust the range of ring counter within 2 ~ 2,147,483,647. H12 SV2 setting error Set SV2 greater than SV1 if zone comparison set is selected. H13 Ring counter and SV2 setting error Adjust the range of ring counter within 2 ~ 2,147,483,647 Set SV2 greater than SV1if zone comparison set is selected

7-5

Chapter 7 Functions
8) Setting Parameter Format

Usage of Various

(1) setting

(a) Linear counterHSC is designate as Linear counter, it can counts from -2,147,483,648 to If 2,147,483,647. The carry flag F18*(* is channel number) turns on when the current value of high speed counter is overflow during up counting and HSC stop counting. The borrow flag F19*(* is channel number) turns on when the current value of high speed counter is underflow during counting and HSC stop down counting. Carry and borrow flags can be reset by preset operation and HSC can re-starts its operation. 2,147,483,647 Current value Decreasin g Borrow occurs (b) Ring counter If HSC is designate as Ring counter, it can counts from 0 to set value. The carry flag turns on when the current value of high speed counter reaches set value during up counting and current is changed to value 0. The borrow flag turns on when the current value of high speed counter is reaches 0 during down counting and current is changed to set value value 1. When set value is out of range(2 ~ 2,147,483,647), Ring counter setting error(h11) occurs and HSC operates as linear counter . When current value is changed to out of range(2 ~ 2,147,483,647) by preset operation, Ring counter setting error(h11) occurs and HSC operates as linear counter. The ring counter setting error can be corrected by re-start of instruction(HSCST) only. 0 -2,147,483,648 Increasin g Carry occurs

Carry occurs Current value 0 Decreasin g Borrow occurs Increasin g

7-6

Chapter 7 Functions
(2) setting Mode

Usage of Various

(a) 1-phase operation mode - Current value increases by 1 at the rising edge of input pulse. A-phase pulse Current value input

(b) 1-phase pulse + direction mode - Current value increases by 1 at the rising edge of A-Phase pulse when B-phase is low state. - Current value decreases by 1 at the rising edge of A-Phase pulse when A-phase is High state.

A-phase pulse B-phase pulse Current value

input Low High

input

10

11

10

(c) 2-phase CW/CCW mode - Current value increases by 1 at the rising edge of A-Phase pulse when B-phase is low state. - Current value increases by 1 at the rising edge of B-Phase pulse when A-phase is low state. A-phase pulse B-phase pulse Current value input

input

10

11

12 7-7

11

10

Chapter 7 Functions

Usage of Various

(d) 2-phase multiplication mode (MUL4) - Up or Down is set automatically by the phase difference between A and B phase. Up counter - At the rising edge of A-Phase pulse when B-phase is low. - At the falling edge of A-Phase pulse when B-phase is high. - At the rising edge of B-Phase pulse when A-phase is high. - At the falling edge of B-Phase pulse when A-phase is low. Up counter - At the rising edge of A-Phase pulse when B-phase is high. - At the falling edge of A-Phase pulse when B-phase is low. - At the rising edge of B-Phase pulse when A-phase is low. - At the falling edge of B-Phase pulse when A-phase is high. A-phase pulse B-phase pulse Current value input

input

10 11 12 13 14 15 16 17 18

17 16 15

14

13

(3) setting

Preset

(a) Internal Preset - Set internal preset area and preset value. - Current value of high speed counter is replaced with preset value at the rising edge of internal preset device. (b) External Preset - Set external preset area and preset value. - External devices are fixed as following Ch0 : P4, Ch1 : P5, Ch2 : P6, Ch3 : P7 - Current value of high speed counter is replaced with preset value at the rising edge of external preset device. 7-8

Chapter 7 Functions
(4) Latch setting

Usage of Various
Counter

If this function is enabled, Current value of high speed counter is always retained.

Current value - When power supply is off. - When is Stop or Pause - When input condition of HSCST is off 0 Latches CV Latches CV Time

(5) Comparison setting

Output

(a) Comparison set - When current value of HSC is equal to SV1, corresponding output point turns on. - P40 ~ P47 are available for comparison output point.

Input pulse Output Contact Current value

98

99

100

101

102 7-9

Chapter 7 Functions

Usage of Various

(b) Zone Comparison Set - When current value of HSC isnt less than SV1 and more than SV2. corresponding output point turns on. - P40 ~ P47 are available for comparison output point. - If SV2 is less than SV1, SV2 setting error(h12) occurs and zone comparison set is disabled.

Input pulse Output point Current value

999

1000

2000

2001

(c) Comparison Task - If Comparison Task is selected in parameter window, corresponding interrupts is enabled. - When current value of HSC is equal to SV1, corresponding interrupt program is executed. - For the details about programming, refer to KGLWIN Users Manual.

7-10

Chapter 7 Functions
(6) RPM setting

Usage of Various

- Can calculates RPM of input pulse - RPM is stored in designated device.

- The RPM is expressed as:

RPM = (Current Value - Last Value) 60,000 Pulses per rotate refresh cycle[ms]

(a) Examples of Program - Refresh cycle : 1000ms, Pulses per rotate : 60, RPM save area : D0 Input pulse Current value D0, D1 Time 1000 2000 2001 4000

500 1000ms 3000ms

1000

2000 2000ms

Last value = 500(Assumption), Current value = 1000 = { (1000 500) * 60,000} / {60 * 1000} = 500 RPM Last value = 1000, Current value = 2000 RPM = { (2000 1000) * 60,000} / {60 * 1000} = 1000 Last value = 2000, Current value = RPM4000(4000 2000) * 60,000} / {60 * 1000} = 2000 ={

7-11

Chapter 7 Functions
9) example

Usage of Various

Programming

(1) Parameter setting Channel : Ch0 Counter format : Ring counter ( 0 ~ 100,000) Counter mode : 2-phase multiplication mode - P0 : A-phase pulse input, P1 : B-phase pulse input Prese t - Preset type : internal preset (M100) - Preset value : 0 Last counter setting None Comparison output - Output mode : Zone comparison set - SV1 : 10,000 SV2 : 20,000 - Output point : P43 RPM setting Refresh cycle 100(*10ms) - Pulses per rotate : 60 - RPM save area : D100 :

7-12

Chapter 7 Functions

Usage of Various

(2) Programming When M0 turns on, HSC starts its operation If current value is not less than 50,000, F170 turns on. Current value is saved in D0(double word).

Remar k The contact point which is designated as HSC input cant be used for pulse catch or external interrupt. Duplicated designation may cause faults.

7-13

Chapter 7 Functions 7.1.2. Pulse Function

Usage of Various Catch

In the main unit, 4(economic type) or 8(standard type) points of pulse catch input contact points are internalized. Through using this contact point, short pulse signal short can be taken which can not be executed by general digital input. 1) Usage When narrow width of pulse signal is input, a trouble occurs which can not be detected by general digital input, so the operation does not perform as user's intention. But in this case through pulse catch function even narrow interval of pulse signal as 10 min. can be detected. 2) Minimum width. input pulse

Type Standard Economic 10 2 points (P0, P1) None 50 6 points (P2 ~ P7) 4 points (P0 ~ P3)

3) Explanation

Operating 10

input signal

input data

image scan 1 scan 2 scan 3

step contents scan1 CPU status. scan2 used image scan3 used image

executing senses input when pulse signal, min. 10 , is input, then saves the to turn on the region of input to turn off the region of input

4) 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.

7-14

Chapter 7 Functions

Usage of Various

Remark

1) Pulse catch input contact points operate as general digital input if they are not designated as pulse catch input. 2) Do not designate HSC input points as pulse catch input.

7-15

Chapter 7 Functions 7.1.3 Input Function

Usage of Various

Filter

External input of MASTER-K120S selects input on/off delay time from the range of 0-1000ms of KGLWIN. Credibility secured system may be established by adjustment of input correction no. through using environment.

1) Usage Input signal status affects to the credibility of system in where noise occurs frequently or pulse width of input signal affects as a crucial factor. 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) Explanation Operating
Input on/off delay 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 one of 0,1,2,5,10,20,50,100,200,500,1000ms to the input on/off delay time of the basic parameter window.(Input on/off delay time is set up as default value of 10ms) (3) Set up input on/off delay time is conformed to all input is used.

The range 1000ms

of

0-

7-16

Chapter 7 Functions

Usage of Various Interrupt

7.1.4 External Function

MASTER-K120S Series can perform max 4(economic) or 8(standard) points of external contact interrupt by using input of main unit without special interrupt module. 1) Usage This function is useful to execute a high speed execution regardless of scan time. 2) Minimum time. processing

Type Standard Economic 10 2 points (P0, P1) None 50 6 points (P2 ~ P7) 4 points (P0 ~ P3) 3) Operating explanation

External signal

input

Scan program

Scan program

In case of occurrence of external interrupt signal pause being executed scan program and process interrupt program

External contact interrupt program.

End the interrupt program process then resume to execute scan program

4) Function

(1) Max. 8 points can be used to external interrupt input within P000 ~ P007.(P000~P003 for economic type) (2) The no. of external interrupt is decreased by using other interrupt (time driven interrupt and HSC driven task) (3) The execution conditions of external interrupt is divided into following 3 kinds. - Rising edge : Interrupt occurs at rising edge of external Interrupt contact point. - Falling edge : Interrupt occurs at falling edge of external Interrupt contact point. - Rising & falling edge : Interrupt occurs at both edge of external Interrupt contact point. (4) In the economic type, falling edge and rising & falling edge interrupt are not available.

7-17

Chapter 7 Functions
5) Usage

Usage of Various

(1) Click twice the parameter on the project window of KGLWIN. (2) Designate contact point, no. of priority and movement condition of the task program which is moved by interrupt inputting.

Time driven Interrupt execution periodic set

interrupt input contact No.

interrupt input e

Rising Falling Rising/Falling

xecutin g

condition

(3) For the details , refer to KGLWIN manual.

7-18

Chapter 7 Functions

Usage of Various

7.1.5 PID control function(Standard type only)

1) Introduction This chapter will provide information about the built-in PID (Proportional Integral Derivative) function of MASTERK120S main unit. The MASTER-K120S series does not have separated PID module like MASTER-K300S and MASTERK1000S series, and the PID function is integrated into the main unit. The PID control means a control action in order to keep the object at a set value (SV). 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 derivative (D).
Manual MV

Set Value

SV Manipulation PID
calculation

MV

valu e

D/A
converting Automated MV module

Control object

Present Value

PV

A/D converting
module

Sensor

The characteristics of the PID function of MASTER-K120S 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 control module. P operation, PI operation, PID operation and On/Off operation can be selected easily. PWM(Pulse Width Modulation) output is available. 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 optimizing to the system characteristics. SV Ramp and Delta MV function are available.

7-19

Chapter 7 Functions

Usage of Various

2) Specification (1) Control operation (a) Proportional operation (P operation) P action means a control action that obtain a manipulate value which is proportional to the deviation (E : the difference between SV and PV) The deviation (E) is obtained by difference between SV and PV and the formula of deviation is as following;

MV = Kp [] - P SV V

where, Kp

: the proportional constant (gain), value,

SV: set PV: value

present

When E happens, MV by P operation is like Fig.7.1

: Deviatio n : Manipulatin valu g e

Deviation(E) (MV)

Manipulate value

Time Fig 7.1 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. 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. 7.2. The manipulation value (MV) varies from 0 to 4,000. User can define the maximum value of MV (MV_MAX) and minimum value (MV_MIN) within the range 0 ~ 4,000. 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

: Kp is too large PV SV Oscillation : Kp is too small

Offset

Time

Fig. 7.2 The relation between Proportional constant (Kp) and prosent value (PV)

7-20

Chapter 7 Functions

Usage of Various

(b) Integral operation (I operation) With integral operation, the manipulate value (MV) is increased or decreased continuously in accordance time in order to eliminate the deviation between the SV and PV. When the deviation is very small, the proportional operation can not produce a proper manipulate value and an offset remains between PV and SV. The integral operation can eliminate the offset value even the deviation is very small. The period of the time from when the deviation has occurred in I action to when the MV of I action become that of P action is called Integration time and represented as Ti. Integral action when a constant deviation has occurred is shown as the following Fig. 7.3.

Fig. 7.3 deviation

The integral action with constant

The expression of I action is as following; Kp M = Ed Ti t V As shown in the expression, Integral action can be made stronger or weaker by adjusting integration time (Ti) in I action. That is, the more the integration time (the longer the integration time) as shown in Fig. 7.4, 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. 7.5, 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 I value is requested. Integral action is used in either PI action in which P action combines with I action or PID action in which P and D actions combine with I action.

7-21

Chapter 7 Functions

Usage of Various

Fig. 2.5 The system response when a long integration time given

Fig. 7.4 given

The system response when a long integration time

Fig. 2.6 The system response when a short integration time given Fig. 7.5 given The system response when a short integration time

(c) Derivative operation (D action) When a deviation occurs due to alteration of SV or external disturbances, D action restrains the changes of the deviation by producing MV which is proportioned with the change velocity (a velocity whose deviation changes at every constant interval) in order to eliminate the deviation. 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. D action can prevent the large changes of control object due to external conditions. 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 Td. 7-22

Chapter 7 Functions

Usage of Various

The D action when a constant deviation occurred is shown as Fig. 7.6

Fig. 7.6 deviation

Derivative action with a constant

The expression of D action is as following; dE

MV = Kp Td

dt

Derivative action is used only in PID action in which P and I actions combine with D action. (d) PID action PID action controls the control object with the manipulation quantity produced by (P+I+D) action PID action when a given deviation has occurred is shown as the following Fig. 7.7.

Fig. 7.7 deviation

PID action with a constant 7-23

Chapter 7 Functions

Usage of Various

(e) Integral windup All devices to be controlled, actuator, has limitation of operation. The motor has speed limit, the valve can not flow over the maximum value. When the control system has wide PV range, the PV can be over the maximum output value of actuator. At this time, the actuator keeps the maximum output regardless the change of PV while the PV is over the maximum output value of actuator. It can shorten the lifetime of actuator. When the I control action is used, the deviation term is integrated continuously. It makes the output of I 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. 7.8 shows the PV and MV of PI control system when the windup occurs. As shown as the Fig. 7.8, 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 < 0). However, the MV keeps the saturated status until the integral term is small enough to cancel the windup of actuator. As the result of the windup, the actuator will output positive value for a while after the PV reached to the SV, and the system show a large overshoot. A large initial deviation, load disturbance, or miss-operation of devices can cause windup of actuator. There are several methods to avoid the windup of actuator. The most popular methods are adding another feedback system to actuator, using the model of actuator and stop integrating when actuator is saturated.

PV SV

10

MV

Integral Term

Fig. 7.8 windup .

Example

of

integral

7-24

Chapter 7 Functions

Usage of Various

(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. (a) P control The digitized formula of P control is as following;

P (n) = K [] ( n) - P (n ) SV V

n : sampling number K : proportional gain constant b : reference SV : set value PV : present value value

(b) I control The continuous formula of I control is as following; K t integral I (t) = e(s)ds : T 0 term i K : proportional gain constant e(s) : deviation value By derivation about t, we can obtain; Ti : integral time

dI K = e where, dt Ti value
The digitized following; formula

e = (SV PV) : deviation is as

I (n + 1) - I (n) K = e(n) where h Ti , Kh I (n + 1) = I(n) + e(n) Ti

h : period

sampling

(c) D control The continuous formula of derivative term is as following; Td d dy

dt

D + D = - KTd

dt

N : high frequency noise depression ration y : the object to be controlled (PV) (3) Instruction and parameter setting For the PID operation of MASTER-K120S, following 2 instruction are included in the KGLWIN software. No. Name Description 1 PID8 Perform the PID operation 2 PID8AT Perform the auto tuning operation

7-25

Chapter 7 Functions
(4) parameter explanation

Usage of Various
setting and parameter setting and

(a) PID8 instruction explanation.

Scan time Scan time is the period of reading data (sampling), and also 10 times scaled up. The range of sampling time is 0.1 ~ 10 seconds, and actual input range is 0 ~ 100. Generally, Scan time of Digital PID control should be less than 1/10 of time constant of system response for better performance. Time constant is the time taken the systems step response reaches to the 63% of steady state. Operation mode Select automatic or manual operating mode Manual operate range When manual operation is designates , manual operation value designates.(input range : 0 ~ 4000) Output limit value Designate minimum and maximum values of available manipulate value.(range : 0 ~ 4000) 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) .

7-26

Chapter 7 Functions

Usage of Various

Proportional gain The MASTER-K120S can handle only integer, not the floating point type. Therefore, to enhance the accuracy of PID operation, the PID8 instruction is designed to input the P_GAIN data as the 100 times scaled up. For example, if the designated P_GAIN is 98, actual input data of P_GAIN should be 9800. If the designated is 10.99, input 1099 to the P_GAIN P_GAIN. Derivative time and integral time I_TIME and D_TIME are 10 times scaled up. For example, input 18894 if the designated I_TIME value is 1889.4. of actual input is 0 ~ 20000. (it is possible that parameter value designates D area The range also) Mode command set In MASTER-K120S, only the following 7 operation modes are available. Other operation modes, such as PD or I, are not permitted. No. EN_P EN_I EN_D PWM output Operation 1 1 (enable) 0 (disable) 0 (disable) P operation 2 1 (enable) 1 (enable) 0 (disable) PI 0 operation (disable) 3 1 (enable) 1 (enable) 1 (enable) 4 1 (enable) 0 (disable) 0 (disable) P operation/PWM

PID operation

output 5 1 (enable) 1 (enable) 0 (disable) PI operation/PWM 1 output (enable) 1 (enable) 1 (enable) 6 1 PID (enable) output 7 0 (disable) 0 (disable) 0 (disable) 0 (disable) On/Off operation PWM set

operation/PWM

PWM(Pulse Width Modulation) is a output method which changes on-off duty of output pulses by calculated manipulation value. Fig 7.9 shows example of PWM output. Using PWM output, PID control system can be constructed easily without D/A conversion module and power regulator. When PWM is designates , scan time item is disabled and PWM items can be designated. In this case, scan time is set to designated PWM output period. The range of PWM output period is 1 ~ 10 seconds, and actualrange is 10 ~ 100. PWM output point is only available for output contact of main input unit. Example) PWM output period : 1s, Output contact : P40, MV limit range : 0~4000 MV = 2000 MV = 1000 0.5s 0.25s 0.75s On P40 Time 0.5s

7-27

Chapter 7 Functions
SV Ramp

Usage of Various

If a large amount of SV changes during PID operation, The deviation(E) changes rapidly. Then manipulation changed rapidly also. This can cause damage on load or actuator. To prevent this situation, SV value(MV) is can changed step by step by parameter be setting. range is 1~4000(Default value is 1). Setting value represents the number of time which taken Setting from starting set value to last set value. For example, if SV-ramp is set to 1000 and SV changed from 1000 to 3000 during operation, it changes 2 every and reach 3000 after 1000 scan scan time. SV Ramp = 1 Changed SV SV Ramp designates Current SV SV Ramp * Scan time Time Delta MV This is useful when wants to limit maximum change of manipulation value. range is 0 ~ 4000 and default value is Setting 4000. Bias The Bias data is used for the compensation of offset in the proportional control. The range of input is 0 ~ 4000. cautious that The actual range of Bias is 2000 ~ 2000. namely, 0~2000 represents 0 ~ +2000 and Be 2001 ~ represents -1 ~ 4000 -2000. Example> If offset(SV-PV) is 100 Bias should be 100. offset(SV-PV) is -100 If Bias should be 2100. SV(Target) and PV(Current) SV (setting value : the designated value) and PV (process value : present value) of MK120S 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 MK120S series (12bits) value. and offset is

PID Algorithm In MASTER-K120S, two type of PID algorithm is available, The velocity form(Speed) and positioning form. Velocity form(Speed) operates incremental manners. Namely, It calculates the change( n) required from previous manipulate value(MVn-1), But positioning form calculates an absolute manipulate value(MVn) every sampling steps. Generally, The velocity form is suit for the system whichs load change is slow like temperature control system, and positioning form is useful for system whichs load change is fast.

7-28

Chapter 7 Functions

Usage of Various

(b) PID8AT instruction parameter setting and explanation.

Scan time S_TIME is the period of reading data (sampling), and 10 times scaled up for more precious operation. The range of sampling time is 0.1 ~ 10 seconds, and actual input range is 0 ~ 100. Control target(SV) SV (set value : the designated value) and PV (process value : present value) of MASTER-K120S PID operation have the range 0 ~ 4000. The range is set with the consideration of the resolution of A/D and D/A module of MASTER-K120S series (12 bits) and offset value. When setting the SV or PV, please be careful convert the analog value of control object (temperature, velocity, etc.) to digital value that are the output of A/D convert module.

When using sensor and A/D conversion module Assume that PID control is used for temperature control with Pt100 (operation range : C ~ 600 C), -200 and the goal value is C. The equivalent digital output of A/D module (current input range : 4 ~ 20mA) 100 is 1500 if the A/D module outputs 0 (4mA) withC, and 4000(20mA) with C. Therefore, the input -200 600 of SV should be 1500, not 100.

When using sensor and RTD module(G7FRD2A) Assume that PID control is used for temperature control with Pt100 (operation range : -200 and the goal value is C. The digital output of RTD module is calculated as 100 below. Temp. 10 + 2000
DigitalOut put = 2

C ~ 600 C),

Therefore, SV should be 1500, Tuning method The MASTER-K120S perform auto-tuning operation in two methods. One is relay response method and the other is process reaction curve method. 7-29

Chapter 7 Functions
Relay method.

Usage of Various

response PID parameters are obtained by On/Off operation during 1 cycle of PV variation. PID parameters are obtained by amplitude and period of oscillation The On/Off operation will be occur at the SV value. MV Period SV Amplitud e

Process reaction curve method(PRC method). PID parameters are obtained by step response of process. s It is useful fo r time 1torder time delay system expressed as following e- L s

case, use method.

relay

Obtained parameters may not accurate if the process cant approximated to 1 response Time delay(L) MV 80% of SV

T +1 s

st

order this

system,

In

4000

63% of SV

Time constant(T)

7-30

Chapter 7 Functions
5) instruction (1) PID8 PID8 Control

Usage of Various

PID

Instructio n n S1

Available Flag
MPKLFTCSD

device
#D

No. of integer Steps Error (F110) 5

Zero (F111)

Carry (F112)

Flag set Error flag turns on when designating area is over

Designation n Registration No. at parameter(0~7)

Error (F110)

and the instruction isnt executed. S1 Execution status registration area

PID8 n S1 a) Usage

when the condition of execution is on, PID operation executes. n is registration No.at parameter( 0 ~ 7) Example

b) program

When the input condition M0 turns on, PID operation executes at no.2 parameter. PID execution status registrate D0000 and the output value of control result registrate D0001 If SV Ramp is designated, current SV is registrate D0005 bF bE bD bC bB bA b9 b8 b1 b7 b6 b5 b4 b3 D0000 b2 b0

Done : signal

normal

execution

7-31

Chapter 7 Functions
(2) PID8AT PID8AT Tuning

Usage of Various

PID

Auto

Instructio n n S1

Available Flag
MPKLFTCSD

device
#D

No. of integer steps Error (F110) 5 Zero (F111) Carry (F112)

Flag set Error (F110) Error flag turns on when designating area is over

Designation n Registration No. at parameter(0~7) and the instruction isnt executed. S1 Execution status registration area

PID8AT n S1 a) Usage when the condition of execution is on, PID auto tuning operation executes and calculates P,I,D constant n is registration No.at parameter( 0 ~ 7) S1 is execution status and P,I,D constant registration area b) program Example

When the input condition M0 turns on, PID operation executes at no.2 parameter. PID execution status stores D0000 and the output value of control result stores D0001 and P,I,D constant sequentially store D002(P),D003(I),D004(D) bF bE bD bC bB bA b9 b8 b1 b7 b6 b5 b4 b3 D0000 b2 b0

Auto tuning end bit Done : signal normal execution

7-32

Chapter 7 Functions

Usage of Various

6) Program Example (1) System configuration

MASTER-K120S DA2I

G7F-

G7FRD2A

RS-232C KGLWIN V3.5 above (PV temperature) (MV: 4~20mA) Heate r Electric Oven :

TPR

(2) In case of using PID function only

When PWM set is selected, Scan time parameter is disabled and this value is ignored

When PWM is designated, this window is activated and PID function operates by PWM period

7-33

Chapter 7 Functions

Usage of Various

a) PID operation explanation (without A/T function) Measure current temperature (- C) by RTD module then digital conversion value(0 ~ 4000) is stored 200~600 to D4780 PID8 instruction will calculate manipulate value (MV : 0 ~ 4000) based on PID parameter settings (P_GAIN, I_TIME, D_TIME, etc.) and PV from RTD module. Then, the calculated MV is output to the channel 0 of D/A module. D/A module will convert the MV to analog signal and output to the actuator (power converter). b) operation parameters Scan time : S_TIME=5 (sampling time = 0.5 seconds) Auto / Manual operation setting : Auto Output limit : Max. = 4000, Min = 0 High frequency noise removal ratio : 10 SV setting : 1300(60C ),1350(7 C ),1400(8 C ),1500(10C) 0 0 0 Current value setting : D4780(Digital value of RTD module Ch0) BIAS setting : 0 (If only P control is used, input proper value other 0) EN_P, EN_I, EN_D setting : input proper values PWM setting : If enabled, input proper values. SV Ramp setting : Input proper values. Delta MV setting : Input proper values. PID Algorithm setting : Select proper algorithm. c) RTD module setting Channel setting : use channel 0 RTD Type setting : Pt100 Digital conversion data registration : D4780 area d) D/A module setting Channel : use channel setting 0 output range setting: DC 4 ~ 20 mA D/A conversion data registration area D4980

7-34

Chapter 7 Functions

Usage of Various

e) Program Explanation When the input condition M0 turns on, PID operation executes at no.0 parameter. PID execution status registrate D0000 and the output value of control result registrate D0001 If SV Ramp is designated, current SV is registrate D0005 D/A module converts the MV to analog signal and output to the actuator (power converter). When the input condition M0 turns off, output 0 to the D/A conversion module.

When M0 turns on, operation executes PID parameter

at

no.0

The manipulated value is out to D/A module

When M0 turns off, CPU stop PID operation and output 0 to D/A module (3) In case of using combined function of PID operation and Auto tuning. a) PID operation explanation (with A/T function) Measure current temperature (- C) by RTD module then digital conversion value(0 ~ 4000) is stored 200~600 to D4780 PID8AT instruction will calculate manipulate value (MV : 0 ~ 4000) based on the SV and PV from RTD module. Simultaneously, the PID8AT instruction will calculate P,I and D parameters. The END bit of auto tuning status device will be 1 when the auto tuning is completed. Then, MASTERK120S will start PID operation with PID parameters that are calculated by A/T module. b) Auto tuning parameters Scan time : S_TIME=5 (sampling time = 0.5 seconds) SV setting : 1300(60C ), 1350(70 C ),1400(8C ),1500(10C) 0 0 Current value setting : D4780(Digital value of RTD module Ch0) Identification method setting : Select PRC Method

When selected, the scan time to 1 fixed sec.

7-35

Chapter 7 Functions

Usage of Various

c) operation parameters Scan time : S_TIME=5 (sampling time = 0.5 seconds) Auto / Manual operation setting : Auto Output limit : Max. = 4000, Min = 0 High frequency noise removal ratio : 10 SV setting : 1300(60C ),1350(7 C ),1400(8 C ),1500(10C) 0 0 0 Current value setting : D4780(Digital value of RTD module Ch0) BIAS setting : 0 (If only P control is used, input proper value other 0) EN_P, EN_I, EN_D setting : input proper values PWM setting : If enabled, input proper values. SV Ramp setting : Input proper values. Delta MV setting : Input proper values. PID Algorithm setting : Select proper algorithm.

As a result of PID8AT execution, Proportional gain(P),Derivative time(D), Integral time(I) are stored D0102,D0103,D0104. d) RTD module setting Channel setting : use channel 0 RTD Type setting : Pt100 Digital conversion data registration : D4780 area e) D/A module setting Channel : use channel setting 0 output range setting: DC 4 ~ 20 mA D/A conversion data registration area D4980

7-36

Chapter 7 Functions

Usage of Various

f) Program Explanation When the input condition M2 turns on, PID auto tuning operation executes at no.0 parameter. When auto tuning finished, PID operation executes with calculated P,I,D parameter. PID execution status registrate D0000 and the output value of control result registrate D0001 If SV Ramp is designated, current SV is registrate D0005 D/A module converts the MV to analog signal and output to the actuator (power converter). When the input condition M2 turns off, output 0 to the D/A conversion module

When auto tuning ends, M0001 turns on and PID control starts. When M0002 turns on, auto tuning starts. Calculated P,I,D parameters are saved to D0002, D0003, D0004

When M0002 turns off, Output 0 to D4980

7-37

Chapter 7 Functions
6) Error code list (1) PID8AT
Error Code

Usage of Various

Descriptio n

Corrective action

H0100 Scan time setting range error Set scan time to available setting range H0200 PV setting range error Set PV setting to available setting range Set SV to available setting range SV H0300 SV setting range error If PRC identification method is selected, check current PV is less than SV.(SV should be greater than PV)

(2) PID8
Error Code

Descriptio n

Corrective action

H0100 Scan time setting range error Set scan time to available setting range H0200 Manual operation range error Setmanual opration value to available setting range H0300 Output limit value error(Min.) Set minimum output limit value to available setting range and Set it less than maximum output limit value Set maximum output limit value to available setting range and Set it greater than minimum output limit value

H0400 Output limit value error(Max.)

H0500 High frequency noise removal ratio setting error Set this parameter to available setting range H0600 Mode command set error Available mode command set are P, PI, PID(PWM for each), On-Off only.

H0700 PWM period setting error Set PWM period to available setting range H0800 P gain setting error Set P gain period to available setting range H0900 I time setting error Set I time period to available setting range H0A00 D time setting error H0B00 Bias setting error Set D time period to available setting range

Set Bias to available setting range

H0C00 PV setting range error Set PV to available setting range H0D00 SV setting range error Set SV to available setting range H0E00 SV Ramp setting error Set SV Ramp to available setting range H0F00 Delta MV setting error Set Delta MV to available setting range H1000 PID algorithm setting error Check PID algorithm setting H1100 Operation mode setting error Available operation mode is 0 or 1

7-38

Chapter 7 Functions

Usage of Various

7. 2 Special module
The special module and allocated data registers are as followings.
Data Register Expansion A/D Combination module Conversion module D/A Conversion module Analog timer

Item RTD input module

G7F-ADHA G7F-ADHB G7F-AD2A G7F-DA2I G7F-DA2V G7F-AT2A G7F-RD2A D4980 CH0 D4981 CH1 #1 D4982 CH0 D4983 D4984 CH0 D4985 CH1 #2 D4986 CH0 D4987 D4988 CH0 D4989 CH1 #3 D4990 CH0 D4991 CH0 A/D value A/D value D/A value - CH1 A/D value CH1 A/D value CH0 D/A value D/A value CH0 A/D value A/D value D/A value - CH1 A/D value CH1 A/D value CH0 D/A value D/A value CH0 A/D value A/D value D/A value - CH1 A/D value CH1 A/D value CH0 D/A value D/A value CH0 A/D value CH1 A/D value CH2 A/D value CH3 A/D value CH0 A/D value CH1 A/D value CH2 A/D value CH3 A/D value CH0 A/D value CH1 A/D value CH2 A/D value CH3 A/D value CH0 D/A value CH1 D/A value CH2 D/A value CH3 D/A value CH0 D/A value CH1 D/A value CH2 D/A value CH3 D/A value CH0 D/A value CH1 D/A value CH2 D/A value CH3 D/A value CH0 D/A value CH1 D/A value CH2 D/A value CH3 D/A value CH0 D/A value CH1 D/A value CH2 D/A value CH3 D/A value CH0 D/A value CH1 D/A value CH2 D/A value CH3 D/A value CH0 A/T value CH1 A/T value CH2 A/T value CH3 A/T value CH0 A/T value CH1 A/T value CH2 A/T value CH3 A/T value CH0 A/T value CH1 A/T value CH2 A/T value CH3 A/T value CH0 Temperature CH1 temperature CH2 temperature CH3 temperature CH0 temperature CH1 temperature CH2 temperature CH3 temperature CH0 temperature CH1 temperature CH2 temperature CH3 temperature

RTD input module store digital conversion value of temperature value to data registers as below
Expansion Temperature Digital conversion value Ch 0 Ch 1 Ch 2 Ch 3 Ch 0 Ch 1 Ch 2 Ch 3

#1 D4980 D4981 D4982 D4983 D4780 D4781 D4782 D4783 #2 D4984 D4985 D4986 D4987 D4784 D4785 D4786 D4787 #3 D4988 D4989 D4990 D4991 D4788 D4789 D4790 D4791

Remar k 1) Offset/gain value cant be changed, it is fixed. 2) Analog inputting is set the current since this is manufactured. 3) Extend to use max.3 Modules 7-39

Chapter 7 Functions

Usage of Various

7.2.1 A/D D/A Combination module

1) Performance specification The performance specification of the analog mixture module are following. Item G7F-ADHA ADHB G7FSpecification s

Analog Input

Analog output

Voltage DC 0~10V (input resistance more than 1 ) DC 0~20 (input resistance Input range 250 ) Current DC 4~20 (input resistance 250 ) Classified by parameter Digital output 12Bit( 0~4000) 1.Setting by jumper pin for V/I 1.Setting by dipswitch for selection selectionleft side of on upper part of on Voltage/Curren product voltage, product voltage, (Up: Down: (Left Right: t selection 2. Voltage/current selected by KGLWIN Current) Current) parameter 3. When current input is used, short the V and I terminal No. of channel 2 Channels/ 1 module Voltage DC Absolute max. input Current DC +12V +24 Voltage DC 0~10V (External load resistance 2 ~1 ) DC 0~20 (External load resistance 510 Output range ) 4~20 (External load resistance 510 DC Current ) Classified by parameter Digital Input 12Bit( 0~4000) Voltage/Curren t selection Separated from terminal No. of channel 1Channel / 1 module 1Channel / 2 module Voltage DC Absolute max. output +12V Current DC +24 Voltage DC0~10V : 2.5 (1/4000) DC0~20 : 5 (1/4000 ) Max. resolution Current DC4~20 : 6.25 (1/3200 ) Accuracy 0.5% [Full scale ] Max. conversion speed 1 /CH + scan time Isolation Photo coupler insulation between I/O terminals and PLC power (No isolation between supply Connect terminal 9channels) Points terminals *2 8 Points terminals *2 Internal current Consumption 20 External power supply 80 DC 21.6 ~ 26.4V 95

V/I

Common

Weight 240g 180g Remar k 1) Offset/gain value cant be changed, it is fixed. 2) Analog inputting is set the current since this is manufactured. 3) Extend to use max.3 Modules 7-40

Chapter 7 Functions

Usage of Various

2) Names of parts and functions Explain about names of parts and functionsG7F(1) ADHA No Contents. RUN Indicate the operating status the G7FLED ADHA Analog input terminal Voltage Input
CH0 (INPUT) V0 I0 COM0

Current inputCH0 (INPUT)

V0 I0 COM0

When current input is used, short the V and I terminal. Jumper pin of analog input Inpu Voltage Current S t e le c t Input Input
CHO CH 1

Right is CH.1selecting left is CH. 0 selecting Analog output terminal Voltage output
V+ V- I+ IOUTPUT

Connect parts upper pins jumper

by

Connect lower parts by jumper pins. Current output

V+ V- I+ IOUTPUT

Only one type of output (Current or Voltage)is available on a module External power input External voltage 24VDC needs to this terminal terminal. Extension This cable is used to connect while analog mixture module is cable used.. Extension cable connector The connector connects extension cable when extended module is used.

7-41

Chapter 7 Functions
(2) ADHB G7F-

Usage of Various

No Contents. RUN Indicate the operating status the G7FLED ADHB Analog input terminal Voltage Input
V0 I0 COM0

Current input

CH0 (INPUT) V0 I0 COM0

V0+ I0+ V1+ I1+ V0- I0V1- I1O U TPU T CH0 CH1

When current input is used, short the V and I terminal. Dip switch of analog input
I np u t S ele c t C h0 C 1

G7F-ADHB
PRO G R AMMA BL E LO G IC CO N TRO L L ER

PW R In p ut

24V V0 24G

CH0 CH1 COM0 I1 I0 V1 COM1

I NP UT

Analog output terminal Voltage output

Right : current input : voltage Left input Current output

V+ V- I+ IOUTPUT

V+ V- I+ IOUTPUT

Only one type of output (Current or Voltage)is available on a module External power input External voltage 24VDC needs to this terminal terminal. Extension This cable is used to connect while analog mixture module is cable used.. Extension cable connector The connector connects extension cable when extended module is used.

7-42

Chapter 7 Functions
3) setting Parameter

Usage of Various

(1) Scaling functionfunction convert automatically range when the inout/output range is not This matched. input/output is current , this function is useful that external equapment range is not matched each In case that other. (MASTER-K120S series converts range automatically as following : 0 ~ 20mA 4~ 20mA) 4000

4000

800 0 0 Resolution : 20 /4000 = 5 20 0 -1000 4 20

Resolution : 20 /3200 = 6.25

Conversion method is as below scaling conversion value (A/D conversion) = [(data of 0 ~ 20 ) 800] x 4000/3200 example) in case of 8 input at range 0 ~ 20 before the scaling conversion : 8 / 5 = 1600 after the scaling conversion : (1600 800) x 1.25 = 1000 scaling conversion value (D/A conversion) = [(data of 4 ~ 20 ) x 3200/4000] + 800 example) in case of 1000 output at range 4 ~ 20 current output value before the scaling conversion : 1000 x 5 = 5 current output value after the scaling conversion : (1000 x 0.8) + 800 = 1600 1600 x 5 = 8 7-43

Chapter 7 Functions
4) Wiring

Usage of Various

(1) Caution for wiring Make sure that external input signal of the mixture module of AC and analog I/O is not affected by induction noise or occurs from the AC through using another cable. Wire is adopted with consideration about peripheral temperature and electric current allowance. Thicker than Max. size of wire AWG22 (0.3 ) is better. If wire is put near to high temp. 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. Be sure to connect with care of polarity while connecting to external 24V DC power supply. In case of wiring with high voltage line or generation line, it makes induction failure so then it may cause of missoperation and out of order. (2) Wiring example a) Analog input
Voltage input Current input
Terminal Terminal V1
in p u t I1

+ +V0
in p ut I0 COM0

COM1

*1

*1

b) output

Analog

Voltage output V+ 2K~1 V*1

GN D

Current output I+ I*1

GN D

Less than 510

*1 : Be sure to use two-core twisted shield wire. careful to use that analog output is 1 * Be channel.

7-44

Chapter 7 Functions
5) I/O characteristics

Usage of Various

converstion

(1) Analog characteristics a) input Voltage

input

4000

2004 2003 2002

2000

2001 2000

0 0V 5V 10V Analog input voltage Input Voltage

A/D conversion characteristics (voltage input) In voltage input, digital amount 0 is output by 0V input and 4,000 is output by 10V input. Therefore input 2.5mV equals to digital amount 1, but value less than 2.5mV cant be converted. b) input Current

4000

2004 2003 2002

2000

2001 2000

0 0 10 20

Analog input current

Input Current

A/D conversion characteristics (Current input) Current input 0mA becomes output 0, 10mA does 2000 and 20mA does 4000. therefore input 5 digital amount 1, but value less tan 5 cant be converted. So abandon it. equals to

7-45

Chapter 7 Functions
(2) Analog characteristics a) output Voltage

Usage of Various

output

10V

5V 5.0025 5V

2.5

2000 20012002 200 0V 0V0 2000 4000

200

200

Digital input

Digital input value

D/A conversion characteristic (voltage output) Input of digital amount 0 outputs analog amount 0V, 4000 does 10V.Digital input 1 equals to 2.5mV of analog amount. b) output Current

20

10 10.005 10.000

2000 20012002 200 0 0V0 2000 4000

200

200

Digital input

Digital input value

D/A conversion characteristic (Current output) In current output, digital amount 0 exchanges to 0mA, and 4,000 does 20mA. Analog amount of digital input 1 equals to 5 .

7-46

Chapter 7 Functions
6) example Program

Usage of Various

(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) configuration System

Main Unit module

A/DD/A combination module

Expansion I/O allocation input : P000 ~ P03F Main unit Main unit output : P050 ~ P07F Expansion module input : P080 ~ P08F Expansion module output : P090 ~ P09F

c) Program

7-47

Chapter 7 Functions

Usage of Various

(2) Program which controls speed of inverter by analog output voltage of 5 steps a) Program explanation -.When P80 becomes On, 2000 output. -. When P81 becomes On, 2400 output. -.When P82 becomes On, 2800 output. -.When P83 becomes On, 3200 output. -.When P84 becomes On, 3600 output. b) configuration Main Unit module System

(5V) is (6V) is (7V) is (8V) is (9V) is

A/DD/A combination module

Expansion

c) Program

7-48

Chapter 7 Functions

Usage of Various

7.2.2 A/D Conversion module

1) Performance specifications The performance specifications of the analog input module are following. Item Specifications Voltage 0~10VDC 1 ) Current Analo 250 ) g input Voltage/Current Selectio n

( input resistance

Digital output (0~4000) 0~10VDC 2.5 Maximum (1/4000) DC 0~20 5 resolutio (1/4000) DC 4~20 5 n (1/3200) Overall accuracy 0.5% [Full Scale] Max. conversion speed 1 /CH + scan time Max. absolute input Voltage : 15V, Current : 25 Number of analog input point 4channels/1module Between input terminal and PLC power supply Isolatio : Photo coupler n isolation (No isolation between channels) Terminal connected 2 points/16 points terminal block Curren t Consumption +5V 100mA Voltage DC 21.6 ~ External 26.4V Power supply consumption Current 100 Weight 300g Remar k Offset/Gain value cant be changed, because it is fixed Analog inputting is set the current since this is manufactured. It is possible to use to extend max.3 modules

DC 4~20 ( input resistance DC 0~20 ( input resistance 250 )) -.Setting by input terminal (When current input is used, short the V and I terminal) - Voltage/Current is selected by KGLWIN parameter 12bit binary

7-49

Chapter 7 Functions

Usage of Various

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 CH0 V0 COM0 I0 Current input CH0 V0 COM0 I0

24V 24G
I n put

When current input is used, short the V and I terminal. Jumper pin of analog input Voltage input
I n put S el e ct
C H3 C H2 C H1 C H0

Current input

CH0
I0

CH1 CH2 CH3

I1 I2 I3 VI

Inpu Se t le c t
C H3 C H2 C H1 CH O CH 3 CH 2 CH 1 CH O C H3 C H2 C H1 C HO

V 0 CO M V 1 CO M V 2 C O M V 3 C O M

Connect left parts by jumper pins

Connect right parts by jumper pins

External power input terminal External voltage 24VDC needs to this terminal. Extension cable This cable is used to connect while analog input module is used.. Extension cable connector The connector connects extension cable when extended module is used.

7-50

Chapter 7 Functions
3) setting Parameter

Usage of Various

(1) Scaling The function function is the same that of A/D, D/A combination scaling module. 4) Wiring (1) Caution for wiring sure that external input signal of the mixture module of AC and analog I/O is not affected by induction Make noise or from the AC through using another occurs cable. Wire is adopted with consideration about peripheral temperature and electric current allowance. Thicker than Max. wire AWG22 (0.3 ) is of size Ifbetter. is put near to high temp. radiated device or contacted with oil for a long time, it may cause of electric wire leakage sogets broken or miss-operation during that it wiring. Be sure to connect with care of polarity while connecting to external 24V DC power supply. In case of wiring with high voltage line or generation line, it makes induction failure so then it may cause of missoperation and out of order. (2) Wiring Voltage Current
Analog Input Analog Terminal Terminal V0 I0 COM0 Input V1 I1 COM1

*1

*1

*1 : Be sure to use two-core twisted shield wire.

7-51

Chapter 7 Functions

Usage of Various

5) Analog/Digital characteristics (1) Analog characteristics a) input Voltage

conversion

input

4000

2004 2003 2002

2000

2001 2000

0 0V 5V 10V Analog Input Voltage Voltage Input

A/D Conversion Characteristics (Voltage Input) In voltage input, digital amount 0 is output by 0V input and 4,000 is output by 10V input. Therefore input 2.5mV equals to digital amount 1, but value less than 2.5mV cant be converted. b) input Current

4000

2004 2003 2002

2000

2001 2000

0 0 10 20 Analog Input Current Current Input

A/D Conversion Characteristics (Current Input 0~20 ) Current input 0mA becomes output 0, 10mA does 2000 and 20mA does 4000. therefore input 5 digital amount 1, but value less tan 5 cant be converted. So abandon it. equals to

7-52

Chapter 7 Functions

Usage of Various

6) Program example (1) Distinction program of A/D conversion value(Analog input range: DC4~20 0~10VDC)

(a) Program explanation When digital value of channel 0 is the same or more than 2000 and the same or less than 3000, P090 is on. When digital value of channel 1 is the same or more than 2000 and the same or less than 3000, P091 is on. When digital value of channel 2 is the same or more than 2000 and the same or less than 3000, P092 is on. 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 Analog input channel 0, 1 : Voltage input (0~10VDC) channel 2, 3 : Current input (DC 4~20 ) Parameter setting

System configuration

Main Unit module

A/D conversion module

Expansion I/O allocation input : P000 ~ P03F Main unit Main unit output : P050 ~ P07F Expansion module input : P080 ~ P08F Expansion module output : P090 ~ P09F

7-53

Chapter 7 Functions
(c) Program

Usage of Various

7-54

Chapter 7 Functions

Usage of Various

7.2.3 D/A Conversion module

1) Performance specifications The performance specifications of the analog output module are following. Specification s G7FDC 0 ~ 10V(Lod resistance 2 ~1 )

Item

Output Range

Digital Output (0~4000) Number of output 4channels/1module Max. absolute output DC +24 DC 12V Maximum DC 0~20 : 5 (1/4000)

G7F-DA2I DA2V DC 0~20 ( Load resistance 510 ) DC 4~20 ( Load resistance 510 ) Classified by parameter 12bit

resolution DC 4~20 : 6.25 (1/3200) Overall accuracy 0.5% [Full Scale] Max. conversion speed 0.5 /CH + scan time 1 /CH + scan time Isolation isolation

2.5 (1/4000)

Between input terminal and PLC power supply: Photo coupler (No isolation between channels) Terminal connected 16 points terminal block 8 points terminal block * 2 Curren t Consumption 20mA 15mA Voltage DC 21.6 ~ Externa 26.4V l Power supply consumption 80 90 Current Weight 160g 280g

7-55

Chapter 7 Functions

Usage of Various

2) Names of parts and functions The Names of parts and functions of the analog input module are following.

24V 24G
In p u

G7F-DA2I
PR OG RA MM AB LE LO GI C C O NT RO L L ER

G7F-DA2V
PRO G R AMMA BL E LO G I C CO N TRO L L ER

24V
24 V 24G

CH0 CH1 CH2 CH3

I+ I+ II + I+ I- I I

PW R

V0+ V1+ V2+ V3+ V0- V1- V2V3-

G7F DA2V

DA2I

G7F

RUN LED
Indicate the operating status the G7F-DA2I Analog output terminal

Current output

External power input terminal

External voltage 24VDC needs to this terminal. Extension cable This cable is used to connect while analog output module is used.. Extension cable connector The connector connects extension cable when extended module is used.

7-56

Chapter 7 Functions
3) setting Parameter

Usage of Various

1) Specify the kind of special module

2) Set Output type of each channel

7-57

Chapter 7 Functions
5) function Scaling

Usage of Various

The scaling function is the same that of A/D, D/A combination module. 6) Wiring (1) Caution for wiring sure that external input signal of the mixture module of AC and analog I/O is not affected by induction noise or Make occurs the AC through using another from cable. Wire is adopted with consideration about peripheral temperature and electric current allowance. Thicker than Max. size ofAWG22 (0.3 wire ) is Ifbetter.is put near to high temp. radiated device or contacted with oil for a long time, it may cause of electric leakage so wire that it broken or miss-operation during gets wiring. Be sure to connect with care of polarity while connecting to external 24V DC power supply. In case of wiring with high voltage line or generation line, it makes induction failure so then it may cause of missoperation out of and order. (2) Wiring
CH0

I+ I-

510 *1
GN D

CH3

I+ I-

Less than 510 *1

GN D

*1 : Be sure to use two-core twisted shield wire. Remar k The common grounding with other devices is permitted when D/A conversion module is used as currenttype. output
. D/A
5 6 CH 0 De vi ce s

CH 3

D/A
+15V AGN D DC/DC - 15 V Converter

11 12

1 2

DC +24V DC 0V

7-58

Chapter 7 Functions

Usage of Various

7) Digital/Analog characteristics (1) G7FDA2Ia) 0~20mA output

conversion

20

10 10.005 10.000

2000 2001 2002 2003 2005 2004 0 0V0 2000 4000 Digital input Digital input

D/A conversion output)

characteristics(Current of analog

Digital amount 0 outputs analog amount 0mA, 4000 does 20mA.Digital input 1 equals to 5 amount. b) output 4~20mA

20mA

12mA 12.006 12.000

6.25

2000 2001 2002 2003 4mA 0V0 2000 4000 Digital nput

2004 Digital input

2005

D/A conversion output)

characteristics(Current of analog

Digital amount 0 outputs analog amount 4mA, 4000 does 20mA.Digital input 1 equals to 6.25 amount.

7-59

Chapter 7 Functions
8) example Program

Usage of Various

(1) Program which controls speed of inverter by analog output voltage of 5 steps(0 ~ 20mA output) a) Program explanation When P80 becomes output. When P81 becomes output. When P82 becomes output. When P83 becomes output. When P84 becomes output. b) System configuration Main Unit module

On, 2000 (10mA) is On, 2400 (12mA) is On, 2800 (14mA) is On, 3200 (16mA) is On, 3600 (18mA) is

D/A conversion module

Expansion I/O allocation input : P000 ~ P03F Main unit Main unit output : P040 ~ P07F Expansion module input : P080 ~ P08F Expansion module output : P090 ~ P09F

c) Program

7-60

Chapter 7 Functions

Usage of Various

7.2.4 Analog timer

1) Performance specification The performance specification of the analog timer module are following. Item Specification Number of channels 4 Output value range 8 Bit (Digital output range: 0 ~ 200) Setting type Setting by variable resistance Accuracy of timer 2.0% (Accuracy about max. value) Operation method Storing data register automatically Internal current consumption 50 Number of module installment Max 3 modules Weight 200g

2) Names functions

of

parts

and

No. Contents RUN LED

Name

Indicate the operating status the G7FAT2A. 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 channel every . Extension cable Extension cable connection terminal

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Chapter 7 Functions
3) example Program

Usage of Various

(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 Main Unit Analog timer module

(3) Program

A/T conversion data is moved D000 always

7-62

Chapter 7 Functions

Usage of Various

7.2.5 RTD input module(Standard type only)

1) Performance specification The performance specification of the RTD input module are following. Item Specification Connectable RTD Pt 100 (JIS C1640-1989, DIN 43760JPt100 (KS C1603-1991, JIS C16041980) 1981) ) Temperature input range Pt 100 : -200 ~ 600 (18.48 to JPt100 : -200 ~ 600 (17.14 to 317.28 ) 313.59 Digital conversion value : 0 to Digital output 4,000 Detected temperature value : -2000 to 6000 (one digit after point * 10) Each of three wires at every channel has detection function. Burn out detection Accuracy 0.5% [Full Scale] Maximum conversion speed 40 scan / 1 module Number of temperature input device points 4Channel / 1module Insulation method Photo-coupler insulation between the input terminal and the PLC supply (non-insulation between power channels) Connection terminal block 8-point terminal block * 2 Current consumption 25 Voltage DC21.6 ~ External 26.4V power supply Current 70 Weight 240g

2) Names of parts and functions

No Contents
24V A b B Ab 24G B Input CH2 CH3

Name

RUN LED Indicate the operating status the G7F-RD2A RTD input terminal Terminal which connects Pt100 or JPt100 External power

G7F-RD2A
PR O G RA MMAB LE L O G IC C O NTR O L LE R

input terminal External voltage 24VDC needs to this terminal Extension cable This cable is used to connect while RTD input module is used Extension cable
b

PW R

CH0 CH1 A b A B B

The connector connects extension cable when extended module is used.

connector

Explain about names of parts and functions

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Chapter 7 Functions
3) setting Parameter

Usage of Various

4) Digital register

conversion

value Digital conversion value Remark

Ch. Detected Temperature value 0 D4980 D4780

1 2 3 0 1 2 3 0 1 2 D4981 D4982 D4983 D4984 D4985 D4986 D4987 D4988 D4989 D4990 D4781 D4782 D4783 D4784 D4785 D4786 D4787 D4788 D4789 D4790 D4880 D4881 D4882 D4883 D4884 D4885

Data

register
Special module #1

Special module #2

Special module #3

5) Error code ( D4880~ D4885 ) bF bE bD bC bB bA b9 b8 b1 D4880 CH1 CH0 Error code Description Corrective action 0 Normal run status 16(10h) A disconnection detected Fix the A disconnection between RTD input module and RTD. 17(11h) B disconnection detected Fix the A disconnection between RTD input module and RTD b disconnection Fix the A disconnection between RTD input module and RTD. detected, and 18(12h A B Or, Fix the A and B ) disconnection detected disconnection. simultaneously. Correctly specify the type of the RTD, or use the temperature 19(13h) Temperature outside withinrange (- C ~ 600.0C) rang the the e 200.0 7-64 b7 b6 b5 b4 b3 b2 b0

Chapter 7 Functions

Usage of Various

6) Temperature conversion characteristics The RTD input module, as shown below, linearlizes the non-linear characteristic resistance input of the RTD

7) Digital conversion value The RTD input module, as shown below, outputs digital converted value of detected temperature value.(Range 0 ~ 4000)
Digital conversion value

4000

-2000

0 value =

Digital Conversion value+2000)/2

6000 (Detected Temp.

Detected temp. value

Example) Assume that Detected temperature value(D4980) is 2345, then real temperature = 234.5 , and Digital conversion value(D4770) is (2345+2000)/2 = 2172.

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Chapter 7 Functions
8) Burn-out function

Usage of Various

detection

The RTD input module has the function of burn-out detection on the Pt100, JPt100 or cable. As shown below, if disconnection occurs in the RTD or cable then a voltage outside the measurable range voltage is inputted by the internal burn-out detection circuit and burn-out detection error code is generated. The RTD input module can detect disconnection for each channel. But, burn-out detection is possible only in the channels enabled. If disconnection is detected in two or more wires, first, disconnection error code is band generated by then disconnection error code is generated A orbsequentially. If disconnection is detected simultaneously A and by in B, only disconnection error code is generated b. by Connectio n Method Connection Example Remark 2burn-out detection area - In 4-wire type, only all wires marked wire '2' type connected to the terminal block A are all detected as disconnection then the A disconnection error can be detected. 3wire type
burn-out detection area

4wire type

burn-out detection area

No wiring

*1 : Pt *2: wire Shield

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Chapter 7 Functions
9) Wiring

Usage of Various

(1) Caution for wiring sure that external input signal of the mixture module of AC and analog I/O is not affected by induction noise or Make occurs the AC through using another from cable. Wire is adopted with consideration about peripheral temperature and electric current allowance. Thicker than Max. size of AWG22 (0.3 wire ) is If better. put near to high temp. radiated device or contacted with oil for a long time, it may cause of electric leakage so wire is that it broken or miss-operation during gets wiring. Be sure to connect with care of polarity while connecting to external 24V DC power supply. In case of wiring with high voltage line or generation line, it makes induction failure so then it may cause of missoperation out of and order. (2) Wiring example Number of method of connection between Pt and RTD input module are three, that is, 2-wired type, 3-wired type and 4-w wired type. The resistance of the wires used to connect Pt to RTD input module should be or less per 10 wire. The same wire (in thickness, length, and kind, etc.) should be used for each channel. Connectio n Method Connection Conditions 2-wired type Example Wire

wire resistance=10 wire resistance=10 wire resistance=10

3-wired type
The difference between the resistance values of the wires and : 1 or less

The difference between the resistance values of the wires and : 1 or less

4-wired type
The difference between the resistance values of the wires and : 1 or less

*1: RTD (Pt100 JPt1000) *:2: Shielded wire - The shields of the RTD and shields of wire should be connected to the FG of the RTD input module. REMAR K The difference between the resistance values of the wires used should or less, or the accuracy be 1 shown in 1) performance specification could not be satisfied. 7-67

Method of Connection between Pt and RTD Input Module or

Chapter 7 Functions

Usage of Various

10) Program example (1) A program for output of detected temperature value as a BCD value a) Program explanation The present A/D conversion value of the detected temperature value which is detected from the temperaturemeasuring resistor Pt 100 is displayed on the BCD digital display by use of channel 0 of the temperature-measuring resistor input module. The lamp turns on when the detected temperature value is a negative number and turns off when it is a positive numbe r b) System configuration and parameter setting COM0 RTD module input

Input condition

(P0000 )

Detected temperature

Turns on when temperature

( P0040 ~ P004F )

BCD segment

value is negative

Main unit input contact : P000 ~ P023 Main unit output contact: P040 ~ P057

c) Program

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Chapter 7 Functions

Usage of Various

7.3 Positioning Function(DRT/DT type only)

The DRT/DT type of MASTER-K120S series support 2 axes of positioning function. The purpose of positioning function is to transfer the moving objects by setting speed from the current position and stop them on the setting position correctly. And it also control the position of high precision by positioning pulse string signal as it is connected to various servo running devices or stepping motor control running devices.

Pulse Directio n Drive r Motor

K7MDRT/DTxxU

7.3.1 Specification
1) Performance Specification Items Specification

No. of control axis 2 axes Control method PTP(Point-To-Point), speed control Control unit Pulse Positioning data 20 data per each axis( Operation step No. : 1 ~ 20) Positioning method Absolute / Incremental method Address range -2,147,483,648 ~ 2,147,483,647 Speed Max. 100kpps , Speed setting range : 5 ~ 100,000pps(unit of pulse)

Positioning

Acceleration/ Deceleration method

Operation pattern : Trapezoidal method Acceleration time : 0 ~10,000 (unit of 1ms) Deceleration time : 0 ~10,000 (unit of 1ms)

Backlash compensation 0 ~ 1,000 Pulse Bias speed 5 ~ 100,000pps Speed limit 5 ~ 100,000pps Operation mode End, Keep, Continuous operation Operation method Single, Repeated operation High speed Speed setting range: 5 ~ 100,000pps Speed Low speed Speed setting range: 5 ~ 100,000pps Return to origin Method Dwell time Setting range : 0~10,000 1 Origin detection when approximate origin turns off 2 Origin detection after deceleration when approximate origin turns on. 3 Origin detection by approximate origin JOG Speed High speed Speed setting range: 5 ~ 100,000pps Low speed Speed setting range: 5 ~ 100,000pps Period setting range: 1 ~ 20,000 Duty setting range: 0 ~ 100%

PWM Output

7-69

Chapter 7 Functions
2) Output P41)

Usage of Various

Specification(P40,

Signal Name Rated load voltage Load voltage range Max. load current Max. voltage drop during On Positioning CW/Pulse CCW/Directio n DC 12/24V DC 10.2~26.4V 100 Forward direction Reverse direction
=

DC 0.3V

3) Names terminal

of

wiring

AC220V FG COM0

P40

P41 COM1

P42 COM2 P43

P44 COM3

Stepping motor

COM

Direction pulse Pulse output

Motor driver

No. Terminal No. Name Usage P040 Positioning(Ch0) Pulse output terminal P041 Positioning(Ch1) Pulse output terminal P042 Direction pulse(Ch0) Direction output terminal P043 Direction pulse(Ch1) Direction output terminal COM0,COM1,COM2 Common Common terminal P 24V External 24V supply terminal

Remar k Positioning function is sensitive to the external noise and should be handled with special care. 1) Be sure to use shielded twisted pair cables. Also provide Class 3 grounding run a twisted pair cable in parallel with power cables or other I/O lines which may generate 2) Do not noise 3) Before applying a power source for pulse generator, be sure to use a noise-protected power supply

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Chapter 7 Functions

Usage of Various

4) Internal example

circuit

and

wiring

P 12/24V) P40 output(Ch0)

R

Power supply(DC pulse

COM0 Output common 0 P41 pulse output(Ch1)

R

Interna l circui t
R

COM1 Output common 1 P42 Direction pulse(Ch0)

P43 pulse(Ch1)
R

Direction

COM2 Output common 2

Motor driver For Ch0

P P40 output(Ch0)
R

(24V)

pulse

COM0 Output common 0 P41 pulse output(Ch1) COM1 1 Output common Direction

Interna l circui t
R

Motor driver For Ch1 (24V)

P42 pulse(Ch0) P43 pulse(Ch1)

Direction

COM2 2

Output common

-+
DC 24V

7-71

Chapter 7 Functions

Usage of Various

7.3.2 Positioning function

1) Positioning function Positioning Control includes position control, speed control. (1) Position control Positioning control from start address (present stopped position) to goal address (transfer amount) for the assigned axis A) Control by Absolute method (Absolute coordinate) control from start address to goal address (the address assigned by positioning Positioning data). Positioning control is carried out based on the address assigned (origin address) by return to origin. direction shall be determined by start address and goal Transfer address. Start address < Goal address : forward direction positioning Start address > Goal address : reverse direction positioning Example] When Start address is 1000 and goal address is 8000, this will be forward direction and transfer amount shall be 7000 (7000=80001000).
0 80001000

Parameter setting

Start address address

Transfer 7000 Goal

amount

Items of positioning data Step No. Coordinate Operation mode Operation method Goal address Speed(pps) Dwell time( )

Setting 1 Absolute End Single 8,000 5,000 100 B) Control by Incremental method (Relative coordinate) Positioning control as much as the goal transfer amount from start address. Transfer direction shall be determined by the sign of transfer amount. When transfer direction is (+) or no sign : forward direction (address increase) positioning When transfer direction is (-) : reverse direction (address decrease) positioning
Start Address

Normal

Reverse

Transfer direction when transfer amount (-) Transfer direction when transfer amount (+) Example) When start address is 5000 and goal address is -7000, this will be reverse direction and positioning will be at the point of 2000
-2000 0 5000

Reverse positioning control (transfer amount-7000) Goal address Start address

Items of positioning data Step No. Coordinate Operation mode Operation method Goal address Speed(pps) Dwell time( )

Parameter setting

Setting 1 Incremental End Single -7,000 5,000 100 7-72

Chapter 7 Functions

Usage of Various

(2) Speed Control (Uniform Speed Operation) This controls the speed by the setting speed until deceleration stop command(POSCTR) is entered after execution by POSVEL command.. The speed can be changed by the speed override instruction(POSSOR) Speed control contains 2 types of start method : Forward direction start and Reverse direction start. - Forward direction : when position address is positive number (+) (0 included) - Reverse direction : when position address is negative number (-) Forward direction Reverse direction Set second operand of POSVEL instruction to 0 Set second operand of POSVEL instruction to 1 Timing diagram Spee d

Setting speed

Dwell time Time

On

Speed control command (POSVEL)

On

Deceleration stop command (POSCTR)

Remar k Please refer to the 7.3.4 Instruction for details.

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Chapter 7 Functions

Usage of Various

2) Operation pattern Operation pattern describes various configuration for how to operate the positioning data using several operation step no and how to determine the speed of position data. Operation mode types are as follows Operation Remark mode
End One operation step is executed with one start command

Keep When one operation step has over, executes next operation step without additional start command Continuous When one operation step has over, executes next operation step without Deceleration.

Operation follows.

methods

are

as

Operation Remark

method

Single When one operation step is over, executes next operation step No. automatically

Repeat When one operation step is over, executes assigned step No. repeatedly

Step No. can be assigned within 1 ~ 20 Items of parameter Step No. Operation

Operatio Coordinate mode nmethod Address Speed(pps) Dwell time End -2.147,483,648 5 Single Setting 1 ~ 20 Absolute Kee ~ ~ Incrementa Repea p Continuous t 2,147,483,647 100,000 l

() 0 ~ 10,000

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Chapter 7 Functions
3) Mode Operation

Usage of Various

(1) End Operation one time start command(rising edge of POSIST command), the positioning to the goal position is executed A) With andthe positioning shall be completed at the same time as the dwell time B) proceeds. This operation mode can be used as last positioning data of pattern operation. C) Operation direction shall be determined by position address. D) Operation action is trapezoid type operation that has acceleration, constant, deceleration section according to the setting speed and position data.
Speed

Dwell time Time On

Start command (POSIST )

[Example] operation Spee d

End

Operation step no.: 1 Operation

On

step no.: 2

Operation step no.: 3

Operation step no.: 4

Time

Start command

Parameter setting
No. of program start command Step No. Coordinate Operationmode Operation method Goal address Speed (pps) Dwell time ()

1 0 2 0 3 0 4 0

1 Absolute End Single 10,000 50,000 2 Absolute End Single 20,000 20,000 3 Absolute End Single 30,000 50,000 4 Absolute End Single 40,000 20,000

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Chapter 7 Functions

Usage of Various

(2) Keep Operation one time Start command(POSIST), the positioning to the goal position of operation step is executed and A) With the positioning shall be completed at the same time as dwell time proceeds and without additional start command, the positioning of operation step for (current operation step no. +1) shall be done. B) Keep operation mode is available to execute several operation step in order.Operation direction shall be determined by position C) address. [ Example operation ]
Speed

Keep

Operation step 1

Operation step 2 Operation step 1 Operation step 2

Time

On

Start command (POSIST) Dwell time Dwell time

Parameter setting
No. of program start command Step No. Coordinate Operationmode Operation method Goal address Speed (pps) Dwell time ()

1 1 Absolute Keep Single 10,000 50,000 10 2 Absolute Keep Single 20,000 20,000 10 3 Absolute End Single 30,000 50,000 0 2 4 Absolute End Single 40,000 20,000 0

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Chapter 7 Functions

Usage of Various

(3) Continuous Operation A) With one time Start command, the positioning for operation step set by continuous operation mode is executed to the goal position without stop and the positioning shall be completed at the same time as dwell time proceeds. B) If you want to operate with the position and speed of next step before the operation step that is active currently reaches the goal position, the operation by Next Move continuous operation command is C) available. Move continuous operation command, the operation in the acceleration, constant speed, With Next deceleration of Continuous operation is section available. D) Operation direction shall be determined by position address and should be same direction. If operation direction is not same, error occurs(Refer to 7.3.5 error flags) [ Example operation ] Continuous
Speed

Operation step 2

Operation step1 On Start command (POSIST )

Time

Parameter setting
No. of program start command Step No. Coordinate Operationmode Operation method Goal address Speed (pps) Dwell time ()

1 1 Absolute Continuous Single 10,000 50,000 10 2 Absolute End Single 20,000 20,000 10

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Chapter 7 Functions
4) Method Operation

Usage of Various

(1) Repeat Operation one time start command, the positioning to the goal position is executed and the positioning shall be A) With completed at time as the dwell time the same B) proceeds. The operation type of Repeat operation mode is same as that of Single operation but the different thing is to determine next operation by operation step no. assigned by repeat step no. change command after positioning completion ofoperation Repeat C) mode. Operation direction shall be determined by position address. [Example] pattern Repeat
Speed

Operation step 1

Operation step 2 Operation step 1 Operation step 2

Time

On

Start command (POSIST)

Parameter setting
No. of program start command Step No. Coordinate Operation mode Operation method Goal address Speed (pps) Dwell time ()

1,3 1 Incremental End Single 10,000 50,000 0 2,4 2 Incremental End Repeat 1 20,000 20,000 0 3 Absolute End Single 30,000 50,000 0 4 Absolute End Single 40,000 20,000 0 In this case, Operation step 3, 4 does not start.

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Chapter 7 Functions
5) Positioning start

Usage of Various

(1) Direct start(POSDST) to operate directly by setting the axis, goal position address, operation speed without parameter This is used setting. Refer to the 7.3.4 Instruction for details. (2) Indirect start(POSIST) This is used to operate by setting the operation step no. by parameter. Refer to the 7.3.4 Instruction for details. (3) Speed control start(POSVEL) to operate directly by setting the axis, direction, operation speed without parameter This is used setting. The speed can be changed by the speed override instruction(POSSOR) Refer to the 7.3.4 Instruction for details. 6) Positioning stop (1) Deceleration stop(POSCTR) If encounters deceleration stop command during operation, it stop operation after deceleration. In case of deceleration stop by deceleration stop command in acceleration or constant speed section, starts to operate operation step again by Start command and operation current Instep of deceleration stop by deceleration stop command in deceleration speed section, starts to operate case current operation step+1 again by Start command and operation step Refer to the 7.3.4 Instruction for details. (2) Emergency stop(POSCTR) If encounters emergency stop command during operation, it stops operation without deceleration. When emergency stop has occurs, emergency stop error and output disable flag are set. Error and output disable flag should be reset by error reset command of POSCTR for re-start operation the 7.3.4 Instruction for Refer to details.

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Chapter 7 Functions

Usage of Various

7) Return to Origin(POSORG : Rising ) edge Return to Origin (homing) is carried out to confirm the origin of the machine when applying the power. In case of Return to Origin, it is required to set Return to Origin parameter for each axis. If the origin position is determined by origin return, the origin detection signal is not recognized during positioning operation. (1) Origin return method Method by approximate origin (approach DOG)Origin return processing method by approximate origin (approach DOG) has 3 kinds of method as follows. (A) Origin detection when approximate origin turns off Origin detection after deceleration when approximate origin turns (B) on Origin detection by approximate (C) origin The items that effects to the origin return from parameter are as follows. Origin return speed (high speed, low (A) speed) (B) Origin return dwell time (2) Origin Detection when Approximate origin turns off This is the method using the approximate origin and origin signal and the action by origin return command(POSORG) is as follows. (A) It accelerates to the setting origin return direction and acts by origin return high speed. this case, if approximate origin as external input is entered, it decelerates and acts by origin return low (B) In speed. origin signal as external input is entered after the approximate origin signal has changed from On to Off, it (C) If stops. Spee d

Origin return high speed

Deceleration when approximate return ON

Origin return low speed

Time Transfer amount after approximate origin ON

Approximate origin signal

While the approximate origin ON, the origin will not be determined by the origin signal.

Origin signal 1 rotation of SERVO motor (PG1 rotation)

Origin return command

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Chapter 7 Functions

Usage of Various

(3) Origin Detection after Deceleration when Approximate origin turns on This is the method using the approximate origin and origin signal and the action by origin return command is as follows. accelerates to the setting origin return direction and acts by origin return high (A) It speed. (B) In this case, if approximate origin as external input is entered, it decelerates and acts by origin return low speed. encounters the origin signal as external input signal while the origin return low speed is active, the origin (C) If shall be determined and it stops.
Speed Deceleration when approximate return ON Origin return high speed

Origin return low speed

Time Transfer amount after approximate origin ON

Approximate origin signal Origin signal

When origin return speed decelerates by approximate origin, the origin will not be determined by the origin signal. 1 rotation of SERVO motor (PG1 rotation)

Origin return command

(4) Origin Detection by approximate origin is the method using the approximate origin signal This only.
Normal rotation Direction conversion at the rising edge of approximate origin signal Origin return high speed Direction conversion at the falling edge of approximate origin signal Origin return low speed Time Origin determination

Reverse rotation

External input high limit

Origin return command

Origin determined state

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Chapter 7 Functions

Usage of Various

8) JOG Operation (POSJOG : Level input) (1) JOG operation Carries out the positioning control by Jog command(POSJOG). Carries out the monitoring when the positioning acts by JOG command and the position address is changed. This is used when acting without origin determination. (2) Acceleration/Deceleration Processing and Jog speed (A) The acceleration/deceleration processing is controlled based on the setting time of JOG acceleration/ deceleration from time parameter setting. Jog high speed operation acceleration/deceleration
Speed

operation

pattern

with

Time

Jog low speed operation acceleration/deceleration

Speed

operation

pattern

without

Time

(B) If speed operand of POSJOG command as device not constant, JOG speed can be changed from low speed to high speed or high speed to low speed during operation (C) If Jog speed is set out of the setting range, error will occur and the operation does not work. Setting range Jog high speed operation 5~100,000 pps Jog low speed operation 5~100,000 pps (Setting 1pps) unit :

9) Speed Override Command(POSSOR : Rising )) edge This is used to change the operation speed from operation data of step no. in operation of each axis This command is used only in Acceleration and Constant speed section from operation pattern. Setting range is 5 ~ 100,000 This command can be used in position control and speed control. Remar k If POSSOR is executed in deceleration section, error code H44 will occur and continues operation

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Chapter 7 Functions

Usage of Various

10) External Input Stroke High/Low Limit External input stroke limit includes External input high limit signal and External input low limit signal. This is used to stop the positioning function promptly before reaching Stroke limit/Stroke End of the Driver by installing the stroke limit inside Stroke limit/Stroke end of the IfDriver. it deviates the high limit, Error H53 will occur and if it deviates the low limit, Error H54 will occur. External input stroke limit can be set in KGLWIN parameter High/Low limit input contact point is fixed to P0,P1 for ch0 and P2,P3 for ch1.
High Low The range available to positioning

Stopper
Tr a n sf e r d ir e ct io n Tr a n sf e r d ir e ct io n Sta rt Sta rt

Sto ppe r

Immediate stop when Detecting the high limit

Immediate stop when Detecting the low limit

Limi t swi tch

Limit switch

K120S Driver

If positioning module stops out of the range available to control, the positioning operation does not work. If it stops by external input stroke limit detection, move within the range of positioning module available to control by manual operation (Jog operation). As external input stroke high/low limit error is detected by the edge of positioning module, it is available to release the output prohibit out of stroke range and carry out manual operation. The flags related with external input stroke limit are as followings. Off : External input stroke Low limit has not detected, On : External input stroke Low limit has - F284(Ch0) detected - F285(Ch0) Off : External input stroke High limit has not detected, On : External input stroke High limit has detected - F304(Ch1) Off : External input stroke Low limit has not detected, On : External input stroke Low limit has detected - F305(Ch1) Off : External input stroke High limit has not detected, On : External input stroke High limit has detected Point If external input stroke High/Low limit signal is occur during origin return, it stops operation Then, changes direction and continues origin return immediately, operation.

11) M Code function(After Mode) function made to set M Code Set bit, if M Code Enable bit was On when positioning was This completed. M code Set bit must reset for run to the next And Then step. Used special relay. Device Description Remark M1911 M Code Enable Bit(Ch0) On : Set up M Code function M Code Set Bit(Ch0) If positioning complete then M1912 set M1913 M Code Enable Bit(Ch1) On : Set up a M Code function M Code Set Bit(Ch1) If positioning complete then M1914 set

7-83

Chapter 7 Functions

Usage of Various

Timing diagram 1) Unused the M Code Output

Continues End Positioning Indirect start Completed Flag Current step M-th step N-th step 2) Use Code the M

Continues End Positioning Indirect start Completed Flag Current step M-th step N-th step M1911

M1912 Reset in the program program Reset in the

12) Error and Output Prohibition includes Light failure error and Heavy failure Error error. If light failure error occurs, the positioning operation will continue and only error will occur. In case of heavy failure error, if the error is not cleared, it is not available to carry out the positioning operation. And if the failure error occurs during operation, the operation will heavy stop. If external high/low limit, external emergency stop during the positioning operation are detected during the positioning it stops promptly and becomes the pulse output prohibition status. Thus it is required to release the operation, pulse output prohibition by Error reset command(POSCTR) For further information, please refer to Error code list . 7-84

Chapter 7 Functions

Usage of Various

7.3.3 Positioning parameter and operation data

1) Positioning parameter Positioning parameter setting Parameter should be assigned for each axis

Basic parameter

(1) Basic parameter (A) Acceleration/Deceleration time This is applied at the starting/ending point of positioning operation, return to origin high speed, and JOG high speed operatio n The setting range is 0 ~ 10,000 (unit: 1ms) for each axis. set to zero, operates constant When speed. Acceleration time : the time required to reach from speed 0(stop state) to the speed limit which is set by parameter. In case of using BIAS, it is the time required to reach from the bias speed to the speed limit which is set by parameter. Deceleration time : the time required to reach from the speed limit set by parameter to the speed 0(stop state). case of using BIAS, it is the time required to reach from the speed limit set by parameter to the setting In bias speed.
Speed Speed limit

Setting speed Actual deceleration time

Actual acceleration time Time

Acceleration time

Deceleration time

- Speed limit : max. speed available for positioning operation to set at the parameter of KGLWIN. - Setting speed : speed value of operation data that position data operates actually. - Actual acceleration time : the time required to reach from speed 0(stop state) to the speed value is set by operation which data. - Actual deceleration time : the time required to reach from the speed set by operation data value to spee d

7-85

Chapter 7 Functions

Usage of Various

(B) Backlash Compensation Amount tolerance that the machine does not work by the wear when the rotation direction changes in case that a The gear, etc is combined to run at the motor axle, is called as screw Backlash.when you change the rotation direction, it is required to add the backlash compensation amount Therefore, to the positioning amount for output. The setting range is 0 ~ 1,000(unit: Pulse) at each axis. If the position moved 1m to the right and again 1m to the left, it is not possible to reach the original position by backlash. At this time, it is required to add backlash compensation amount.
Gear 1m movement right side (normal) 1m movement left side (reverse) Direction change Backlash

Transfer amount including Backlash compensation amount

Backlash

(C) Bias Speed the stepping motor has unstable torque near zero speed, the start speed shall be set in the beginning of As operation in command to smooth the rotation of motor and reduce the positioning time. The speed to be set at this time is called Bias Speed. The setting range is 5~10,000(unit: 1pps) at each axis. Bias speed shall be used for the main axis of positioning operation by setting command, origin operation, JOG operation.
Speed Speed limit Bias speed setting action Positioning speed Origin return speed JOG Speed Interpolation operation speed

return

Bias speed not-setting action

Bias speed Acceleration time Deceleration time

Time

(D) Speed Limitmax. Speed available to set for positioning operation. The setting range is 5~100,000 (unit : 1pps). The operation speed of positioning operation, origin return speed and Jog operation speed is influenced by speed and if they are set as higher value than speed limit, error will limit occur.

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Chapter 7 Functions
(2) Origin parameter

Usage of Various

return

(A) Origin return method For the details, please refer to 7) Return to Origin in chapter 7.3.2 (B) DOG, signal origin Ch 0 Ch 1 DOG P0005 P0007 Origin P0004 P0006

(C) Origin return speed The speed when returning to the origin by origin return command : high speed and low speed When setting the origin return speed, it should be speed limit = origin return high speed = origin return low speed = bias speed. Origin return high speed The speed that acts to the constant speed command. Origin return-high speed setting range : 5 1pps) Origin return-Low speed The speed that acts to the constant speed command. Origin return-low speed setting range : 5 1pps)

section via acceleration section by origin return ~ 100,000(unit:

section via deceleration section by origin return ~ 100,000(unit:

Remar k When setting the origin return speed, it is recommended to set the origin return-low speed as low speed as If setting the low speed as too fast, it may cause the incorrect origin signal possible. detection. (D) Dwell Time This is the time needed to maintain the precise stop accuracy of SERVO motor when using the SERVO motor for positioning. Practically, Dwell time is the time needed to remove the residual pulse of deviation counter after completion ofand especially Dwell time when returning to the origin is called as origin return dwell positioning time. Setting range of Origin return dwell time : 1 ) 0 ~ 10,000(unit:

7-87

Chapter 7 Functions

Usage of Various

(3) speed

JOG

(A) JOG High Speed JOG high speed operation has operation pattern as acceleration, constant speed, deceleration section. Therefore, acceleration section and deceleration section is controlled by JOG acceleration/deceleration time. JOG high speed setting range : 5 ~ 100,000(unit: 1pps) when setting the high speed : Bias speed = Jog high speed = Speed (notices limit) (B) JOG Low Speed JOG low speed operation has only constant speed operation pattern. JOG low speed setting range : 5~ 100,000 (unit: 1pps) 2) Positioning parameter Here describes Positioning parameter

(1) Step No. The setting range of positioning data as serial no. is 1 ~ 20. Remar k If step No. set to 0, operating step increase to next step automatically when current operation step finished

7-88

Chapter 7 Functions

Usage of Various

(2) Coordinate coordinate of position data includes Absolute and The Incremental (A) Absolute Coordinate (Control by Absolute method) This carries out the positioning control from the current position to the goal position (the goal position assigned by positioning data). Positioning control is carried out based on the assigned position of origin return or POSPRS command (origin address). Transfer direction shall be determined by the current position and goal position. - Start position < Goal position : forward direction positioning - Start position > Goal position : reverse direction positioning (B) Relative Coordinate (Control by Incremental method) This carries out the positioning control as much as goal transfer amount from the current position. Transfer direction shall be determined by the sign of transfer amount. - When transfer direction is (+) or no sign : normal direction positioning (position increase direction) - When transfer direction is ( - ) : reverse direction positioning (position decrease direction)
Current position

Reverse

Normal

Transfer direction when transfer amount is (+) Transfer direction when transfer amount is (-)

(3) Operation Mode (End / Keep / Continuous) Operation Mode is divided into following three kinds. For the details, please refer to 3) Operation mode in chapter 7.3.2 Control method mode Position control Operation End Kee p Continuous

(4) Operation Method (Single/Repeat) Select operation method : Single operation or Repeat operation. For the details, please refer to 4) Operation method in chapter 7.3.2
Control method

Position Repeat

control

Operation method Single

(5) Positioning Address is the area to set the transfer amount of position data as positioning This address. The setting range is 2,147,483,648 ~ 2,147,483,647(setting unit: Pulse). The change of position address value is available when assigned by D area 7-89

Chapter 7 Functions

Usage of Various

(6) Speed Operation speed can be assigned for each operation step No. Setting range of operation speed : 5 ~ 100,000( Setting unit: 1pps ) The change of speed value is available when assigned by D area (7) Dwell Time This is the waiting time before carrying out the next positioning operation after completing one positioning operation. Setting range is 0 ~ 10,000 (setting unit : 1 ). Especially, in case of using SERVO motor, this is the data to set the waiting time by the stable stop state as positioning module is in the stop state but actual SERVO motor does not reach to the goal position or in transition state.

7-90

Chapter 7 Functions

Usage of Various

7.3.4 Instructions
1) Positioning start(POSIST) POSIST Start Indirect

Positioning Indirect

Instructio n S n

Available Flag
MPKLFTCSD

device
#D

No. of integer steps Error (F110) 5 Zero (F111) Carry (F112)

Flag set

Designation S Channel which is designated at parameter(0~1)

Error (F110)

Error flag turns on when designating area is over and the instruction isnt executed n

Starting step No. (0~20) designated as 0, starting step is When increased automaticall y

POSIST S n
(1) Functions

(2) Example program

When input condition turns on, corresponding positioning control starts from assigned step No. Positioning operation is edge . triggered When input condition turns on, Ch.0 starts positioning from Step no.1

7-91

Chapter 7 Functions

Usage of Various

2) JOG Operation(POSJOG) POSIST Start Positioning Indirect

Instructio n S n1 n2

Available Flag
MPKLFTCSD

device
#D

No. of integer steps Error (F110) Zero (F111) Carry (F112)

Flag set Error (F110) Error flag turns on when designating area is over and the instruction isnt executed

Designation S n1 n2

Ch. for JOG operation(0~1) Direction( 0 : Forward, 1: Backward) Speed (0 : Low speed,1: High speed)

POSJOG S n1 n2 (1) Functions When input condition turns on, corresponding Ch. Starts JOG operation. If input condition turns off, corresponding Ch stops JOG operation. The speed can be changed during operation but the direction cant be changed. (2) Example program When input condition M0000 turns on, Ch.1 starts JOG operation by designated direction(M0001) and speed(M0002) When input condition turns off, Ch.1 stops JOG operation.

7-92

Chapter 7 Functions

Usage of Various

3) Positioning Instruction(POSCTR) POSCTR instruction Instructio n S n1 Positioning

Control

control Available Flag device

#D

No. of integer steps Error (F110) 5 Zero (F111) Carry (F112)

MPKLFTCSD

Flag set

Designation S Channel designation(0~1)

Error (F110)

Error flag turns on when designating area is over n1

Control instruction designation stop. 1:Emergency stop. 0: Deceleration

2: Error reset

POSCTR S n1 (1) Functions Operates designated control operation at the rising edge of input condition. - Deceleration stop : Stops positioning after deceleration - Emergency stop : Stops positioning immediately without deceleration - Error Reset : Resets occurred error and output prohibition signal. (2) Example program When input condition M0000 turns on, Ch.1 stops positioning after deceleration.

7-93

Chapter 7 Functions
4) Current (POSPRS) POSPRS preset Instructio n S SV1

Usage of Various

position

preset

Current

position Available Flag device

#D

No. of integer steps Error (F110) 5/7 Zero (F111) Carry (F112)

MPKLFTCSD

Flag set Error (F110)

Designation S Channel designation(0~1) Error flag turns on when designating area is over SV1

Preset value designation (-2,147,483,648 ~ 2,147,483,647)

POSPRS S SV1 (1) Functions Current address is changed to preset value at the rising edge of input condition. (2) Example program When input condition M0000 turns on, Address of Ch.0 is changed to 100,000.

7-94

Chapter 7 Functions
5) PWM (PWM) PWM output Instructio n S SV1 SV2

Usage of Various

output

PWM(Pulse Width Modulation) Available Flag

MPKLFTCSD

device
#D

No. of integer steps Error (F110) Zero (F111) Carry (F112)

Flag set Error (F110) Error flag turns on when designating area is over and the instruction isnt executed

Designation S SV1 SV2

Ch. for PWM output(0~1) PWM output period( 1 ~ 20000) [ms] Off Duty(0 ~ 100%)

PWM S SV1 SV2 (1) Functions When input condition turns on, Output pulses which have period as SV1. Duty ratio of pulses is assigned by SV2. When input condition turns off, PWM operation stops (2) Example program When input condition turns on, Output pulses as below

Positioning Ch 1(P41) 450ms 50ms Input condition(M0000)

500ms

7-95

Chapter 7 Functions
6) Speed (POSVEL) POSVEL operation Instructio n S n1 SV

Usage of Various

control

operation

Speed

control

Available Flag
MPKLFTCSD

device
#D

No. of integer steps Error (F110) Zero (F111) Carry (F112)

7/9

Flag set Error (F110) Error flag turns on when designating area is over and the instruction isnt executed

Designation S n1 SV

Ch. for control(0~1) Operation 1:Reverse) Speed (5 100,000pps)

speed direction(0:Forward, ~

POSVEL S n1 SV (1) Functions When input condition turns on(Rising edge), Corresponding Ch. Starts speed control by designated direction and speed. (2) Example program When input condition(M0000) turns on, Ch. 0 starts speed control by designated direction(M0001) and 10kpps. Speed can be changed by POSSOR instruction. Operation stops after deceleration by POSCTR instruction.

7-96

Chapter 7 Functions
7) Speed (POSSOR) POSSOR instruction Instructio n S SV

Usage of Various

override

Speed

override

Available Flag
MPKLFTCSD

device
#D

No. of integer steps Error (F110) 5/7 Zero (F111) Carry (F112)

Flag set Error (F110) Error flag turns on when designating area is over and the instruction isnt executed SV

Designation S

Ch. for override(0~1) Speed (5 100,000pps)

speed ~

POSSOR S SV (1) Functions When input condition turns on(Rising edge), Operation speed of corresponding Ch. changed to designated speed. This instruction is valid to current operating channel only Speed changing within deceleration section is not available. (2) Example program When input condition(M0000) turns on, Operation speed of Ch. 0 is changed to 10kpps.

7-97

Chapter 7 Functions

Usage of Various

8) Positioning start(POSDST) POSDST start Instructio n S n1 SV1 SV2

direct

Positioning direct

Available Flag
MPKLFTCSD

device
#D

No. of integer steps Error (F110) Zero (F111) Carry (F112)

9/11/13

Flag set

Designation S

Error (F110)

Error flag turns on when designating area is over and the instruction isnt executed

n1 SV1 SV2

Ch. for positioning start(0~1) Absolute/Incremental designation (0:Absolute, 1:Incremental) Positioning address -2,147,483,648 ( 2,147,483,647) Positioning speed (0 100,000pps)

direct coordinate

~ ~

POSDST S n1 SV1 SV2 (1) Functions When input condition turns on(Rising edge), corresponding Ch. starts positioning by designated coordinate, address and speed (2) Example program When input condition(M0000) turns on, Ch. 0 outputs 100,000 pulses by designated coordinate(M0001), forward direction and speed of 10kpps. Acceleration/deceleration time is applied by corresponding parameter

7-98

Chapter 7 Functions
9) Return origin(POSORG) POSORG origin

Usage of Various

to

Return

to

Instructio n S n1 SV

Available Flag
MPKLFTCSD

device
#D

No. of integer steps Error (F110) Zero (F111) Carry (F112)

Set S Error (F110) Error flag turns on when designating area is over and the instruction isnt executed n1 SV

Ch. for origin return(0~1) Operation direction(0:Forward, 1:Reverse) Address (5 ~ 100,000pps)

POSORG S n1 SV (1) Functions When input condition turns on, corresponding origin return operation starts(Rising edge trigger) After operation, Current address is preset to designated origin address (2) Example program When input condition(M0000) turns on, Ch. 0 operates return to origin function by designated direction and address After return to origin operation, position address become the value in D0002 and D0003.

7-99

Chapter 7 Functions

Usage of Various

7.3.5 Flag list and Error codes

1) Flag list Device Description Function

F0280 Operating flag Operation status of Ch0 (0: stop, 1:Busy) F0281 Error status Error status of Ch0 (0: normal, 1: error) F0282 End of positioning Indicates end of operation for Ch0 (0: operating, 1: End) *1Scan On F0283 End of Origin return Indicates end of origin return operation of Ch0(0:operating, 1: End) F0284 Low limit detection Indicates stroke low limit detection of Ch0 F0285 High limit detection Indicates stroke high limit detection of Ch0 F0286 Emergency stop status Indicates emergency stop status Ch0 (0: enable, 1: Disable) F0287 Output prohibition Output prohibition of Ch0 (0: enable, 1: disable) F0288 Direction Operation direction of Ch0 (0: Forward, 1: Backward) F0289 Acceleration Accelerating Ch0 F028A Constant speed Constant speed operation of Ch0 F028B Deceleration Decelerating Ch0 F028C Dwelling Dwelling Ch0 F0290 Position control Position control operation of Ch0 F0291 Speed control Speed control operation of Ch0 F0292 Return to origin Return to origin operation of Ch0

F0293 JOG low speed JOG low speed operation of Ch0 F0294 JOG high speed JOG high speed operation of Ch0 F0295 PWM operation PWM output operation of Ch0 F0300 Operating flag Operation status of Ch1 (0: stop, 1:Busy) F0301 Error status Error status of Ch1 (0: normal, 1: error) F0302 End of positioning Indicates end of operation for Ch1 (0: operating, 1: End) *1Scan On F0303 End of Origin return Indicates end of origin return operation of Ch1(0:operating, 1: End) F0304 Low limit detection Indicates stroke low limit detection of Ch1 F0305 High limit detection Indicates stroke high limit detection of Ch1 F0306 Emergency stop status Indicates emergency stop status Ch1(0: enable, 1: Disable) F0307 Output prohibition Output prohibition of Ch1(0: enable, 1: disable) F0308 Direction Operation direction of Ch1(0: Forward, 1: Backward) F0309 Acceleration Accelerating Ch1 F030A Constant speed Constant speed operation of Ch1 F030B Deceleration Decelerating Ch1 F030C Dwelling Dwelling Ch1

7-100

Chapter 7 Functions

Usage of Various

Device Description

Function

F0310 Position control Position control operation of Ch1 F0311 Speed control Speed control operation of Ch1 F0312 Return to origin Return to origin operation of Ch1

F0313 JOG low speed JOG low speed operation of Ch1 F0314 JOG high speed JOG high speed operation of Ch1 F0315 PWM operation PWM output operation of Ch1 F0320~ F032F Current Step No. Current step No. of Ch0 F0330~ F033F Error code Error code of Ch0 F0340~ F035F Current address Current position address of Ch0 F0360~ F037F Current speed Current speed of Ch0 F0400~ F040F Current Step No. Current step No. of Ch0 F0410~ F041F Error code Error code of Ch0 F0420~ F043F Current address Current position address of Ch0 F0440~ F045F Current speed Current speed of Ch0 M1911 M Code Enable Bit(Ch0) On : Set up M Code function M1912 M Code Set Bit(Ch0) If positioning complete then set M1913 M Code Enable Bit(Ch1) On : Set up a M Code function M1914 M Code Set Bit(Ch1) If positioning complete then set

7-101

Chapter 7 Functions
2) code Erro r code Condition Error

Usage of Various

Operation

Corrective action

H10 Acceleration time of basic parameter is out of range Stop Set Acceleration time within 0~10,000 range H11 Deceleration time of basic parameter is out of range Stop Set Deceleration time within 0~10,000 range H12 Speed limit of basic parameter is out of range Stop H13 Bias speed of basic parameter is out of range Stop H14 Backlash compensation of basic parameter is out of range Stop H15 JOG high speed of parameter is out of range Stop H16 JOG low speed of parameter is out of range Stop H17 Origin return high speed of parameter is out of range Stop H18 Origin return low speed of parameter is out of range Stop H19 Dwell time of parameter is out of range Stop H20 Operation speed of positioning parameter is out of range Stop Set speed limit within 5~ 100,000 range. Set bias speed within 5 ~ 100,000 range. Set backlash compensation within 0~ 1,000 range Set JOG high speed within bias speed ~ speed limit Set JOG high speed within 5 ~ JOG high speed Set Origin return high speed within bias speed ~ speed limit Set Origin return low speed within bias speed ~ Origin return high speed Set Dwell time within 0 ~ 10000. Set Operation speed within bias speed ~ speed limit

H21 Dwell time of pulse out parameter is out of range Stop Set Dwell time of pulse out parameter within 0 ~ 10000 H30 POSIST command cant be executed during operation Operating Check if positioning operation is executing when POSIST signal occur. Check if output is prohibited when POSIST signal occur. Output can be H31 POSIST command cant be executed when output is prohibited Stop enabled by POSCTR command. POSIST command cant be executed when origin is not H32 determined Stop H33 Step No. of POSIST command cant be over 20 Stop Origin can be designated by POSORG or POSPRS command. Set step No. within 0~20 Check if origin is not designated when POSIST signal occur.

H34 POSDST command cant be executed during operation Operating Check if positioning operation is executing when POSDST signal occur. POSDST command cant be executed when output is H35 prohibited POSDST command cant be executed when origin is not H36 determined Stop H37 Operation speed of POSDST command is out of range Stop Origin can be designated by POSORG or POSPRS command. Set Operation speed within 5 ~ speed limit Stop enabled by POSCTR command. Check if origin is not designated when POSDST signal occur. Check if output is prohibited when POSDST signal occur. Output can be

H38 POSVEL command cant be executed during operation Operating Check if positioning operation is executing when POSVEL signal occur. POSVEL command cant be executed when output is H39 prohibited H3A Operation speed of POSVEL command is out of range Stop Stop enabled by POSCTR command. Set Operation speed within 5 ~ speed limit Check if output is prohibited when POSVEL signal occur. Output can be

H3B POSJOG command cant be executed during operation Operating Check if positioning operation is executing when POSJOG signal occur. POSJOG command cant be executed when output is H3C prohibited Stop enabled by POSCTR command. Check if output is prohibited when POSJOG signal occur. Output can be

H3D Direction cant be changed in JOG operation Operating Change direction after JOG operation end. H3E PWM command cant be executed during operation Operating Check if positioning operation is executing when PWM signal occur. Check if output is prohibited when PWM signal occur. Output can be enabled H3F PWM command cant be executed when output is prohibited Stop by POSCTR command. H40 PWM period of PWM command is out of range Stop H41 Off duty of PWM command is out of range Stop Set period within 1 ~ 20,000 Set duty within 0 ~ 100

H42 POSSOR command is available during operating only Stop Check if positioning operation is not executing when POSSOR signal occur. H43 Speed override value of POSSOR command is out of range Operating Set override value within 5 ~ speed limit

7-102

Chapter 7 Functions
Erro r code Condition

Usage of Various

Operation

Corrective action
Check if positioning is in the decelerating section when POSSOR signal occur.

H44 POSSOR command cant be executed during decelerating Operating H45 POSORG command cant be executed during operation Operating Check if positioning operation is executing when POSORG signal occur. POSORG command cant be executed when output is H46 prohibited H47 POSCTR setting error Stop enabled by POSCTR command. Check if output is prohibited when POSORG signal occur. Output can be

Check control command is within 0~3 Check if positioning operation is not executing when deceleration stop

H48 Deceleration stop command is available during operating only Stop command occur H49 POSORG command cant be executed when JOG operating Operating Check if JOG operation is executing when deceleration stop command occur H50 POSPRS command cant be executed during operation Operating Check if positioning operation is executing when POSPRS signal occur H51 Direction cant be changed in continuous operation Stop Set operation mode as end or keep mode Remove the causes of emergency stop and clear error by POSCTR H52 Emergency stop error Stop command Get rid of the external upper limit signal range by POSJOG command and H53 Stroke high limit error Stop then carry out POSCTR command and clear the error. Output prohibit shall be released by POSCTR command as output prohibit release option Get rid of the external lower limit signal range by POSJOG command and then H54 Stroke low limit error Stop carry out RST command and clear the error. Output prohibit shall be released by POSCTR command as output prohibit release option. Install the upper limit detection sensor in the direction that the current H55 The position of High/Low limit detection Sensor has been changed. Stop position increases and the lower limit detection sensor in the direction that the current position decreases

7-103

Chapter 7 Functions

Usage of Various

7.3.6 Wiring with servo and stepping motor driver (Open Collector)
1) Wiring with stepping motor driver(DC 5V)
K7 M- DR T * * U
Si gn al na me C h0 C h1 P ul se P 40 P4 1 CWCW+ * 2 D i r ecti on P4 2 P 43 C omm on C O M2 C OM 2 In put + 24V P P D C 5V CCWCCW+ Max : 2m * 4 S te ppi ng Mot or D r i ver

C omm on C O M0 C OM 1

* 1 Ori g i n P0 4 P 06 DO G Lo w l i m i P0 0 P 02 t H i g h Li m i t P0 1 P 03 *3 Em e rg en c y s t o p Inp ut P oi nt P0 5 P 07

T IMIN G C OM

C omm on C OM0 (Inp ut)

D C 5V

2) Wiring with stepping motor driver (DC 24V)

K 7 M-D RT * * U
S i gna l nam e Ch 0 C h1 Pu ls e P4 0 P 41

M ax : 2 m

*4 S tepp i ng M otor D ri ve r

CW2K , 1 /2W *2 CCW2 K , 1/ 2W D C 24V CCW+ CW+

C om mo n C OM 0 C OM1 D i re cti on P 42 P 43 C om mo n C OM 2 C OM2 Inpu t +2 4V P P

*1 O ri gi n P 04 P 06 DO G P 05 P 07 TI MIN G C OM

L o w l i mi t P 00 P 02 H i gh Li mi t P 01 P 03 *3 Em erg e n c y s t op Inpu t Po i nt

C om mo n CO M0( Inpu t)

D C 24V

Remar k 1 ) In case of VEXTA RK series, TIMMING output turns on when a motor rotates at every 7.2 degree. For exact return to origin, we suggest you to configure AND operation using TIMMING output and DOG sensor. It may be different to each system features to return to origin by the DOG sensor without TIMMING output signal (The rated input for the origin of K120S is DC 24V.) 2) Using DC 24V, wire a proper resistor to driver in series. 3) Input points for origin, approximate origin point, and upper/lower limit signal are fixed but, if theyre not used you able to use them general input point. You can use emergency stop with the command(POSCTR) 4) Positioning phase of K120S is as follow: Set the input mode of a step mode driver to 1 phase input mode because motor operation mode is determined by rotating direction input.

7-104

Chapter 7 Functions

Usage of Various

3) Wiring with servo motor driver(MR-J2/J2SA)

HC - MF H A -FF S eri e s mo tor NF MC L1 Po w er 3 Ph ase 2 00V A C L2 L3 L 11 L 21 C TE 2 D P CN 1 A 24V D C OP P of S er vo ON si gnal C u toff b y al ar m si g nal CN2 S ig na l C h0 C h1 P ul se P 40 P 41 B2 e l ectr oni c br ake dete ctor PE EM G PE B1 M R -J2 S- A TE 11 U V W W E U V SM

K7 M- DR T * * U

Ma x: 2m

* 3
PP 3 SG 10 NP 2

C o mmo n C OM 0 C OM1 D i r ecti on P 42 P 43 C o mmo n C OM 2 C OM2 In put +24V P P

OP C 11 C OM 9

* 1
Ori g i n P 04 P 06 DO G P 05 P 07 OP 14 LG 1 SD Pl at e 12 Tx D 2 nt 1 D C 24V 11 5 15 C N 1E Oute r em er gency stop S er vo : ON R ese t PID To rqu e Li m i t *3 For w ard di re cti on p osi ti on l i mi t t E MG 15 S ON 5 RE S 14 PC 8 TL 9 LS P 16 LS N 17 S G 10 S G 20 VDD 3 C OM 13 RA1 fai l ur e zer o spe ed d etect on i i n tor que l i mi t AL M 18 RA2 RA3 ZS P 19 TL C 6 4 3 14 13 Pl at e GN D RS CS DR ER W i th i n 2m A 10k M oni tor ou tput A 10k M ax 10 mA Rx D LG LG LG LG CN3 RD SD G ND G ND RS CS DR ER P erso nal com pute r

* 3

L o w L i mi t P 00 P 02 H i gh Li mi t P 01 P 03 Em e rg e nc y Inpu t po i

C o mmo n C OM0 (Inp ut)

*3 R ever se di r ecti on posi ti o n Li m i

P1 5R 11 A nal og tor que l imit T LA 12 LG 1 S D Pl a te Wi t hi n 2m +1 0V /ma x. cur ren t

Remar k 1) The rated input for the origin of K120S is DC 24V. 2) Input points for origin, approximate origin point, and upper/lower limit signal are fixed but, if theyre not used you able to use them general input point. You can use emergency stop with the command(POSCTR) 3) Positioning phase of K120S is as follow: Set the input mode of a step mode driver to 1 phase input mode is determined by rotating direction input.

7-105

Chapter 7 Functions

Usage of Various

4) Wiring with Servo motor driver(FDA-5000 AC Servo Driver)

K7MDRT**U
Si gn al na me Ch 0 C h1 P ul se P4 0 P 41

* 4
Max 2m F D A- 500 0

* 3
10 1 .5 K, 1/ 2W 11 12 24G P2 4V 1 .5 K, 1/ 2W 9 PF IN PP FI N PR IN PP RI N

C om mon C OM 0 CO M1 D i re cti on P4 2 P 43 C om mon C OM 2 CO M2 Inp ut + 24V P P O r i g i n P0 4 P 06

SSR
*1
P0 5 P 07 P0 0 P 02 P0 1 P 03 Inpu t poi n t 20

5 30 21 22 47 48

PZ O+ PZ ORD Y IN PO S 0 SP EE D BR AK E AL AR M A_ CO DE 0 A_ CO DE 1 A_ CO DE 2 GN D2 4 GN D2 4 SV ON EN CL R CC WL IM CW LI M ES TO P AL MR ST P/ P1 TL IM

DO G * 2 Lo w Li mi t H i gh Li mi t Eme rg e n cy St o p

45 Co mm on CO M0 (I np ut ) P2 4V 19 44 24 25 18 38 15 40 39 38 24 G 41 14

49

+2 4V IN

Remar k 1) The rated input for the origin of K120S is DC 24V. Linedriver output, wire a DC SSR and return to origin by DOG signal or using a origin sensor of original signal. 2) Input points for origin, approximate origin point, and upper/lower limit signal are fixed but, if theyre not used you able to use them general input point. You can use emergency stop with the command(POSCTR) 3) Using DC 24V, wire a proper resistor(1.5K, 1/2W) to driver in series. 4) Positioning phase of K120S is as follow: Set the input mode of a step mode driver to 1 phase input mode because motor operation mode is determined by rotating direction input.

7-106

Chapter Functions

Communication

Chapter Functions

8.

Communication

8.1 Dedicated Protocol Communication

8.1.1 Introduction
MASTER-K120Ss built-in Cnet communication uses only MASTER-K120S main unit for a dedicated communication. That is, it doesnt 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. MASTER-K120S main unit serves as follows: Individual/continuous reading of device Individual/continuous writing of device Reading CPU status Monitor devices registration Executing monitoring 1:1 connection (link between MASTER-Ks) system configuration (MASTER-K120S main unit : RS232C)

Remar k MASTER-K120S built-in communication function supports Cnet communication without any separate Cnet I/F module. It must be used under the following instructions. 1) Channel 0 of MASTER-K120S main unit supports 1:1 communication only. For 1:N system having masterslave Format, use RS-485 communication in channel 1 or MASTER-K120S main unit with G7L-CUEC module connected. G7L-CUEC module supports RS-422/485 protocol. 2) RS-232C communication cable for MASTER-K120S main unit is different from RS-232C cable for KGLWIN in pin arrangement and from the cable for Cnet I/F module, too. The cable cant be used without any treatment. For the detailed wiring method, refer to 8.1.2. Its possible to set baud rate type and station No. in KGLWIN.

8-1

Chapter Functions

Communication

8.1.2 System configuration method

According to the method of connection, the system using MASTER-K120S built-in communication can be composed. 1) Connecting system configuration (link between MASTERKs) (1) 1:1 connection with general PC a) Communication program made by C or BASIC computer language on the users computer, or utility program like FAM or CIMON can be used. MASTER-K120S unit main

RS-232C interface

b) method

Wiring

PC main Pin No. 1

1 2 3 4 9 5

MASTER-K120S Pin assignment direction

And

unit Pin No. Signal 1 5V 2 RXD1 3 TXD1 4 RXD2 5 SG 6 5V 7 TXD2 8 SG 9 SG

2
6 7 8

3 4 5 6 7

Female Type

8 9

TXD1, RXD1 are for loader communication and TXD2, RXD2 are for Cnet

8-2

Chapter Functions

Communication

(2) 1:1 connection with a monitoring device like PMU

PMU(LGIS ) RS-485 interface

MASTER-K120S unit

main

RS-232C interface

PMU main Pin No. 1

1 2 3 4 9 5 6 7 8

MASTER-K120S Pin assignment direction

and

unit Pin no. Signal 1 5V 2 RXD1 3 TXD1 4 RXD2 5 SG 6 5V 7 TXD2 8 SG 9 SG

2 3 4 5 6 7

Female Type

8 9

PMU Connection method and signal direction MASTER-K120S main unit 485+ 485+ 485485-

8-3

Chapter
.Functions

Communication

(3) 1:1 connection with other MASTERK120S

MASTER-K120S main unit unit

MASTER-K120S main

RS-485 interface

RS-232C interface

MASTERK120S main unit unit Pin no. 1 1 5V

5 9 4 8 3 7 2 6 1

MASTER-K120S main Pin assignment direction

and Pin no. Signal

2 2 RXD1 3 3 TXD1 4 4 RXD2 5 5 SG 6 6 5V 7 7 TXD2 8 8 SG

Male Type

9 SG

MASTER-K120S main unit Connection method and signal direction MASTER-K120S main unit 485+ 485+ 485- 485-

8-4

Chapter Functions

Communication

8.1.3 Frame Structure

1) Base Format (1) Request frame(external communication device Bytes) Heade r (ENQ ) Station

MASTER-K120S main unit), (Max. 256

number Command Command type Structurized data area Tail

(EOT )

Frame check (BCC)

(2) ACK Response frame (MASTER-K120S main unit normally) (max. 256 Bytes) Heade r (ACK ) Station number Command

external communication device, when receiving data

Command Structurized data area or null code type Tail external communication

(ETX )

Frame check (BCC)

(3) NAK Response frame (MASTER-K120S main unit device,

when receiving data abnormally) Bytes)

(max. 256

Heade r (NAK )

Station number Command Command type Error code (ASCII 4 Byte) Tail (ETX )

Frame check (BCC)

Remar k 1) Used control codes are as follows. Be familiar with the following control codes. Because they are importantly used for communication. Codes Hex value Name Contents ENQ H05 Enquire Request frame initial code ACK H06 Acknowledge ACK response frame initial code NAK H15 Not Acknowledge NAK response frame initial code EOT H04 End of Text Request frame ending ASCII code ETX H03 End Text Response frame ending ASCII code

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Communication

Remar k 1) The numerical data of all frames are ASCII codes equal to hexadecimal value, if theres no clear statement. The terms in hexadecimal are as follows.
Station No. When the main command is R(r) or W (w) and the command type is numerical (means a data type) All of the terms indicating size of all data in the Formatted data area. Monitoring registration and command registration number of execution commands. All contents of data 2)

If it is hexadecimal, H is attached in front of the number of frames like H01, H12345, H34, H12, and H89AB

2) Sequence of command frame (1) Sequence of command request frame ENQ Station No. response) Command Fomatted data EOT BCC (PLC ACK ACK Station No. Command BCC NAK Station No. Command BCC (PLC NAK response) Error code ETX Data or null ETX

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Chapter Functions

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8.1.4 List of commands

Main command type Items Code ASCII code Code ASCII code Readin g devic e Individual H72 r(R) Continuous r(R)

Classificatio n

Command Command Treatmen t

(H52) SS 5353 Reads data from device of Bit, Byte, Word type. (Continuous reading (H52) SB 5342 Reads device Word in block unavailable) unit. Bit is

H72 w

Writin g devic e

Individual H77

(W) (H57) SS 5353 Writes data to device of Bit, Byte and Word type. (Continuous reading Bit (H57) SB 5342 Writes data to Byte and Word type in block unavailable) unit. (H53) ST 5354 Reads flag list like PLC operation status and information error . is

w(W) Continuous H77

CPU Status reading H73

r(R)

Command Classificatio Main command Register n Treatmen No. t Item Code ASCII code Register no. ASCII code Monitoring variable register x(X) H58 H00~H09 3030 ~ 3039 Register device to H78 monitor. Execution of monitoring y(Y) (H59) H00~H09 3030 ~ 3039 Execute registered device to H79 monitor. Remar k

MASTER-K120S main unit identifies capitals or small letters for main commands, but not for the others.

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8.1.5 Data type

Its possible to read and write device in built-in communication. When device is used, be aware of data type.

1) Data type of variable

Available types of device Device Name Explanation Read/Write Bit/Byte/Word Assignment P Input/Output relay Available All M Auxiliary relay Available All L Link relay Available All K Keep relay Available All C Counter Available All(Current value when Word) T Timer Available All(Current value when Word) D Data Register Available Byte, Word S Step relay Available Byte, Word F Special relay Read Only All When variable is used, attach %(25H) in front of the marking characters. Data type Marking characters Examples Bit X(58H) %PX000, %MX000, %LX000, %KX000, %CX000, %TX000, %FX000 Byte B(42H) %PB000, %MB000, %LB000, %KB000, %CB000, %TB000, %FB000 Word W(57H) %PW000, %MW000, %LW000, %KW000, %CW000, %FW000, %DW000, %TW000, %SW000

Remar k 1) Timer/Counter used in bit command means contact point values.(word command means current values.) 2) Data register and Step relay can uses only word or byte commands. 3) In byte type commands, address is doubled For example, D1234 is addressed to %D1234 in word type, and is addressed to %2468 in byte type.

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8.1.6 Execution of commands

1) Individual device(R(r)SS) reading of

(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 format

request

Format name Header

Station No.

Command

Command Number type of blocks

Device length

Device name Tail ......

Frame check EOT BCC

Ex. of frame ENQ H20 R(r) SS H01 H06 %MW100 ASCII value H05 H3230 H52(72) H5353 H3031 H3036 H254D57313030 H04

1 block(setting can be repeated up to max. 16 blocks) Item Explanation

BCC

Number of Blocks

Device length (Length of device name)

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 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). This indicates the number of name's characters that means device, which is allowable up to 16 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 %MW0, it has 4 characters to be H04 as its length. If %MW000 characters to be H06.

Device name Address to be actually read is entered. This must be ASCII value within 16 characters, this name, digits, upper/lower case, '%' only is allowable to be and in entered. Remar k

H of example frame represents hex value, and is unnecessary during preparing real frame.

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(3) Response response)

format

(ACK

Format name Header

Station No.

Command

Command Number of Number type blocks of data

data Tail

Frame ...... check ETX BCC

Ex. of frame ACK H20 R(r) SS H01 H02 HA9F3 ASCII value H06 H3230 H52(72) H5353 H3031 H3032 H41394633 H04

1 block(max. possible) Item Explanation BCC

16

blocks

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,B,W) included in device name of computer request Format.

Number data

of

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
Byte(B) %(P,M,L,K,T,C,D,S,F)B 1 Word(W) %(P,M,L,K,T,C,D,S,F)W 2

Data In data area, there are the values of hex data converted to ASCII code saved.

Ex.1 The fact that number of data is H04(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. Ex.2 If number of data is H04 and the data is H12345678, ASCII code converted value of this is "31 32 33 34 35 36 37 38," and this contents is entered in data area. Name directly, highest value is entered first, lowest value last.

Remar k 1) If data type is Bit, data read is indicated by bytes of hex. Namely, if Bit value is 0, it indicated by H00, and if 1, by H01.

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(4) Response response)

format

(NAK

Format name Header Station No. Command Command type Ex. of frame NAK H20 R(r) SS H1132 ETX BCC ASCII value H15 H3230 H52(72) H5353 H31313332 H03

Error code (Hex 2 Byte)

Tail Frame check

Item Explanation BCC When command is lowercase(r), only one lower byte of the value resulted by Byte each to ASCII values from NAK to ETX is converted into ASCII and added to adding 1 BCC. Error code Hex and 2 bytes(ASCII code, 4 bytes) indicate error type. For the details, see 8.1.8 codes. Error

(5) Example

K120S main 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 Unit) MASTER-K120S main
Format name Device length Frame check

CommandNumber of Variable Format name Header Station No. Command type blocks length

Format name Tail

Ex. of frame ENQ H01 r SS H02 H05 %MW20 H06 %PW001 EOT BCC ASCII value H05 H3031 H72 H5353 H3032 H3035 H254D57 3230 H3036 H25505730 3031 H04

For ACK response after execution of command(PC Unit)

MASTER-K120S main
Number of data Frame check

CommandNumber ofNumber of Format name Header Station No. Command type blocks data Ex. of frame ACK H01 r SS H02 H02 H1234 H02 H5678 ETX BCC

Data

Data Tail

ASCII value H06 H3031 H72 H5353 H3032 H3032 H31323334 H3032 H35363738 H03

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For NAK response after execution of command(PC Unit)

MASTER-K120S main

Format name Header Station No. Command Command type Error code Tail Frame check Ex. of frame NAK H01 r SS Error code (2 bytes) ETX BCC ASCII value H15 H3031 H72 H5353 Error code (4 bytes) H03

2) Continuous device

reading(R(r)SB)

of

(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 format request
Number of data Device (Max. 128 Bytes) Tail

Format name Header

Station No.

Command

Command Device type length

Frame check

Ex. of frame ENQ H10 R(r) SB H06 %MW100 H05 EOT BCC ASCII value H05 H3130 H52(72) H5342 H3036 H254D57313030 H3035 H04

Remar k 1) Number of data specifies the number to read according to the type of data. Namely, if the data type of device is word and number is 5, it means that 5 words should be read. 2) Max. of %MW in number of data can be used up to 120(240bytes). 3) Protocol of RSB doesn't have number of blocks. 4) R(r)SB command of bit devices is not available. Item Explanation BCC When command is lowercase(r), only one lower byte of the value resulted by adding 1 each to ASCII values from ENQ to EOT is converted into ASCII and added to Byte BCC. Device This indicates the number of name's characters that means device, which is allowable length up to (Length 16 characters. This value is one of ASCII converted from hex type, and the range is of from device H01(ASCII value:3031) to H10(ASCII name) value:3130). Address to be actually read is entered. This must be ASCII value within 16 characters, and in Device this name, digits, upper/lowercase, and '%' only are allowable to be name entered.

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(3) MASTER-K120S Main unit response format (MASTER-K120S of ACK response)

Command Number of type blocks Number of data Frame check

Format name Header Station No. Command

data Tail

Ex. of frame ACK H10 R(r) SB H01 H02 H1122 EOT BCC ASCII value H06 H3130 H52(72) H5342 H3031 H3134 H31313232 H03

Item Explanation BCC

When command is lowercase(r), only one lower byte of the value resulted by adding 1 Byte each to ASCII values from ACK to ETX is converted into ASCII and added to BCC, and sent. It means byte number of hex type, and is converted into ASCII. This number is determined by multiplying the data number of computer request Format by the data size(in below table) according to memory type(B,W,D) included in variable name of computer request Format. Data type Available device Data size WORD(W) %(P,M,L,K,F,T,C,D,S)W 2

Number data

of

Dat a Ex.1

.In data area, there are the values of hex data converted to ASCII code saved.

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.

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(4) Response response)

format

(NAK

Format name Header Station No. Command Command type Ex. of frame NAK H10 r SB H1132 ETX BCC ASCII value H15 H3130 H72 H5342 H31313332 H03

Error code (Hex 2 Byte)

Tail Frame check

Item Explanation BCC When command is lowercase(r), only one lower byte of the value resulted by adding 1 each to ASCII values from NAK to ETX is converted into ASCII and added to BCC, and Byte sent. Error code Hex and 2 bytes(ASCII code, 4 bytes) indicate error type. For the details, see 8.1.8 codes. Error

(5) Example This example supposes that 2 WORDs from M000 of station No. 10 is read and BCC value is checked. Also it is supposed that data in M000 and in M001 is as follow: M000 = H1234 M001 = H5678

Computer request format (PC Unit)

MASTER-K120S Main
Command type

Format name Header Station No. Command

Device length Device name Number of data Tail Frame check

Frame (Example) ENQ H0A r SB H06 %MW000 H02 EOT BCC ASCII value H05 H3041 H72 H5342 H3036 H254D5730 3030 H3032 H04

For ACK response after execution of command(PC Unit)

Format name Header Station No. Command

MASTER-K120S Main

Command Number of type data

Data Tail Frame check

Frame (Example) ACK H0A r SB H04 12345678 ETX BCC ASCII value H06 H3041 H72 H5342 H3034 H3132333435363738 03

For NAK response after execution of command(PC Unit)

Format name Header Station No> Command Command type Error code

MASTER-K120S Main
TailBCC

NAK Frame (Example)

H0A r SB

(2Byte) Error code (4Byte) Error code

ETX BCC H03

ASCII value H15 H3041 H72 H5342

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3) Individual device(W(w)SS)

writing

of

(1) Introduction This is a function that writes the PLC device memory directly specified in accord with memory data type. (2) PC format request

Command Format name Header Station No. Command type Frame (Example) ENQ H20 W(w) SS H01 H06 %MW100 H00E2

Number of blocks

Device Device Name Data Tail Length

Frame

.....
EOT BCC

check

ASCII value
H05 H3230 H57(77) H5353 H3031 H3036

H254D5731 3030

H30304 H04 532

1 block(setting can be repeated up to max. 16 blocks) Item Explanation BCC When command is lowercase(r), only one lower byte of the value resulted by adding 1 each to ASCII values from ENQ to EOT is converted into ASCII and added to Byte BCC. This specifies how much of the blocks composed of "[device length][device name]" are in Number of this request Format. This can be set up to 16. Therefore, the value of [Number of blocks blocks] must be set between H01(ASCII value:3031)-H10(ASCII value:3030). Devic This indicates the number of name's characters that means device, which is allowable e up to length(Nam 16 characters. This value is one of ASCII converted from hex type, and the range is e from length of H01(ASCII value:3031) to H10(ASCII device) value:3130). device Address to be actually read is entered. This must be ASCII value within 16 characters, in this name, digits, upper/lower case, and '%' only are allowable to be and entered. If the value to be written in %MW100 area is H A, the data Format must be H000A. If the Dat value to be written in %MW100 area is H A, the data Format must be H000A. In data a 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. Remar k 1) Device data types of each block must be the same. 2) If data type is Bit, the data to be written is indicated by bytes of hex. Namely, if Bit value is 0, it must be indicated by H00(3030), and if 1, by H01(3031). 8-15

Chapter Functions

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(3) Response response)

format

(ACK

Format name Header Station No. Command Command type Tail Frame check Frame (Example) ACK H20 W(w) SS ETX BCC ASCII value H06 H3230 H57(77) H5353 H03

Item Explanation BCC When command is lowercase(r), only one lower byte of the value resulted by adding 1 each to ASCII values from ACK to ETX is converted into ASCII and added to BCC, and Byte sent. (4) Response response) format (NAK

Format name Header Station No. Command Command type Frame (Example) NAK H20 W(w) SS H4252 ETX BCC ASCII value H15 H3230 H57(77) H5353 H34323532 H03

Error code (Hex 2 Byte)

Tail

Frame check

Item Explanation BCC When command is lowercase(r), only one lower byte of the value resulted by adding 1 each to ASCII values from NAK to ETX is converted into ASCII and added to BCC, and Byte sent. Error code Hex and 2 bytes(ASCII code, 4 bytes) indicate error type. For the details, see 8.1.8 codes. Error

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(5) Example This example supposes that "HFF" is written in M230 of station No. 1 and BCC value is checked. Computer request format (PC unit) MASTER-K120S main

Command Number of Format name Header Station No. Command Device Length Device Name Data Tail type blocks Frame (Example) ENQ H01 w SS H01 H06 %MW230 H00FF EOT BCC ASCII value H05 H3031 H77 H5353 H3031 H3036 H254D5732 3330 H30304646 H04

Frame check

For ACK response after execution of command(PC unit)

MASTER-K120S main

Format name Header Station No. Command Command type Tail Frame check Frame (Example) ACK H01 w SS ETX BCC ASCII value H06 H3031 H77 H5353 H03

For NAK response after execution of command(PC Unit)

MASTER-K120S main

Format name Header Station No. Command Command type Error code Tail Frame check Frame (Example) NAK H01 w SS Error code (2) ETX BCC ASCII value H15 H3031 H77 H5353 Error code (4) H03

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4) Continuous device(W(w)SB)

writing

of

(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) format Request

Format name Frame (Example) ASCII value

Header

Station Comman Comma Device No. d nd type Length

Number of data Device (Max.128 Byte)

Data Tail

Frame check

ENQ H10 W(w) SB H06 %MW100 H02 H11112222 EOT BCC H254D57 313030 H31313131 32323232

H05 H3130 H57(77) H5342 H3036

H3032

H04

Remar k 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 240Bytes(120 Words).

Item Explanation BCC When command is lowercase(r), only one lower byte of the value resulted by adding 1 each to ASCII values from ENQ to EOT is converted into ASCII and added to Byte BCC. Devic This indicates the number of name's characters that means device, which is allowable e up to length(Name 16 characters. This value is one of ASCII converted from hex type, and the range is length from of H01(ASCII value:3031) to H10(ASCII variable) value:3130). device Address to be actually read. This must be ASCII value within 16 characters, and in name, digits, upper/lower case, and '%' only are allowable to be this entered.

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(3) Response response)

Format

(ACK

Format name Header Station No. Command Command type Tail Frame check Frame (Example) ACK H10 W(w) SB ETX BCC ASCII value H06 H3130 H57(77) H5342 H03

Item Explanation BCC

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 response)

Format

(NAK

Error code Format name Header Station No. Command Command type Frame (Example) ENQ H10 W(w) SB H1132 EOT BCC ASCII value H05 H3130 H57(77) H5342 H31313332 H03 (Hex 2 Byte)

Tail

Frame check

Item Explanation BCC

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.

Error code Hex and 2 bytes(ASCII code, 4 bytes) indicate error type. For the details, see 8.1.8 codes. Error

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(5) Example This example supposes that 2 byte HAA15 is written in D000 of station No. 1 and BCC value is checked. Computer request Format (PC unit)
Station No.

MASTER-K120S main

Format name Header

Command Device Command type Length

Device

Number of data

Data Tail

Frame check

Frame (Example) ENQ H01 w SB H06 %DW0000 H01 HAA15056F EOT BCC ASCII value H05 H3031 H77 H5342 H3036 H254457303030 H3031 H414131353 0353646 H04

For ACK response after execution of command (PC unit)

MASTER-K120S main

Format name Header Station No. Command Command type Tail Frame check Frame (Example) ACK H01 W SB ETX BCC ASCII value H06 H3031 H77 H5342 H03

For NAK response after execution of command(PC unit)

MASTER-K120S main

Format name Header Station No. Command Command type Error code Tail Frame check Frame (Example) NAK 01 W SB Error code (2) ETX BCC ASCII value H15 H3031 H77 H5342 Error code (4) H03

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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 Format request
Frame Format name Header Station No. Command Registration No. Registration Format Tail Frame (Example) ENQ H10 X(x) H09 Refer to registration Format EOT BCC ASCII value H05 H3130 H58(78) H3039 [ ]H04 check

Item Explanation BCC When command is lowercase(x), only one lower byte of the value resulted by adding 1 each to ASCII values from ENQ to EOT is converted into ASCII, added to byte BCC. Register No. This can be registered up to 10(0 to 9, H00-H09), and if an already registered registered again, the one currently being executed is No. is registered. Register Format This is used to before EOT in command of Formats of separate reading of continuous reading, and named variable variable, reading. Register Format : Register Format of request Formats must select and use only one of the followings. Individual device RSS reading of ...

Number of blocks(2 Byte) Device length (2 Byte) Device name (16 Byte)

1 block(max. 16 blocks) Continuous reading device RSB

of

Device length (2 Byte)

Device name (16 Byte)

Number of data

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(3) Response response)

Format

(ACK

Format name Header Station No. Command Registration No. Tail Frame check Frame (Example) ACK H10 X(x) H09 ETX BCC ASCII value H06 H3130 H58(78) H3039 H03

Item Explanation BCC

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 response)

Format

(NAK

Registration Format name Header Station No. Command

Frame (Example) ACK H10 X(x) H09 H1132 ETX BCC ASCII value H06 H3130 H58(78) H3039 H31313332 H03

Error code (Hex 2Byte)

No.

Tail

Frame check

Item Explanation BCC

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.

Error code Hex and 2 bytes(ASCII code, 4 bytes) indicate error type. For the details, see 8.1.8 codes. Error

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(5) Example This example supposes that device M000 of station NO. 1 is monitor registered. Computer request Format (PC unit) MASTER-K120S main

Registration Format name Header Station No. Command No. R##

Registration Format Number of blocks Tail Frame check Device length Device name

Frame (Example) ENQ H01 x H01 RSS H01 H06 %MW000 EOT BCC ASCII value H05 H3031 H78 H3031 H525353 H3031 H3036 H255457 303030 H04

For ACK response after execution of command(PC unit)

MASTER-K120S main

Format name Header Station No. Command Registration No. Tail Frame check Frame (Example) ACK H01 x H01 ETX BCC ASCII value H06 H3031 H78 H3031 H03

For NAK response after execution of command (PC unit)

MASTER-K120S main

Format name Header Station No. Command Registration No. Error code Tail Frame check Frame (Example) NAK H01 x H01 Error code (2) ETX BCC ASCII value H15 H3031 H78 H3031 Error code (4) H03

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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 Format request

Format name Header Station No. Command Registration No. Tail Frame check Frame (Example) ENQ H10 Y(y) H09 EOT BCC ASCII value H05 H3130 H59(79) H3039 H03

Item Explanation Register No. Register No. uses the same number registered during monitor register for monitor It is possible to set from 00-09(H00execution. H09). BCC When command is lower case(y), only one lower byte of the value resulted by adding 1 each to ASCII values from ENQ to EOT is converted into ASCII, added to byte BCC. (3) Response response) Format(ACK

In case that the register Format of register No. is the Individual reading of device
Station No. Registratio Number of Number of Command n No. Blocks data Frame check

Format name Header

Data Tail

Frame (Example) ACK H10 Y(y) H09 H01 H04 H9183AABB ETX BCC ASCII value H06 H3130 H59(79) H3039 H3031 H3034 H3931383341 414242 H03

In case that the register Format of register No. is the continuous reading of device
Station No. Registration Command No. Frame check

Format name Header

Number of data Data Tail

Frame (Example) ACK H10 Y(y) H09 H04 H9183AABB ETX BCC ASCII value H06 H3130 H59(79) H3039 H3034 H3931383341414242 H03

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(4) Response response)

Format

(NAK
Registration Error code (Hex 2Byte)

Format name Header Station No. Command Frame (Example) NAK H10 Y(y) H09 H1132 ETX BCC ASCII value H15 H3130 H59(79) H3039 H31313332 H03

No.

Tail Frame check

Item Explanation BCC

When command is lowercase(y), only one lower byte of the value resulted by adding 1 Byte each to ASCII values from NAK to ETX is converted into ASCII and added to BCC, and sent.

Error code Hex and 2 bytes (ASCII code, 4 bytes) indicate error type. For the details, see 8.1.8 codes. Error

(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 Unit) MASTER-K120S Main

Format name Header Station No. Command Registration No. Tail Frame check Frame (Example) ENQ H01 y H01 EOT BCC ASCII value H05 H3031 H79 H3031 H04

For ACK response after execution of command (PC Unit)

MASTER-K120S Main

Format name Header Station No. Command

Registration Number of Number of Blocks No. data

Data Tail

Frame check

Frame (Example) ACK H01 y H01 H01 H04 H23422339 ETX BCC ASCII value H06 H3031 H79 H3031 H3031 H3034 H3233343232 333339 H03

For NAK response after execution of command (PC Unit)

MASTER-K120S Main

Format name Header Station No. Command Registration No. Error code Tail Frame check Frame (Example) NAK H01 y H01 Error code (2) ETX BCC ASCII value H15 H3031 H79 H3031 Error code (4) H03

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7) Reading Status(RST)

PLC

(1) Introduction This is a function that reads flag list including operating status of PLC and error information. (2) PC Format request

Format name Header Station No. Command Command type Tail Frame check

Frame (Example) ENQ H0A R(r) ST EOT BCC ASCII value H05 H3041 H52(72) H5354 H04

Item Explanation BCC When command is lowercase(r), only one lower byte of the value resulted by adding 1 each to ASCII values from ENQ to EOT is converted into ASCII and added to Byte BCC. (3) Response response) Format (ACK
PLC status data (Hex 20 Byte) Tail Frame check

type Frame (Example) ACK H0A R(r) ST Status data Format ETX BCC ASCII value H06 H3041 H52(72) H5354 [ 1] H03

Format name Header Station No. Command Command

Item Explanation BCC When command is lowercase(r), only one lower byte of the value resulted by adding 1 each to ASCII values from ACK to ETX is converted into ASCII and added to BCC, and Byte sent.
1

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. 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 CPU Ver. CPU null connection No. CPU Type CPU Type K120S K80S K200SA K200SB K200SC K300S K1000S Code 42 41 3A 3B 3C 33 32 Version No. Bit Ex) 0 0 01 0 0 10 CPU Mode Ex) Bit Version 1.2 Connectio n ----- - 0 0 Null

Null Type Mode

Ex) Bit

- - -0 0 0 0Bit 1 Bit 2 Bit 3 Bit 4 Bit 0 Bit 1 Stop Run PAUSE DEBU Loca G l Mode Mode Mode Mode 8-26

connectio n

Remot e connectio n

Chapter Functions

Communication

(4) Response response)

Format

NAK
Error code

Format name Header Station No. Command Command type Frame (Example) NAK H0A R(r) ST H1132 ETX BCC ASCII value 15 3041 5272 5354 31313332 03

(Hex 2 Byte)

Tail Frame check

* 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 codes. (5) Example This example supposes that the status of MASTER-K120S Main unit of station No. 1 is read. Computer request Format (PC Unit) MASTER-K120S Main

Format name Header Station No. Command Command type Tail Frame check Frame (Example) ENQ H01 R(r) ST EOT BCC ASCII value H05 H3031 H52(72) H5354 H04

For ACK response after execution of command (PC Unit)

MASTER-K120S Main

Format name Header Station No. Command Command type Status data Tail Frame check Frame (Example) ACK H01 R(r) ST ASCII value H06 H3031 H52(72) H5354 H03 See status data Format ETX BCC

For NAK response after execution of command (PC Unit)

MASTER-K120S Main

Format name Header Station No. Command Command type Error code Tail Frame check Frame (Example) NAK H01 R(r) ST Error code (2) ETX BCC ASCII value H15 H3031 H52(72) H5354 Error code (4) H03

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8.1.7 1:1, 1:n Built-in communication between MASTERK120S's

1) Introduction 1:1 built-in communication between MASTER-K120S's is that which constitutes a built-in communication system with the method of 1(master) : 1(slave). Setting Base parameter and communication parameter in KGLWIN can easily constitute this system. Communication protocol currently applied is the same with Cnet I/F used for MASTER-K. Main functions are following. It can organize device area into 64 data access blocks by WORD unit, and set a communication time-out limit for each block. It can reestablish flag in relation with error codes and slave PLC operating mode according to parameter setting. It can reset flag related with error codes and sending/receiving error frequency of each parameter. It monitors communication status, using monitoring function of KGLWIN. MASTERK120S main unit
(Master: station no. 1)

G7E-DR10A

MASTERK120S main unit

(Slave: station No. 31)

1:1 built-in communication between MASTERK120S This communication cabling map is the same for (3) 1:1 Connecting with other MASTER-K120S in 8.1.2 "System configuration method using built-in communication."

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2) setting

Communication

Parameter

(1) Communication Parameter Setting Open a new project file from KGLWIN - MASTER-K120S must be selected as PLC type. After selecting communication parameter from KGLWIN and clicking twice, this window comes up. (a) When uses Ch.0 : Built-in RS-232C or External Cnet I/F module

(b) When uses Ch.1 : Built-in RS485

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Set according to the following table Item

Contents

Station No. Sets one of station from 0 to 31. Baud rate Sets one of 1200, 2400, 4800, 9600, 19200, 38400, 57600 bps Data bit Sets one of 7 or 8 Bits Parity bit Sets one of none, Even, Odd Stop bit Sets one of 1 or 2 Bit(s) RS232C null modem or RS422/485: can be selected as a communication channel when communication is processed by built-in functions of MASTER-K120S Main unit or Cnet I/F module (G7LCUEC). RS232C dedicated modem : can be selected when communication is processed by Cnet I/F module (G7LCUEC). RS232C dial-up modem: can be selected when common modem communication calling the opponent station is processed by Cnet I/F module (G7LCUEC). * 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 RS422/485. Its an interval waiting after sending request frame from Master MASTER-K120S before receiving a response . default value is 500ms. Setting must be done in consideration of maximum interval of sending and receiving cycle of a master PLC. If the time out is less than the maximum interval of the s/r cycle, error can occur.

Communicatio n channe l

Timeout in Master Mode

Dedicate d Master/Slave Master MASTER-K120S can read from and write on Slave MASTERK120S. Read status can be select especially when you read Slave MASTER-K120S for monitoring, but not for the other of purposes, slave PLC lest it may cause decreasing communication speed. (2) Setting registration list Click 'master' from 'exclusive use' in 'protocol and sending mode' then 'List' button will be activated.

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Click the List button to open the registration list window.

Total 64 data blocks can be assigned. But it's not possible to set a register number. Sending and receiving data size can be set up to 60 Words. Set device area - Sending: reading device area P,M,L,K,T,C,D,S saving device area : P,M,L,K,T,C,D,S - Receiving : reading device area P,M,L,K,T,C,D,S saving device area : P,M,L,K,T,C,D,S Designate station no., size, mode, area in following. windows

- Station no. : 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 Sending mode Receiving mode that is in the slave station for the data Area(from) that is in the master station to to be temporarily save the data to be written. read. Area(to) that is in the slave station to write the data. that is in the master station to save the data to be temporarily read. 8-31

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3) Flag related with operating status (1) Sending/receiving error count for each station (total 32 stations) Error code is saved following area according to station Station Device Station Remarks 0,1 D4400 16,17 D4408 2,3 D4401 18,19 D4409 4,5 D4401 20,21 D4410 6,7 D4403 22,23 D4411 8,9 D4404 24,25 D4412 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 4,5 D4418 20,21 D4426 6,7 D4419 22,23 D4427 Each device contains the Information of 2 station 8,9 D4420 24,25 D4428 The information of each station is saved in 10,11 D4421 26,27 D4429 1byte. 12,13 D4422 28,29 D4430 14,15 D4423 30,31 D4431 Device

Each device contains the Information of 2 station The information of each station is saved in 1byte.

(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 Remarks 0,1 D4432 16,17 D4440 2,3 D4433 18,19 D4441 4,5 D4434 20,21 D4442 6,7 D4435 22,23 D4443 8,9 D4436 24,25 D4444 10,11 D4437 26,27 D4445 12,13 D4438 28,29 D4446 14,15 D4439 30,31 D4447 Device

Each device contains the Information of 2 station The information of each station is saved in 1byte.

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Chapter Functions
Error bit b7

Communication

b6

b5

b4

b3

b2

b1

b0

Operation mode of slave PLC b4 : STOP b5 : RUN b6 : PAUSE b7 : DEBUG

Reserve d

Error status of slave PLC 1 : Error 0 : Normal

(4) Status flag of the master PLC Status Information of master PLC is saved in D4448 b15 b3 ---------b2 b1 b0 D4448

b1 : be set in case station is duplicated in case device area b2 : be set over

(5) Max/min/current sending/receiving cycle of set parameter Contents: the interval between after sending and before receiving Saved area (Channel 0) Saved area(Channel 1) Max. D4449 D4450 D4349 D4350 Min. D4451 D4452 D4351 D4352 Current D4453 D4454 D4353 D4354

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4) Example

Communication

MASTER-K120S main unit (Master : Station No. G7E0) DR10A

MASTER-K120S main unit (Slave : Station No. 31)

1:1 built-in communication between MASTERK120S Device M000 is increased by program per 1 second. Writing M000 to output area P004 of slave Reading slaves output area P004 Writing it to masters output area P009 The following example uses the above diagram to explain the operation of MASTER-K120S main unit. The data of the master MASTER-K120S main unit is increased by INCP instruction and sent to be written on the output contact point P004 of the slave MASTER-K120S main unit. And in return, the master MASTER-K120S main unit reads the data that is written on the output contact point of the slave MASTER-K120S to write them on the output contact point of extended digital input/output module, G7EDR10A. (1) Setting communication parameter of the master station and its program Work on the master station 0. Open a new project file and a new program for the master station. Double click parameter item for parameter settings. If you click the Comm. button in parameter window in KGLWIN, you can see the following window of the communication parameter.

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Set parameters as the following table.

Communication Protocol
Communication

Method

and mode

Station no. Baud rate Data bit Parity bit Stop bit Communication channel Timeout Dedicated

Enable 0 19200 8 None 1 RS232C null modem or

RS422/485 500ms Master

Click List button to activate registration list window

double click list number 0 in List window , then following window for Private 1 item 0 edit is open

Set parameters like the following table and click OK button.

Station No. Size Mode Area to read(From) Area to save(to) 31 1 Send M000 (See the above) P004 (See the above)

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The registration list 0 registered in the registration list can be confirmed through a window like the following.

Double click the No. 1 for receive parameter setting and Set parameters like the following table and click OK button.
Station No. Size Mode Area to read(From) Area to save(to) 31 1 Receive P004 (See the above) P009 (See the above)

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(2) Program

Communication

(2) Parameter setting for slave station. Set parameters as the following table.

Communication Protocol
Communication

Method

and mode

Station no. Baud rate Data bit Parity bit Stop bit Communication channel Timeout Dedicated RS232C null modem or RS422/485

Enable 31 19200 8 None 1

- slave

Slave station does not need program. Baud rate, parity bit, data bit, stop bit setting must be same with master station.

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8.1.8 Error code

Error code Treatment

Error type

Error condition and causes

Check if other letters than capitals/small letters,

H0001 PLC system error Interface with PLC is impossible. Off/On the power H0011 Data error Errors occurred when exchanging ASCII data to numbers. numbers, and (%,_,.) in device and data, correct and execute again.

H0021 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. Wrong command type that is to use characters H0031 Command type error like wSS, wSB using other letters from SS orCheck command type SB H1132 Device memory error Set wrong device memory other than P,M,L,K,T,C,F,D,S H1232 Data size error The number of data in execution is 0 or bigger than 128 bytes. When use other characters than x (X), w (W) H2432 Data type error at MASTER-K120S. When use b (B), d (D) at MASTER-K120S. Ex1) Use commands like %DB or %DD. H7132 Device request Format error When omit %. Check Format, correct and execute again. H2232 Area exceeding error When exceed assigned area. Ex1) MX2000 or %DW5000 Correct the size within the assigned area and execute again. Check data type and execute again. Check device type Correct length of data (If data type is bite, the number of data must be from 1 ~ 128.)

H0190 Monitor execution error Exceeding limit of register No. Rearrange the monitor register9 and reset. over than no. not to go H0290 Monitor register error Exceeding limit of register No. Rearrange the monitor register no. not to go over than 9 and reset. When use commands that arent supported. H6001 Syntax error Ex1) When use device like %MX100 in RSB command Be familiar with the manual. Check if the system stopped. reset

H6010 Syntax error OVER-RUN, FRAME error Be familiar with the manual. Confirm the setting of the communication ports of RSH6020 Syntax error TIME_OUT error 232C. reset H6030 Syntax error Syntax error in commands Check if each sends frame has ENQ, EOT. H6040 Syntax error When a FRAME text exceeds over 256 bytes. Rearrange send frame not to go over 256 bytes. H6050 Syntax error BCC error Check if BCC is right.

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8.2 User Defined Protocol Communication

8.2.1 Introduction
User Defined Protocol Communication allows users who do communication between MASTER-K120S main unit and other kind of device to define the other companys protocol at MASTER-K PLC. Therere a number of kinds of protocols made by many companies, that its difficult to have all protocols in it. So if a user defines a protocol that can be applied to his/her purpose, MASTER-K120S main 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 can download a user defined protocol frame into MASTER-K120S main unit and it is saved. it is not erased by powers off/on. For using user-defined mode, he/she should program with instruction controlling sending of PLC as well as edit frames. This section explains User Defined Protocol Communication setting & usage.

8.2.2 Parameter Setting

1) Setting Communications Parameter (1) Open a new project file from KGLWIN and select K120S as PLC type (2) After setting communication parameter at KGLWIN. Double click it to activate this window.

(3) Set according to the following table. Communication Method mode

Communi -cation Station no. Baud rate Data bit Parity bit Stop bit Communicationchannel Timeout User defined

Protocol and

Enable 0 19200 8 None 1 RS232C null modem

or RS422/485 500ms Master

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2) Setting frame (1) Click List button to activate the following window.

(2) Select one of 1~15 in frame list to open the following window.

Frame specification Heade r - Used in [Header] type. - Possible characters, as headers are 1 alphabet letter, 1 numeric number, or control characters as below. Available Control Code NUL(H00) SOH(H01) STX(H02) ETX(H03) EOT(H04) ENQ(H05) ACK(H06) BEL(H07) BS(H08) HT(H09) LF(H0A) VT(H0B) FF(H0C) CR(H0D) SO(H0E) S1(H0F)
DLE(H10) DC1(H11) DC2(H12) DC3(H13) DC4(H14) NAK(H15) SYN(H16) ETB(H17) CAN(H18) EM(H19) SUB(H1A) ESC(H1B) FS(H1C) GS(H1D) RS(H1E) US(H1F) DEL(H7F)

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Example 1) [NUL] , [ENQ] , [1] , [A] : Possible Example 2) NUL, ENQ , [12] , [ABC] : impossible - It is allowed to be only 3 consecutive characters. Example 3) [ENQ][STX][NUL] : Possible Example 4) [A][NUL][ENQ][STX] : impossible / Send Receive - Not defined : It is the initial value that doesnt 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 . Segment (1-8): Enter segment by segment to separate fixed sending data area (CONSTANT) and device area (Array). Item Contents To set a segment type, therere NONE (not defined), CONST (fixed data area), ARRAY (Device area). CONST declares commands and fixed data are used for communication frame and ARRAY is used to input and that savedata needed for interactive communication. ARRAY type must be the alwaysbyte. set by 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 10 characters and hex within 20 characters. If the number exceeds the within limit, next segment as the same type and continue to input there. As set the an dedicated protocol communication, 10RSB06%MW10006 is a frame to execute 6 word data from M100 at the slave station no. reading 16. Ex1) 10RSB06%MW10006

If the segment is declared as ARRAY type, designate transmitting device (P,M,L,K, F,T,C,D) and number of transmitting. Thebyte unit is Ex2) If you want to transmit D000 ~ D003, the setting is as below. (transmitting device : D000 , number of transmitting : 6 bytes)

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Item Contents It is a radio button to select the input type of commands. Therere 2 kinds as hex or ASCII value. Ex1) ASCII : 1 0 R S B 0 6 % M W 1 0 0 Ex2) Hex : 31 30 52 53 42 30 36 25 57 44 31 30 30

If ARRAY is set, it asks whether it would convert data to ASCII to send (at send frame), or convert to hexadecimal to receive(at receive frame). If ARRAY is set, the size of area is to be set by byte. Thebyte. a unit is

Tail - Used in [Tail] type. - Possible characters as headers are 1 alphabet below

letter, 1 numeric number, or control characters as Control

NUL(H00) SOH(H01) STX(H02) ETX(H03) EOT(H04) ENQ(H05) ACK(H06) BEL(H07) BS(H08) HT(H09) LF(H0A) VT(H0B) FF(H0C) CR(H0D) SO(H0E) S1(H0F) DLE(H10) DC1(H11) DC2(H12) DC3(H13) DC4(H14) NAK(H15) SYN(H16) ETB(H17) CAN(H18) EM(H19) SUB(H1A) ESC(H1B) FS(H1C) GS(H1D) RS(H1E) US(H1F) DEL(H7F)

Available Code

Example 1) [NUL] , [ENQ] , [1] , [A] : Possible impossible - It is allowed to be only 3 consecutive characters. Example 3) [ENQ][STX][NUL] : Possible impossible

Example 2) NUL, ENQ , [12] , [ABC] :

Example 4)

[A][NUL][ENQ][STX] :

- Its possible to use BCC that can detect errors. BCC must be set as [BCC] to be used. To set BCC contents, click BCC Setting button on the right side. Example 5)

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BCC setting: set BCC when it is needed.

Item Contents Data Type ASCII adds 2 bytes BCC value in ASCII type to frame. Hex adds 1 byte BCC value in Hex type frame. For the detailed setting BCC, refer to 8.1.6 Execution of to Commands. nd data to the data before the data marked as [BCC] and input Default It is that sum all the data from the result to the [BCC] 2 area SUM 1 BCC method uses sum like defaults, but the user can set the BCC area. SUM 2 BCC method is the same with SUM 1, but its used when the user masks any value to the last value. BCC XOR 1 OR). BCC method is OR (Exclusive

XOR 2 BCC method is the same with XOR 1, but its used when the user masks any value to the last value. BCC MUL 1 BCC multiplication. method is MULTIPLY that is,

MUL 2 BCC method is the same with MUL 1, but its used when the user masks any value to the last value. BCC Rang e H signifies header, S is for segment, and T is for tail. 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 [BCC] value. If mask setting is done after taking a complement number, the user can set any value to do masking. 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 : &FF 8-43

Complemen t

Mask

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Communication

Frame size

- ASCII communication : max. 128 bytes - Hex communication : max. 256 bytes

Link relay (L) - Its a flag to indicate whether a user defined frame is received in the order set by the user. - If the received frame is matched with the declared frame in frame list number 3, L003 starts blinking (0 1 0).

When frame receiving is done, MASTER-K120S main unit check if theres 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. BCC example> calculation When frame is set as below, the result of calculation is as follow.

(1) setting

Default

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The kinds of Input segment check

ASCII Type Hex Type ASCII Input 31 + 32 +33 +34 +04 = CE 05 31 32 33 34 04 43 41 05 31 32 33 34 04 CE Hex Input 12 + 34 +04 = 4A 05 12 34 04 34 41 05 12 34 04 4A

The value of sum

The last transmitting frame BCC Type setting

(2) SUM 1 , XOR 1 or MUL 1 setting.

SUM 1 The last transmitting frame Type setting BCC

The kinds of segment input

The value of sum ASCII Type Hex check 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 XOR 1

The kinds of segment input

The value of sum ASCII Type Hex check Type ASCII Input 05 ^ 31 ^ 32 ^ 33 ^ 34 ^ 04 = 05 05 31 32 33 34 04 30 35 05 31 32 33 34 04 05 Hex Input 05 ^ 12 ^ 34 ^ 04 = 27 05 12 34 04 32 37 05 12 34 04 27 MUL 1

The last transmitting frame Type setting BCC

The kinds of segment input

The value of sum ASCII Type Hex check Type ASCII Input 05 x 31 x 32 x 33 x 34 x 04 = 60 05 31 32 33 34 04 36 30 05 31 32 33 34 04 60 Hex Input 05 x 12 x 34 x 04 = 20 05 12 34 04 32 30 05 12 34 04 20 8-45

The last transmitting frame Type setting BCC

Chapter Functions

Communication

Complement setting : Complement calculation as below example> 1s and 2s Complements of D3

bit 7

bit 0

11010011
bit 7

= h D3(sum value)

check

bit 0

00101100
bit 7

1 complement = h 2C(the last sum check value) 2 complement = 1 complement + 1 = h 2D(the last sum check l)

bit 0

00101101

Mask setting : Masking method is as below bit 0 bit 7 11010011

bit 7

= h D3 (sum check value) = hFF value) AND hD3 (masking

bit 0

11111111
bit 7

bit 0

11010011
bit 7

masking

bit 0

11010011
bit 7

OR masking = hFF

bit 0

00101100

Exclusive OR masking = h2C

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8.2.3 Instruction
1) User defined instruction(SNDCOM) SNDCO M User defined instruction communication

communication

Available Device Flag Instruction MPKLFTCSD Ch n1 D

#D

integer

No. of steps

Error (F110)

Zero (F111)

Carry (F112)

Flag Set

Designation

Erro r (F110)

Error flag turns on when designating area is over and the instruction isnt executed

Ch Designated communication channel n1 Frame lists which is designated at parameter D Device which the communication status is stored

SNDCOM Ch n1 D (1) Function the execution condition is on, the communication starts with protocol at parameter which is designated When early. is communication channel and n is a frame number at parameter which is Ch designateddevice which the communication status is D is a stored. (2) example of program input condition is on, channel 1 stars communication with protocol at user defined parameter When The communication state is stored M000 and the format of M000 Iis as rnumber 3. below

bit 15

bit 8

bit 1 bit 0

Error code (1 byte) Error bit Done bit Done bit : When transfer is completed normally, this bit turns on during 1 scan. Error bit : When communication error occurs, ,this bit turns on. Error code : When error bit turns on, the error code is stored.

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3) code

Communication

Error Code Error type explanation 06 Slave Device Busy Its sending or waiting to receive 09 Parameter Error Communication parameter setting error, Link enable setting error 10 Frame Type Error Frame does not setting or frame does not sending

8.2.4 Example of Usage

This example is supposed that theres a communication between MASTER-K120Ss 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. MASTER-K120S main unit (Master: Station no. 0) MASTER-K120S main unit (Slave: Station No. 1)

1:1 dedicated protocol communication cable The data in M area of the master station is sent to the slave station and the slave station saves received data in M area, output as direct variable, and sends the data back to the master. This process repeats between the master and the slave. 1) The Programming and setting communication parameter of the master station Select the communication parameter and then select communication method and communication channel. Select user Defined at protocol and mode item(list item is activated), then Click the list

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Double click the number 0

Designate the header, segment, send/receive , tail as below and then click the BCC Setting

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Designate BCC Setting as below and Click the OK button, then you can see the frame list window which is designated

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Double click the number 1 frame

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.

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Progra m

Communication

When the data is received at frame no. 1, link relay L001 turns on during 1 scan. At that moment, M000 increases and the value of M000 moves output relay P004. The new value of M000 is sending again every 1 second period (F092 is 1second period flag) The number of sending normally stores D000. When error occurs, the number of sending error stored in D001. 2) Setting and program of slave station Make the new project file and setting new parameter. Click the list after set the communication method and communication channel.

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Double click the frame list number 0

Click the BCC Setting after set the header , segment , tail as below.

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Click the OK button after BCC setting as below. Then you can see the frame list which is designated.

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Set the frame number 1 as below and click the BCC Setting

BCC Setting method is same as master station.

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After the frame setting and BCC setting completes, click the OK button. You can see the frame list window which is designated as below

Progra m

When the data is received at frame no. 0, link relay L000 turns on during 1 scan. At that moment P004 increases and the value of P004 moves M000. The new value of P004 is sending again every 1 second period (F092 is 1second period flag) The number of sending normally is stored in D000. When error occurs the number of sending error is stored in D001.

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8.3 Modbus Protocol Communication

8.3.1 Introduction
MASTER-K120S built-in communication supports Modbus, the Modicon products communication protocol. It supports ASCII mode, using ASCII data and RTU mode using Hex data. Function code used in Modbus is supported by instruction and especially function code 01, 02, 03, 04, 05, 06, 15 and 16. Refer to "Modicon Modbus Protocol Reference Guide"

8.3.2 Basic Specification

1) ASCII mode (1) It communicates, using ASCII data. (2) Each frame uses ': (colon : H3A)', for header, CRLF (Carriage Return-Line Feed : H0D H0A), for tail. (3) It allows Max. 1 second interval between characters. (4) It checks errors, using LRC. (5) Frame structure (ASCII data) Item Header Address Function code Data LRC Tail(CR/LF) Size 1 byte 2 bytes 2 bytes n bytes 2 bytes 2 bytes

2) RTU mode (1) It communicates, using hex data. (2) There's no header and tail. It starts with address and finishes frame with CRC. (3) It has at least 3.5 character times between two frames. (4) It ignores the current frame when 1.5 character times elapse between characters. (5) It checks errors, using 16 bit CRC. (6) Frame structure (hex data). Item Address Function code Data CRC Size 1 byte 1 bytes n bytes 2 bytes

REMAR K 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 second to send 1200 bits. To send 1 bit, 1 sec/1200 bits = 0.83 ms. Therefore 1 character time is 0.83ms * 8 bits = 6.64ms. 3) 584, 984 A/B/X executes frame division, using intervals of more than 1 sec without LRC in processing internally.

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3) area

Communication

Address

(1) Setting range is available from 1 to 247, but MASTER-K120S supports from 0 to 31. (2) Address 0 is used for broadcast address. Broadcast address is all slave device recognize and respond to like the selfaddress, which can't be supported by MASTERK120S. 4) Function code area (1) MASTER-K120S 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) [Confirm1000 0011 ] (H83) It returns as it sets the 8th bit of function code of request frame.

5) area

Data

(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 rules.

REMAR K 1) All numerical data can use hexadecimal, decimal, and binary type. If we convert decimal 7 and 10 into each type: Hexadecimal : H07, H0A or 16#07, 16#0A Decimal : 7, 10 Binary 2#1010 : 2#0111,

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7) Function code types and memory mapping Code Function code name Modicon Data address PLC Remark 01 Read Coil Status 0XXXX(bit-output) Read bits 02 Read Input Status 1XXXX(bit-input) Read bits 03 Read Holding Registers 4XXXX(word-output) Read words 04 Read Input Registers 3XXXX(word-input) Read words 05 Force Single Coil 0XXXX(bit-output) Write bit 06 Preset Single Register 4XXXX(word-output) Write word 15 Force Multiple Coils 0XXXX(bit-output) Write bits 16 Preset Multiple Registers 4XXXX(word-output) Write words MASTER-K120S Mapping Bit area Word area Address Data area Address Data area h0000 P area h0000 P area h1000 M area h1000 M area h2000 L area h2000 L area h3000 K area area h4000 F area area h5000 T area area) C area h6000 area) h7000 S area h8000 D area 8) Modbus addressing rules MASTER-K120S main unit starts its address from 0 and matches with 1 of Modicon products' data address. So MASTERK120S'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 communication address 0 and the input contact point 1 (0001) of Modicon products is marked as communication address 0 in MASTERK120S. 9) The size of using data As for data size, MASTER-K120S main 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." h3000 K h4000 F h5000 T area(current value h6000 C area(current value

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10) wiring

Communication

Map

of MASTER - K120S main unit Pin no. 1 1 CD

5 9 4 8 3 7 2 6 1

Connecting direction

no.

and

Quantum (9PIN) Pin no. Signal

2 2 RXD 3 3 TXD 4 4 DTR 5 5 SG 6 6 DSR 7 7 RTS

Male Type

8 8 CTS 9 9

Use RS-485 connector when using channel 2.

8.3.3 Parameters Setting

1) Setting parameter communication

(1) Open a new project file at KGLWIN. K120S should be selected in PLC types. Open a new project file for each of the master and the slave. (2) Select a communication parameter at KGLWIN and double click to open the following window.

If communication mode is ASCII, Be sure to set 7bit

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(3) Set the contents as follows. Item Setting contents Station No. Set a number between 0 to 31 (Dont assign no. 0 as broadcasting station lest it may be a for mistaken cause operation) Baud Rate Set one from 1200, 2400, 4800, 9600, 19200, 38400, or 57600 bps. Set 7 or 8. Data Bit ASCII mode: Set as 7 bits. RTU mode: Set as 8 bits. Parity Bit Set as one of None, Even, or Odd. Set 1 or 2 bit(s). Stop Bit When parity bit is set: Set as 1 bit. When parity bit isnt set: Set as 2 bits. RS232C Null Modem or RS422/485 : Its a communication channel for the communication, using MASTER-K120S main units built-in communication and Cnet I/F module (G7LCUEC). RS232C Modem (Dedicated Line) : Its to be selected for the communication, using an dedicated modem with Cnet I/F module (G7LCommunicatio CUEB). S232C Dial Up Modem : Its to be selected for the general communication connecting n Channe through the telephone line by dial up modem and Cnet I/F module (G7Ll CUEB). Note : Using Cnet I/F module (G7L-CUEB) supporting RS232C, RS232C dedicated or dialup modem communication can be done, but not through Cnet I/F module (G7LCUEC) supporting RS422/485. Its the time waiting a responding frame since the master MK80S main unit sends a request frame Time out in . The default value is MasterMode 500ms. It must be set in consideration of the max. periodical time for sending/receiving of the master PLC. If its set smaller than the max. send/receive periodical time, it may cause communication Modbus Iferror.set as the master, its the subject in the communication system. If its set as the slave, it is Master/ it Slave only responds to the request frame of the master. Transmissio n Mode Select ASCII mode or RTU mode.

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8.3.4 Instruction and example

1) MODBUS instruction(MODCOM) MODCO M MODBUS communication Available Flag MPKLFTCSD device
#

communication

Instructio n Ch
S1 S2 S3

D integer

No. of steps Error

(F110)

Zer o (F111 )

Carr y (F112)

Flag

Designatio n
Ch Designated communication channel

Error (F110)

Error flag turns on when designating area is over the instruction isnt and executed

S1 Device which is registered communication parameter S2 Device which stored communication data S3 Device which stored communication status

MODCOM Ch S1 S2 S3 (1) Example program Designate slave station No. , function code,.address, No. of reading When input condition(M0020) turns on, MODBUS communication starts. Receiving data are stored D1000, and communication status is stored to M100

When operates as slave, MASTER-K120S responses to master station without commands. And When operates as master, MASTER-K120S sends data in S1 with MODBUS protocol at rising edges of execution condition.

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S3 format below. bit 15

is

as bit 8 bit 1 bit 0

Error bit NDR Error bit code NDR : when the communication ends normally, this bit turns on during 1 scan. Error bit : when communication error occurs, this bit turns on during 1 scan. At that time error code stores bit 8 ~ bit 15. Error code is as follow Code Error type Meaning 01 Illegal Function Error in inputting function code in instruction. 02 Illegal Address Error of exceeding the area limit of reading/writing on the slave station. 03 Illegal Data Value Error when the data value to be read from or write on the slave station allowed isnt . 04 Slave Device Failure Error status of the slave station. Its a responding code of the slave station for the master station to prevent the master station time-out error, when request command processing takes 05 time. The master station marks an error code and waits for a certain time Acknowledge without making any second request. 06 Slave Device Busy Error when request command processing takes too much time. The should request master again. 07 Time Out Error when exceeds the time limit of the communication parameter communicates as it . 08 Number Error Errors when data is 0 or more than 256 bytes 09 Parameter Error Error of setting parameters (mode, master/ slave) 10 Station Error Error when the station number of itself and the station number set by S1 of instruction are the the same. Remar k -. In MASTER-K120S series, the MODBUS command which has been used in MK80S series can be used.this case, communication channel is fixed to channel In 0.

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2) Example program 1 Its supposed that MASTER-K120S main unit is the master and it reads Coil Status of the station no. 17, a Modicon product. The master reads status of the Coil 00020 ~ 00056 of the slave station no. 17. The Coil of the slave station is supposed to be as follows and the data that are read is saved in D1000 Coil 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 Status X X X 1 1 0110000111 0 1 0 11 Hex 1 B 0 E B Coil
39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 44 43 42 41 40

Status 0 0 1 0 0 1101011110 0 1 1 01 Hex 2 6 B C D The status of Coil 57, 58, 59 are redundancy. Data is sent starting from the low bit by byte unit. If the deficient bit of a byte is filled with 0. An example of sending the above data is as Following example 1. Example 1) CD B2 0E 1B

It designates slave station and function code (No. of station : h11(17) , function code : h01) Address setting - Address 0 at MODBUS protocol means address 1 actually .So if you want to designate address 20 , write address 19 Reading number setting ( Reading number is 37 from 20 to 56.) This is MODBUS Communication instruction. - Data is sent starting from the low bit by byte unit. If the deficient bit of a byte is filled with 0. An example of sendingabove data is as the follows. - The data transmission starts lower byte. The remnant part of byte is filled with 0 Stored data at D1000,D1001,D1002 are : Device Stored data D1000 h CD 6B D1001 h B2 CE D1002 h 00 1B

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3) Example program 2 Its supposed that MASTER-K120S main unit is the master and it reads Coil Status of the station no. 17, a Modicon product. The master reads status of the input contact 10197 ~ 10218 of the slave station no. 17. The input contact of the slave station is supposed to be as follows and the data that are read is saved in M015. Input
10220 10219 10218 10217 10216 10215 10214 10213 10212 10211 10210 10209

Status X X 1 1 0 1 0 1 1 1 0 1 Hex 3 5 D Input

10208 10207 10206 10205 10204 10203 10202 10201 10200 10199 10198 10197

Status 1 0 1 1 1 0 1 0 1 1 0 0 Hex B A C The status of input contact 10219,10220 are redundancy. Data is sent starting from the low bit by byte unit. If the deficient bit of a byte is filled with 0. An example of sending the above data is as follows. Example 2) AC DB 35

: It designates slave station and function code ( No. of station : h11(17) , function code : h02 ) : Address setting Address 0 at MODBUS protocol means address 1 actually .So if you want to designate address 10197 , write address : Reading number10196 ( Reading number is 22 from 10197 to setting 10220.) : This is MODBUS Communication instruction. The data transmission starts lower byte. The remnant part of byte is filled with 0 Stored data at D200,D201 are : Device Stored data D200 h AC DB D201 h 00 35

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4) Example program 3 The master writes data D1000 ~ D1003 to contact 40000 of the slave station no. 10.

: It designates slave station and function code ( No. of station : h0A(10) , function code : h10 ) : Address setting 0 of function code 16 at MODBUS protocol means address 40000 Address actually. number setting ( Writing number is : Writing 4) This is : instruction. MODBUS Communication

5) Example program 4 The master writes data in D1000 to contact 40000 of the slave station no. 10.

: It designates slave station and function code ( No. of station : h0A(10) , function code : h06 ) : Address setting Address 0 of function code 16 at MODBUS protocol means address 40000 actually. number setting ( Writing number is : Writing 1) : This is MODBUS Communication instruction. 8-66

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8.4 No Protocol Communication

8.4.1 Introduction
No protocol communication is useful when communication between MASTER-K120S main unit and other kind of devices defined protocol is impossible. User defined protocol is very convenient when there are enough interval with user between a kind of frame is less than 16. But, When the kind of frame is greater than 16 or frames are continued frames or without user defined protocol is not interval, available. kinds of frame are more than 16, they cant be registered in parameter area, therefore MASTER-K120s When the cant these frames. Also, if there are no interval between frame, MASTER-K120S cant find end of transfer frame. To overcome these defects of user defined protocol, MASTER-K120S provide No Protocol Communication . Communication, frames are designated by commands, not by parameter setting. So Max. 128 frames In the No Protocol candesignated when using this communication mode. This section explains No protocol Communication setting & be usage. 1) Data Sending

Command : DSND stored data in designated device at the rising edge of input Sends condition. Data and the number of character must be stored in designated device before they are sent. Operand s (a) First operand Designates communication channel (b) Second operand Number of data to sending (Unit of byte) (c) Third operand Starting address of devices which stores sending data Fourth operand Device address which indicates communication (d) status. Receiving

2) Data

Command : DRCVreceived data to pre-defined receiving devices when designated ending condition is Saves occurs. The ending condition can be designated by following two kinds. number of character which is - By received. - By designated last byte. It is useful when there is no interval between received frames. Supports hexdecimal type. Operand s (a) First operand Designates communication channel (b) Second operand Designates receiving format (c) Third operand Starting address of devices which stores receiving data (d) Fourth operand Device which indicates end of receiving

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Receiving format can be designated as below. Upper byte(hex) Lower byte(hex) H00(Receiving by Length of frame) H03 (Receives when length of frame data is 3) H01(Receiving by last byte) H03 (Receives when last frame data is 03(ETX)) - When designated as length of frame : Stores received data to devices when number of received byte is equal to designated lower byte value of receiving format.(setting range : - When designated last byte : Stores 1~255) data to devices when receives designated ending received byte.

8.4.2 Parameter setting

1) Setting Parameter Communications

(1) Open a new project file from KGLWIN and select MK120S as PLC type (2) After selecting communication parameter at KGLWIN. Double click it to activate this window

(3) Set the communication methods and channel (Refer to Chapter 8.1.7 for details.) (4) Click No protocol, then parameter setting is finished

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8.4.3 Instructions
1) No receive(DRCV) DRCV protocol protocol

No receive

Instructio n
Ch Cw D SS

Available Flag MPKLFTCSD

Device
#

D Integer

No. of step Error

(F110)

Zer o (F111 )

Carr y (F112)

Flag

Erro r (F110)

Error flag turns on, when designating area is over.

Designatio n Ch Designated communication channel CW Designated format of receiving frame D Device address which is stored communication data SS Device address which is displayed status communication

DRCV

Ch

Cw D SS

(1) Function the execution condition is on, the communication starts with No When protocol. data is stored in device Received D If received data is not match to the designated format by Cw, data is not saved to D The communication status is saved in SS . (2) Example program

When the execution condition M0000 is on, the communication starts with channel 1 When EXT(h03) is received, Received frames are saved to D0100 When NDR is on, the length of received frames is saved to M010 by byte.

Length of received data

error bit Done 8-69

Chapter Functions

Communication

1) No send(DSND) DSND No send

protocol

protocol

Instructio n
Ch n S SS

Available Flag M P K L F T CSD

Device
#

D Integer

No. of step Error

(F110)

Zer o (F111 )

Carr y (F112)

Flag

Designation

Erro r (F110)

Error flag turns on, when designating area is over.

Ch Designated communication channel n Number of data to sending by bytes S Device address which is stored communication data SS Device address which is displayed status communication

DSND

Ch

SS

(1) Function the execution condition is on, the No protocol communication When starts n represents the number of data to send (unit of byte) and Sending data is stored in device D is designated communication channel and Communication status is saved in Ch SS. (2) Example program

When the execution condition P0040 is on, the communication starts with channel 1 Length of sending data which is stored in D0100 is 10 byte and the communication status is stored in M000.

Length of sent data (3) code Error Code Error Description 06 Parameter Error Communication parameter setting error 08 Slave Device Busy Slave device is busy 09 Frame Type Error Size of sending byte is out of range 8-70

error bit Done

Chapter Functions

Communication

8.4.4 Examples
Assume that a electrical weighing machine sends data which has unfixed size continuously. MASTER-K120S can communicates with it using no protocol. MASTER-K120S unit Electrical machine weighing Main

For no protocol communication, one of following ending condition is designated. One is size of received data and the other is whether it has some pre-defined data. In this example, assume that received data is as following. ENQ(1Byte) + Station No.(1Byte) + Data(1~10 Words) + EOT(1Byte) When above frame is received, Received framed is saved to designated device If designated Receiving Format(Cw) is h0104. and decides if use these data or not. After that, sends data which is in sending device if required. Assume that the sending data format is as following. ACK(1Byte) + Station No.(1Byte) + OK(2Bytes) + EOT(1Byte) In this example the size of received data is 1 word.

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1) Communication Parameter Setting Open a new project file from KGLWIN - K120S must be selected as PLC type. After selecting communication parameter from KGLWIN and clicking twice, this window comes up. Designate baud rate, data bit, parity bit, stop bit, and protocol.

2) Program

Save sending data to D0100 : ack + 0 + OK + ETX If h04(EOT) is received, h3004 is saved to D0000, and Weight data to D0111(1 Word) Sending 5bytes in D0100 using DSND instruction

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8.5 Remote connection and communication I/F module

8.5.1 Remote connection
MASTER-K120S series can connect to other PLC by built-in Cnet interface or communication I/F modules. 1) Remote connection by built-in Cnet I/F Remote connection by built-in Cnet I/F is available by dedicated communication protocol only. If KGLWIN and Master station is connected physically, it can connect to each slave station using remote connection function.

KGLWI N Local connection Ch.0 Slave, station #1 G7LCUEC

Master station

G7LCUEC

RS-422/485 I/F Ch.1 Slave, station #2 RS-485 I/F Ch0, station#2 Slave

Ch.1 Slave, station #31

Ch0, station#31

Slave

Ch.1, system Using Cnet

RS-485 multi-drop built-in

Ch.0 RS-422/485 system Using G7LCUEC

multi-drop

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Open a new project file from KGLWIN After selecting menu-project-option, click connection option

Click Remote 1 in depth of connection -. Type : Select GLOFA Cnet. -. Base : Select 0. -. Clot : set to 0 when uses channel 0, and 1 when uses channel 1 -. Station No. : Input slave station number to connect Click OK Remote connection is available by dedicated protocol only 2) Remote modem connection by

Remote connection by modem is available by G7L-CUEB I/F module.time, TM/TC switch of G7L-CUEB module must be set to In this On. G7L-CUEB CUEB G7L-

Modem Modem

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Dedicated modem and dial-up modem are both available and Set connection option of KGLWIN as below.

3) Remote connection by Fnet I/F module G7L-FUEA FUEA G7L-

Remote connection by Fnet interface is available by setting connection option of KGLWIN as below

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8.5.2 Communication I/F module

MASTER-K120S series supports various kinds of communication I/F module. In this time, Built-In Cnet in main unit must be set to Off as below and only one communication module can be extended BUILT_IN CNET OFF Must be ROM MODE G7L-

ON off

1) Usage CUEB

of

Using G7L-CUEB, MASTER-K120S can connect to other PLC by dedicated modem or dial-up modem

TM/TC Switch

Set TM/TC switch to On when uses remote connection function Set TM/TC switch to Off when uses data communication function Data communication and remote connection function are not allowed simultaneously Data communication mode supports every communication protocol but In remote connection function supports dedicated protocol only. 2) Usage CUEC of G7L-

Channel 0 can be used as RS-422/485 I/F by using G7L-CUEC I/F module method is same as built-in Cnet interface and wiring is as Operating below

RDA RDB SDA SDB SG

RDA RDB SDA SDB SG

RDA RDB SDA SDB SG

RDA RDB SDA SDB SG

Terminatin g resisto r

Master Slave Slave Slave Wiring Example : RS-422 I/F 8-76

Chapter Functions RDA RDB SDA SDB SG

Communication

RDA RDB SDA SDB SG

RDA RDB SDA SDB SG

RDA RDB SDA SDB SG

Master Slave

Slave Slave Wiring Example : RS-485 I/F

3) Usage FUEA/RUEA

of

G7L-

G7L-FUEA and G7L-RUEA are Field Bus Interface module of LGIS and they support High speed link communication service by parameter setting. But communication by command(Read, Write) are not available

Station switch

number

setting

After selecting communication parameter from KGLWIN and select FIELDBUS MASTER as below

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Clicking List button then this window comes up. Designate self-station No. and set link items after double clicking entry list For the details, refer to Users manual of Fnet I/F module

4) Usage PBEA/DBEA

of

G7L-

G7L-PBEA support profibus slave function only and G7L-DBEAsupports DeviceNet slave interface function only. After selecting communication parameter from KGLWIN and select FIELDBUS slave as below

Clicking List button then this window comes up. After double clicking entry list 0, designate from/to area Pnet For maximum Sending/Receiving data size is 244 byte and that of DeviceNet are 30/32 byte. For the details, refer to corresponding Users manual

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Chapter wiring

9.

Installation

and

9.1 Installation
9.1.1 Installation Environment
This unit has high reliability regardless of its installation environment, but be sure to check the following for system reliability. 1) Environment requirements Avoid installing this unit in locations which are subjected or exposed to: (1) Water leakage and dust. (2) Continuous shocks or vibrations. (3) Direct sunlight. (4) Dew condensation due to rapid temperature change. (5) Higher or lower temperatures outside the range of 0 to 55 (6) Relative humidity outside the range of 5 to 95 (7) Corrosive or flammable gases 2) Precautions installing during

(1) During drilling or wiring, do not allow any wire scraps to enter into the PLC. (2) Install it on locations that are convenient for operation. (3) Make sure that it is not located on the same panel that high voltage equipment located. (4) Make sure that the distance from the walls of duct and external equipment be 50mm or more. (5) Be sure to be grounded to locations that have good ambient noise immunity. 3) Heat protection design of control box (1) When installing the PLC in a closed control box, be sure to design heat protection of control box with consideration of the heat generated by the PLC itself and other devices. (2) It is recommended that filters or closed heat exchangers be used. (3) The following shows the procedure for calculating the PLC system power consumption.

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4) Power consumption block diagram of PLC systems

Main Unit
I 5V powe r supply part
AC power Supply
CPU part output part (transistor) Output Current. (IOUT)Vdrop Output Current (I
OU T

5VDC line

Input

Expansion module
special module Output part (Transistor) (I Output Current. )V dro p OU T Output Current (IOU T ) (I Input part Input Current )V dr op IN Input Current (IOU T )

input part

I 24V
24VDC line External 24VDC power Supply

(I

Input Current )V dr op IN Input Current (I

OU T

) Load Load

5) Power consumption of each part (1) Power consumption of a power supply part Approximately 65% 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. W p w= 3.5 / 6.5 {(I x 5) + (I 24V x 24)} 5V (W) where, circuit current consumption of each 5VDC l5v: part l24v:24VDC circuit average current consumption of output part (with points simultaneously switched ON). Not 24VDC power supplied from external or power supply part that has 24VDC output. for no (2) Total 5VDC power consumption The total power consumption of all modules is the power of output circuit of the power supply 5VDC the W 5V= I5V 5 (W) part. (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. W 24V= I24V 24 (W)

(4) Average power consumption by voltage drop of output part (with points simultaneously switched ON) the rate of points switched on simultaneously Wout = Iout V drop output points (W) I out : output current (actual operating current) (A) V drop : voltage dropped across each output load (V) (5) Average power consumption of input parts (with points simultaneously ON) W in= l inE input points the rate of points switched on simultaneously (W) I in: input current (effective value for AC) (A) E : input voltage (actual operating voltage) (V) 9-2

Chapter 9 Installation and Wiring

(6) Power consumption of the special module W = I5V X 5 + 24VX I 24 S (W) (7) The sum of the above values is the power consumption of the entire PLC system. W = W + W5V + W24V + W + Win+ Ws (W PW out ) (8) 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) 2 A : Control panel inside surface [m] area U : if the control panel temperature is controlled by a fan, etc if control panel air is not circulated 4

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. 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) Main unit or Expansion Module handling instructions The followings explains instructions for handling or installing the Base unit or Expansion Module. (1) I/O specifications recheck 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) wire Used Select the wire with due consideration of ambient temperature and rated current. Its minimum specifications should be AWG24(0.18 ) or more.

(3) Environment When wiring the I/O part, if it locates near a device generating an cause short circuit, destruction or malfunction.

(4) Polarity

Before applying the power to part that has polarities, be sure to check its polarities.

(5) 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 9-3

Chapter 9 Installation and Wiring

(6) Wiring

Wiring I/O wires with high voltage cable or power supply line can cause malfunction or disorder. Be sure that any wire does not pass across during input LED(I/O status will not be clearly identified). If an inductive load has been connected to output part, connect parallel surge killer or diode to a load. Connect the cathode of diode to the + part of the power supply. OUT Output part COM Inductive load Surge Killer

OUT Output part COM

Inductive load Diod e

+ -

(7) Be cautious that strong shock does not applied to the I/O part. (8) Do not separate the PCB from its . case 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. (2) Make sure that MASTER-K120S is installed in figure below for most effective heat radiation.

K 7M- D R 30U

(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

9-4

Chapter 9 Installation and Wiring

(4) Mount the wire duct as it is needed. If the clearances are less than those in Fig below, follow the instructions shown below If the wire duct is mounted on the upper part of the PLC, make the wiring duct clearance 50 or less for good ventilation. Also, allow the distance enough to press the hook in the upper part from the upper part of the PLC. If 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 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 or more. 80mm or more

Othe r devic e 100mm more or

80mm or more

High voltage device

Heat device

generating

(6) MASTER-K120S has hooks for DIN rail in the base unit and expansion modules.

DIN rail
K 7M- D R 30U

9-5

Chapter 9 Installation and Wiring

9.1.3 Connection of expansion module

The following expansion explains the Connection ofmodules to the main unit.

(1) Open the connector cover of the main unit. (2) Insert the connector of the expansion module to the connector of the base unit.

: Main unit : Connector cover : expansion module : expansion cable

(3) Close the connector cover of the main unit.

9-6

Chapter 9 Installation and Wiring

9.2 Wiring
The followings explains the wiring instructions for use of the system.

9.2.1 Power Supply Wiring . (1) When voltage fluctuations are larger than the specified value, connect a constant-voltage transformer (2) Use a power supply which generates minimal noise across wire and across PLC and ground. (When excessive noise is generated, connect an insulating transformer)

MASTERK120S main unit

AC100240VFG

Constant-voltage transformer

(4) When wiring, separate the PLC power supply from those for I/O and power device as shown below.

AC220 V

Main power

PLC power

T1

PLC

I/O power

T2 I/O device Main device

Main circuit T1,T2 : transformer constant voltage

circuit

(5)To minimize voltage drop, use the thickest (max. 2 possible

) wires

(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 distance between the cables and wires.

9-7

Chapter 9 Installation and Wiring

(7) As a measure against very large surge(e.g. due to lightening),connect a surge absorber as shown below.

PLC

E1
Surge absorber for lightening

E2

(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. Remar k
1)

Ground the surge absorber(E1) and the PLC(E2) separately from each other. 2) Select a surge absorber making allowances for power voltage rises.

9.2.2 Input Wiring

and

Output

Devices

(1) Applicable size of wire to the terminal block connector is 0.18 to 2 . However, it is recommended to use wire of 0.5 for convenience . (2) Separate the input and output lines. (3) I/O signal wires must be at least 100 (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 batchshielded cables. Under some conditions it may be preferable to ground on the other side. PLC cable Shielded RA

Input

DC

(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. (7) If wiring over 200m or longer distance, trouble can be caused by leakage currents due to line capacity. Refer to the section 11.4 Troubleshooting Examples. 9-8

Chapter 9 Installation and Wiring

9.2.3 Grounding
(1) This PLC has sufficient protection against noise, so it can be used without grounding except for special much noise. However, grounding it should be done conforming to below . when items (2) Ground the PLC as independently as possible. Class 3 grounding should be used (grounding resistance 80 or less). (3) When independent grounding is impossible, use the joint grounding method as shown in the figure below (B).

PLC

Other device

PLC PLC

Other device

Other device

Class 3 grounding grounding

Class

(A)Independent grounding : Best (B) Joint grounding : Good (C) Joint grounding : Not allowed (4) Use 2 (14AWG) or thicker grounding wire. Grounding point should be as near as possible to the PLC to minimize the distance of grounding cable.

9.2.4 Cable Specifications for wiring

The specifications for wiring is as follows: Kinds of connection external Cable Specifications () Minimum Maximum

Digital Input 0.18 (AWG24) 1.5 (AWG16) Digital Output 0.18 (AWG24) 2.0 (AWG14) Analog Input / Output 0.18 (AWG24) (AWG16) Communication 0.18 (AWG24) 1.5 (AWG16) Main power 1.5 (AWG16) 2.5 (AWG12) Grounding 1.5 (AWG16) 2.5 (AWG12)

1.5

Be sure to use solderless terminal for power supply and I/O wiring. Be sure to use M3 type as terminal screw. Make sure that terminal screw is connected by 6~9 torque.. Be sure to use fork shaped terminal screw as shown below. cable solderness shaped) less than 6.2mm terminal (fork

9-9

Chapter 10 Maintenance

Chapter 10 Maintenance daily and periodic maintenance and inspection in order to maintain the PLC in the best Be sure to perform
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 ~ + C Adjust the operating temperature and humidity with 55 the defined Ambien Humidity 5 ~ range. t 95%RH environmen t Vibration No vibration Use vibration resisting rubber or the vibration method. prevention Play of modules No play allowed Securely enrage the hook. Connecting conditions of terminal screws No loose allowed Retighten terminal screws. Change rate of input - 15% to 10% Hold it with the allowable voltage range. Check the number of Spare Spare parts and Cover the shortage parts their conditions Store conditions

and

improve

the

10.2 Daily Inspection

The following table shows the inspection and items which are to be checked daily. Check Items Corrective Check Points Judgement Action s

Connecting check for loose mounting screws Screws should not be loose Screw conditions Retighten of terminal block s or extension cable Check the distance between terminals Proper clearance should be provided solderless Correct 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 LED ERR LED Check that the LED is OFF during Run OFF(ON indicates an error) See chapter status 11 Input LED Check that the LEO turns ON and OFF ON when input is OFF when input is off See chapter ON, 11 Output LED Check that the LEO turns ON and OFF ON when output is OFF when output is off See chapter ON, 11

10-1

Chapter 10 Maintenance

10.3 Periodic Inspection

Check the following items once or twice every six months, and perform the needed corrective actions. Check Items Actions Checking Methods Judgment Corrective

C 0 ~ 55 -. Measure with thermometer and Ambient Ambient Humidity 5 ~ 95%RH hygrometer Environment -. measure corrosive gas There should be no Ambience corrosive gases The module should be Looseness, Ingress The module should be move PLC the unit mounted securely. Conditions dust or foreign material Visual check No dust or foreign material Loose terminal screws Re-tighten screws Screws should not be loose Retighten Distance between terminals Visual check Proper clearance Correct Loose connectors Visual check Connectors should not be loose.

Ambient temperature

Adjust to general standard (Internal environmental standard of control section)

Retighten screws

Connecting conditions

Retighten connector mounting screws

Line voltage check Measure voltage between input terminals

*85 ~ 264V AC *20~28V DC Change supply power If fuse melting disconnection, change the fuse periodically because a surge current can cause heat

Fuse Visual check No melting disconnection

10-2

Chapter 11 Troubleshooting

Chapter 11 Troubleshooting
The following explains contents, diagnosis and corrective actions for various errors that can occur during system operation.

11.1 Basic Procedures of Troubleshooting

System reliability not only depends on reliable equipment but also on short downtimes in the event of faults. The short discovery and corrective action is needed for speedy operation of system. The following shows the basic instructions for troubleshooting. 1) Visual checksthe Check following points. Machine operating condition (in stop and operating status) Power On/OffStatus of I/O devices - Condition of wiring (I/O wires, extension and communications cables) states of various indicators (such as POWER LED, RUN LED, ERR. LED and I/O - Display LED). checking them, connect peripheral devices and check the operation status of the PLC After and the program contents. 2) Trouble Check Observe any change in the error conditions during the following. the STOP position, and then turn the power on and Switch to off. 3) Narrow down the possible causes of the trouble where the fault lies, i.e.: Inside or outside of the PLC? I/O module or another module? PLC program?

11.2 Troubleshooting
This section explains the procedure for determining the cause of troubles as well as the errors and corrective actions.
Is the power LED turned OFF?

Flowchart used when the POWER LED is turned OFF ? Flowchart used when the ERR LED is flickering Flowchart used when the RUN turned OFF.

Is the ERR LED flickering

Are the RUN LED turned OFF?

Flowchart used when the output load of the output module doesnt turn on. Program cannot be written Flowchart used when a program cant be written to the PLC
I/O module doesnt operate properly

11-1

Chapter 11 Troubleshooting 11.2.1 Troubleshooting flowchart used when the POWER LED turns OFF.
The following flowchart explains corrective action procedure used when the power is supplied or the power led turns off during operation . Power LED is turned OFF

Is the power supply operating?

No Yes No

Supply power.

the

Yes
Does the power led turn on?

Is the voltage within the rated power ? Yes No

No

See the power supply be within AC 85-264 V.

Yes
Does the power led turn on?

Is the fuse blown?

Yes Replace fuse. No

Does the power led turn on?

the

No Yes

Is the power supply cable connected?

No Connect the correctly. No

Does the power led turn on?

power

cable

Yes Yes

Yes
Over current protection device activated? 1)Eliminate the excess current 2)Switch the input power OFF then ON

No

Write down the troubleshooting questionnaire and contact the nearest service center

No

Yes
Does the power led turn on?

Complete

11-2

Chapter 11 Troubleshooting 11.2.2 Troubleshooting flowchart used when the ERR LED is flickering
The following flowchart explains corrective action procedure use when the power is supplied starts or the ERR LED is flickering during operation .

ERR LED goes flickering.

Check the error code, with connected KGLWIN.

Yes Warning error?

See App-2 System Warning Flag and remove the cause of the error.

No

Yes

Is ERR LED still flicking

No

Complete

Write down the Troubleshooting Questionnaires and contact the nearest service center.

REMAR K Though warning error appears, PLC system doesnt stop but corrective action is needed promptly. If not, it may cause the system failure.

11-3

Chapter 11 Troubleshooting 11.2.3 Troubleshooting flowchart used when the RUN LED turns off.
The following flowchart explains corrective action procedure to treat the lights-out of RUN LED when the power is supplied, operation starts or operation is in the process.

RUN LED is off.

Turn the power unit off and on.

No

Is RUN off?

LED

Yes

Contact center.

the

nearest

service

Complete

11-4

Chapter 11 Troubleshooting

11.2.4 Troubleshooting flowchart used when the I/O part doesnt operate normally.
The following flowchart explains corrective action procedure used when the I/O module doesnt operate normally.

When the I/O module doesnt work normally.

Is the indicator LED of the P40 on?

No

Yes

Measure the voltage of power supply in P40

Correct wiring

Replace the connector of the terminal board

Check the status of P40 by KGLWIN

No Is the voltage of power supply for load applied? Is the terminal connector

No No Yes Is it normal condition?

No

Is the output wiring correct? Yes

connector appropriate? Yes

Yes Separate the external wiring than check the condition of output module.

Yes Is it normal condition? No Continue

Check the status of P40 Replace the Unit

11-5

Chapter 11 Troubleshooting

Continue

Are the indicator LED of the switch 1 and 2 on?

No

Yes

Check the status of the switch 1and 2

Check the status of the switch 1and 2

Is input wiring correct?

Is input wiring correct?

Yes

Is the terminal screw tighten securely?

No Yes No

NO Yes

Yes Is input wiring correct?

Is the condition of the terminal board connector appropriate?

Separate the external wiring witch then check the status by forced input

No

No

Correct wiring Retighten the terminal Correct the wiring No Yes screw

Replace the terminal board connector

Unit replacement is needed

Check the status of the switch 1 and 2

Check from the beginning

Unit replacement is needed

11-6

Chapter 11 Troubleshooting 11.2.5 Troubleshooting flowchart used when a program cannot be written to the CPU part
The following flowchart shows the corrective action procedure used when a program cannot be written to the PLC module.
Program cannot be written to the PC CPU

Is the mode-setting switch set the re mote STOP?

No

Switch to the remote STOP mode and execute the program write.

Yes

Is ERR. LED blinking?

Yes

After reading error code by using peripheral device, correct the contents.

No

Complete

11-7

Chapter 11 Troubleshooting

11.3 Troubleshooting Questionnaire

When problems have been met during operation of the MASTER-K120S series, please write down this Questionnaires and contact the service center via telephone or facsimile. For errors relating to special or communication modules, use the questionnaire included in the Users manual of the unit. 1. Telephone & FAX No Tell) 2. Using model: 3. Details equipment CPU model: .( equipment of using ) Serial No.( )

FAX)

) OS version 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 ( ), - External memory module operation or (

), communications ), ), No( )

6. Is the ERR. LED of the CPU module turned ON? Yes( 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 Repetitive ): Periodic( ), Related to a particular sequence( ( ) Sometimes ): General error ( interval: 12. Detailed Description of error contents:

), Related to environment(

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 Actions Input signal doesnt off. Cause Corrective Leakage current of external device as a drive by non-contact (Such switch)
AC input C R
External device Leakage current

turn

Connect an appropriate register and capacity, which will make the voltage lower across the terminals of the input module.
AC input C R ~

Input signal doesnt turn off. (Neon lamp may be still on)

Leakage current of external device by a limit switch with neon (Drive lamp)
AC input C
R Leakage current

CR values are determined by the leakage current value. - Recommended value C : 0.1 ~ 0.47 R: 47 ~ 120 (1/2W ) Or make up another independent display circuit.

External device

Input signal doesnt off.

turn

Leakage current due to line capacity of wiring cable. Locate the power supply on the external device side as shown below.
AC input ACinput
Leakage current

~
External device External device

Input signal doesnt off.

turn

Leakage current of external device (Drive by switch Connect an appropriate register, which will with LED make indicator) the voltage higher than the OFF voltage across the DCinput input module terminal and common terminal. DCinput
Leakage current R External device

Input signal doesnt off.

Sneak current due to the use of two different power supplies. turn
L E1 E2 DCinput

Use only one power supply. Connect a sneak current prevention diode.
E1 DC E
L input

E1 > sneaked.

E2, 11-9

Chapter 11 Troubleshooting 11.4.2Output

circuit troubles and corrective actions The following describes possible troubles with input circuits, as well as their corrective actions.
Condition Cause Corrective Action When the output is off, excessive voltage is applied to the load. Load is half-wave rectified inside (in some cases, it is true Connect registers of tens to hundreds K across the of a solenoid) When the polarity of the power supply is as shown in , C is charged. When the polarity is as shown in , the voltage charged in C plus the line voltage are applied across D. Max. voltage is approx. 2v2. C ~
Load

load in parallel.

R D R ~

C R

Load

*) 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. The load doesnt turn off. Leakage current by surge absorbing circuit, which is connected to output element in parallel.
Output Load

Connect C and R across the load, which are of registers of tens K . When the wiring distance from the output module to the load is long, there may be a leakage current due to the line capacity.

C R
Leakage current

R Load

Load

When the load is constant fluctuates.

Leakage current by surge absorbing circuit, which is

Drive the relay using a contact and drive the C-R type timer using the since contact. Use other timer than the C- R contact some timers have half-ware rectified internal circuits therefore, be cautious.

C-R type timer, time connected to output element in parallel.

Output

Load C R Leakage current ~

T X

Timer

Output

The load does not turn off.

Sneak current due to the use of two different power supplies.

Output

Use only one power supply. Connect a sneak current prevention diode.
Output

Load

Load

E1
E2

If the load is the relay, etc, connect a counter-electromotive E1<E2, sneaks. E1 is off (E2 is on), sneaks. voltage absorbing code as shown by the dot line.

11-10

Chapter 11 Troubleshooting
Output circuit (continued). Condition actions The load off response time is long. troubles Cause and corrective actions

Corrective Insert a small L/R magnetic contact and drive the load using the same contact.

Over current at off state [The large solenoid current fluidic load (L/R is large) such as is directly driven with the transistor output.
Output Off current Load

Output

Load

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 transistor is destroyed . Surge current of the white lamp
Output

To suppress the surge current make the dark current of 1/3 to 1/5 rated current flow.
Output

E1

A surge current of 10 times or more when turned on.

Output

Sink type transistor output

Source type transistor output

11-11

Chapter 11 Troubleshooting

11.5 Error code list

Error Code Message CPU state Message Cause Corrective Actions Internal system Fault of some area of operating ROM, 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 center. 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 0007h down error Stop Sub Power Error Extension Rack Power down or Error Check the power of the xtension rack e 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 Common RAM error Stop Common RAM Error Common RAM interface error Contact the service center. 000Ah Fuse break error Continue (stop) I/O Fuse Error Break of fuse used in output units or Mixed I/O Check the fuse LED of the unit. Turn the power off and replace the fuse.

000Bh Instruction code error Stop OP Code Error Instructions unreadable by theare included. (during execution) Contact the service center. CPU Flash memory Check and replace the 000Ch error(during Stop User Memory Error Read to/Write from the inserted Flash memory is not performed. flash memory. execution) Turn the power off and Mounting/dismounting of I/O units mount the unit firmly, and during operation, or connection fault restart the system. 0010h I/O slot error Stop I/O Slot Error I/O unit defect or extension cable Replace the I/O unit or defect extension cable. Points of mounted I/O units overrun the maximum I/O points. (FMM 0011h Maximum I/O Replace the I/O unit. error Stop MAX I/O Error mounting number over error, MINI_MAP over) 0012h Special card interface error Stop Special I/F Error Special Card Interface error Contact the service center. 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. 0020h Parameter Error Stop Parameter Error A written parameter has changed, or checksum error 0021h I/O Parameter Error Stop (continue) I/O Parameter Error Correct the content of the parameter.

When the power is applied or RUN Correct the content of the starts, I/O unit reservation information parameter, or reallocate or differs from the types of real loaded replace the I/O unit. I/O units. The point of the reserved I/O information or real loaded I/O units overruns the maximum I/O point. Correct the content of the parameter.

0022h Maximum I/O Over Stop I/O PARA Error

0023h FMM 0 Parameter Error Stop FMM 0 PARA Error FMM 0 Parameter Error Correct the parameter. 0024h FMM 1 Parameter Error Stop FMM 1 PARA Error FMM 1 Parameter Error Correct the parameter. 0025h FMM 2 Parameter Error Stop FMM 2 PARA Error FMM 2 Parameter Error Correct the parameter.

11-12

Chapter 11 Troubleshooting
(continued ) Error
Code Error CPU state Message Cause Corrective Actions 0026h FMM 3 Parameter Error 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. An operand value is outside the defined operand range. Correct the content of the error step. Check the maximum scan time of the program and modify the program or insert programs. Program replacement has not been completed during run. (JMP ~ JME, FOR ~ NEXT, CALLx and SBRTx )

0030h Operation Error Stop Operation Error

0031h WDT Over Continue

time. (stop) WDT Over Error Scan time has overrun the watch dog

0032h

Error of Program Change during run.

Stop PGM Change Error

An error has occurred at program change during run. (NO SBRT, JME and END )

0033h Program Check Error Continue Code Check Error An error has occurred while checking a program. Correct the error. 0040h Code Check Error Stop Code Check Error An instruction unreadable by the CPU is included. Correct the error step. 0041h Missing the END instruction in the program. Missing the RET instruction in the program. Stop Miss END Error The program does not have the END instruction. Stop Miss RET Error The subroutine does not has the RET instruction at its bottom. Insert the END instruction at the bottom of the program. Insert the END instruction at the bottom of the program. Insert the SBRT instruction.

0042h

0043h

Missing the SBRT instruction in the Stop Miss SBRT Error The subroutine does not has the subroutine SBRT instruction. program.

0044h The JMP ~ JME instruction error Stop JMP(E) Error The JMP ~ JME instruction error Correct the JMP ~ JME instruction. 0045h The FOR ~ NEXT instruction error Stop FOR~NEXT Error The FOR ~ NEXT instruction error Correct the FOR ~ NEXT instruction. 0046h The MCS ~ MCSCLR instruction error Stop MCS~MCSCLR Error The MCS ~ MCSCLR instruction error Correct the MCS ~ MCSCLR instruction.

0047h

The MPUSH ~ MPOP instruction Stop MPUSH ~ MPOP Error The MPUSH ~ MPOP instruction error Correct the MPUSH ~ instruction MPOP error Correct timer, counter. Check and correct the program.

0048h Dual coil error Stop DUAL COIL Error Timer or counter has been duplicated.

0049h Syntax error Stop Syntax Error Input condition error, or too much use of LOAD or AND(OR) LOAD.

11-13

Appendix 1 Definitions

System

Appendix Definitions
1) Option

1.

System

(1) Connect Option should set the communication port (COM1~4) to communicate with You PLC. Select the Project-Option-Connection Option Default Connection is RS-232C interface. For the detail information Connection about Option in menu.

, refer Manual.

to

KGLWIN

App11

Appendix 1 Definitions
(2) option Editor

System

Monitor display type - Select the desired type in the monitor display type(4 types). Source File Directory : - You can set directories for the files to be created in KGLWIN. - In Source Directory, KGLWIN saves source program files of program, parameter etc. Auto save - This function is to set the time interval for Auto saving (Range : 0 ~60 min) - Automatically saved file is saved in the current directory. - 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. - This function is to set the time interval for Auto saving. - When set to 0, auto save function is disabled.

App12

Appendix 1 Definitions

System

(3) Page setup You can select print option when the project print out .(margin, cover, footer)

App13

Appendix 1 Definitions
2) Parameters Basic

System

The basic parameters are necessary for operation of the PLC. Set the Latch area, Timer boundary , Watchdog timer, PLC operation mode, Input setting, Pulse catch

(1) Latch area setting Set the retain area on the inner device. (2) Timer boundary setting Set the 100ms/10ms/1ms timer boundary. ( If 100ms and 10ms timer are set, the rest of timer area is allocated 1ms automatically) (3) Watchdog timer setting For the purpose of the watch of normal program execution ,. This parameter is used to set the maximum allowable execution time of a user program in order to supervisor its normal or abnormal operation. (Setting range is 10ms ~ 6000ms) (4) Input setting set the input filter constant and input catch contact point (5) Remote access control setting When this parameter is set, the operation mode of PLC system can be changed by remote access with FAM or communication . module

App14

Appendix 2 Flag List

Appendix List

2.

Flag

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~F000B Unused F000C User memory installation Turns on when a user memory is installed. F000D RTC installation Turns on when a RTC module is installed. F000E Unused F000F 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 Turns on when the breakpoint run is operated in the Debug mode. F0022 Scan run Turns on when the scan run is operated in the Debug mode. F0023 Coincident contact value run Turns on when the coincident contact 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 occurred. F0031 Ordinary error Turns occurred. F0032 WDT Error Turns on occurred. F0033 I/O combination error occurred. when a fatal error has on when an ordinary error has when a watch dog timer error has Turns on when an I/O error has

(When one or more bit(s) of F0040 to F005F turns on) F0034 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.Program editing Turns on during program edit while running the F003B program. F003C Program edit error Turns on when a program edit error has occurred while the running program. F003D to F003F Unused

App21

Appendix 2 Flag List

(Continued ) Relay Description

Function I/O

When the reserved I/O module (set by the parameter) differs real loaded I/O module or a I/O module has from the been mounted or dismounted, the corresponding bit turns on. F0060 to F006F Storing error code Stores the system error code, (See Section 2.9) F0070 to F008F Unused F0040 to F005F error F0090 20-ms cycle clock F0091 100-ms cycle clock F0092 200-ms cycle clock F0093 1-sec cycle clock F0094 2-sec cycle clock F0095 10-sec cycle clock F0096 20-sec cycle clock F0097 60-sec cycle clock F0098 to F009F Unused F0100 User clock 0 F0101 User clock 1 F0102 User clock 2 F0103 User clock 3 F0104 User clock 4 F0105 User clock 5 F0106 User clock 6 F0107 User clock 7 F0108 to F010F Unused Turning On/Off is repeated with a constant cycle. On Of f

Turning On/Off is repeated as many times as the scan specified by Duty instruction.
DUTY F010x N1 N2

N2 Off N1 Off scan

scan

F0110 Operation error flag Turns 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 Turns on when an output instruction is executed. F0115 Operation error flag (Latch) Turns on when an operation error has occurred. (Latch) F0116 Overflow error flag Turns on when overflow has occurred. F0117 to F011F Unused F0120 LT flag Turns on if S F0121 LTE flag Turns on if S F0122 EQU flag Turns on if S F0123 GT flag Turns on if S F0124 GTE flag Turns on if S F0125 NEQ flag Turns on if S F0126 to F013F Unused < S 2 when using instruction. = S 2 when using 1 instruction. = S 2 when using 1 instruction. > S 2 when using 1 instruction. = S 2 when using 1 instruction. S 2 when using 1 instruction.
1

the the the the the the

CMP CMP CMP CMP CMP CMP

F0140 to F014F FALS No. The error code generated by FALS instruction is stored to this flag. F0150 to F016F Unused F0170 to F173 HSC output bit Turn on when the current value of HSC reaches setting value F0180 to F183 Carry flag for HSC Turn on when carry is occurred on the HSC current value App22

Appendix 2 Flag List

(Continued ) Relay

Function Description F190 to F193 Borrow flag for HSC Turn on when borrow is occurred on the HSC current value F200 to F20F Unit ID code Stores error of HSC code Stores error of HSC code Stores error of HSC code Stores error of HSC

F0210 to F021F HSC error Ch0 to F022F HSC error F0220 Ch1 F0230 to F023F HSC error Ch2 F0240 to F024F HSC error Ch3 F0250 to F027F Unused

F0280 to F045F Positioning flags Refer to 7.3.5 Flag list and error code F0500 to F050F 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 (year/month) Clock data (year/month) F0540 to F054F Clock data (day/hour) Clock data (day/hour) F0550 to F055F Clock data (minute/second) Clock data (minute/second) F0560 to F056F Clock data (day of the week) Clock data (day of the week) F0570 to F058F Unused F0590 to F059F Storing error step program. F0600 to F063F Unused Stores the error step of the

2) (M)

Internal relay

Relay Function Description M1904 Write Time Write time to RTC when this bit turns on M1910 Forced I/O enable Enables forced I/O

App23

Appendix 2 Flag List

3) Data relay (D) When communication function is used, its status are stored in D register, and they can be monitored. And If correspond communication function is unused, these flags can be used as general data register. (1) When connected FNET module is Function
Communications module station No. Indicates the number which is set on communications module station switch. Fnet : Station switch No. marked on the front of communications module. Increments by one whenever sending error of communications frame D4504 _C0TXECNT Communications frame sending error occurs. Connection condition of network is evaluated by this value. Increments by one whenever receiving error of communications frame D4505 _C0RXECNT Communications frame receiving error occurs. Connection condition of network is evaluated by this value. Increments by one whenever communications service fails. Connection D4506 _C0SVCFCNT Communications service processing error D4507 _C0SCANMX Maximum communications scan time (unit : 1 ms) D4508 _C0SCANAV Average communications scan time (unit : 1 ms) D4509 _C0SCANMN Minimum communications scan time (unit : 1 ms) D4510 _C0LINF Communications module system information condition of network and overall communication quantity and program stability can be evaluated by this value. Indicates the maximum time that is spent until every station connected to network has the token at least one time and sends a sending frame. Indicates the average time that is spent until every station connected to network has the token at least one time and sends a sending frame. Indicates the minimum time that is spent until every station connected to network has the token at least one time and sends a sending frame.

Relay Description
D4500 D4502

Keyword

_C0STNOL _C0STNOH

Indicates operation state of communications module with a word.

D4510.B _C0CRDER System error (error = 1) Indicates communications module hardware or system O/S error. D4510.C _C0SVBSY Insufficient common RAM (Insufficient = 1) Indicates that service cannot be offered due to insufficient common RAM. D4510.D _C0IFERR Interface error (error = 1) Indicates that interface with communications modules has been stopped. D4510.E _C0INRING In-ring (IN_RING = 1) Indicates that the communications module can communicates with other station or not. D4510.F _C0LNKMOD Operation mode (RUN=1) Indicates that operation mode of communications module is in the normal operation mode or test mode.

App24

Appendix 2 Flag List

(2) When communication mode is dedicated master mode (Channel 0) Relay Function Function Relay

D4400 Communication Error Code of station 0 and1 D4432 Mode and Error of Slave station 0 and 1 D4401 Communication Error Code of station 2 and 3 D4433 Mode and Error of Slave station 2 and 3 D4401 Communication Error Code of station 4 and 5 D4434 Mode and Error of Slave station 4 and 5 D4403 Communication Error Code of station 6 and 7 D4435 Mode and Error of Slave station 6 and 7 D4404 Communication Error Code of station 8 and 9 D4436 Mode and Error of Slave station 8 and 9 D4405 Communication Error Code of station 10 and 11 D4437 Mode and Error of Slave station 10 and 11 D4406 Communication Error Code of station 12 and 13 D4438 Mode and Error of Slave station 12 and 13 D4407 Communication Error Code of station 14 and 15 D4439 Mode and Error of Slave station 14 and 15 D4408 Communication Error Code of station 16 and 17 D4440 Mode and Error of Slave station 16 and 17 D4409 Communication Error Code of station 18 and 19 D4441 Mode and Error of Slave station 18 and 19 D4410 Communication Error Code of station 20 and 21 D4442 Mode and Error of Slave station 20 and 21 D4411 Communication Error Code of station 22 and 23 D4443 Mode and Error of Slave station 22 and 23 D4412 Communication Error Code of station 24 and 25 D4444 Mode and Error of Slave station 24 and 25 D4413 Communication Error Code of station 26 and 27 D4445 Mode and Error of Slave station 26 and 27 D4414 Communication Error Code of station 28 and 29 D4446 Mode and Error of Slave station 28 and 29 D4415 Communication Error Code of station 30 and 31 D4447 Mode and Error of Slave station 30 and 31 D4416 Error count of station 0 and 1 D4417 Error count of station 2 and 3 D4418 Error count of station 4 and 5 D4419 Error count of station 6 and 7 D4420 Error count of station 8 and 9 D4421 Error count of station 10 and 11 D4422 Error count of station 12 and 13 D4423 Error count of station 14 and 15 D4424 Error count of station 16 and 17 D4425 Error count of station 18 and 19 D4426 Error count of station 20 and 21 D4427 Error count of station 22 and 23 D4428 Error count of station 24 and 25 D4429 Error count of station 26 and 27 D4430 Error count of station 28 and 29 D4431 Error count of station 30 and 31

App25

Appendix 2 Flag List

(3) When communication mode is dedicated master mode (Channel 1) Relay Function Function Relay

D4300 Communication Error Code of station 0 and1 D4332 Mode and Error of Slave station 0 and 1 D4301 Communication Error Code of station 2 and 3 D4333 Mode and Error of Slave station 2 and 3

D4301 Communication Error Code of station 4 and 5 D4334 Mode and Error of Slave station 4 and 5 D4303 Communication Error Code of station 6 and 7 D4335 Mode and Error of Slave station 6 and 7 D4304 Communication Error Code of station 8 and 9 D4336 Mode and Error of Slave station 8 and 9 D4305 Communication Error Code of station 10 and 11 D4337 Mode and Error of Slave station 10 and 11 D4306 Communication Error Code of station 12 and 13 D4338 Mode and Error of Slave station 12 and 13 D4307 Communication Error Code of station 14 and 15 D4339 Mode and Error of Slave station 14 and 15 D4308 Communication Error Code of station 16 and 17 D4340 Mode and Error of Slave station 16 and 17 D4309 Communication Error Code of station 18 and 19 D4341 Mode and Error of Slave station 18 and 19 D4310 Communication Error Code of station 20 and 21 D4342 Mode and Error of Slave station 20 and 21 D4311 Communication Error Code of station 22 and 23 D4343 Mode and Error of Slave station 22 and 23 D4312 Communication Error Code of station 24 and 25 D4344 Mode and Error of Slave station 24 and 25 D4313 Communication Error Code of station 26 and 27 D4345 Mode and Error of Slave station 26 and 27 D4314 Communication Error Code of station 28 and 29 D4346 Mode and Error of Slave station 28 and 29 D4315 Communication Error Code of station 30 and 31 D4347 Mode and Error of Slave station 30 and 31 D4316 Error count of station 0 and 1 D4317 Error count of station 2 and 3 D4318 Error count of station 4 and 5 D4319 Error count of station 6 and 7 D4320 Error count of station 8 and 9 D4321 Error count of station 10 and 11 D4322 Error count of station 12 and 13 D4323 Error count of station 14 and 15 D4324 Error count of station 16 and 17 D4325 Error count of station 18 and 19 D4326 Error count of station 20 and 21 D4327 Error count of station 22 and 23 D4328 Error count of station 24 and 25 D4329 Error count of station 26 and 27 D4330 Error count of station 28 and 29 D4331 Error count of station 30 and 31

App26

Appendix 2 Flag List

(4) D register for Forced I/O setting I/O Forced I/O designation register register
P000 D4700 D4800 P001 D4701 D4801 P002 D4702 D4802 P003 D4703 D4803 P004 D4704 D4804 P005 D4705 D4805 P006 D4706 D4806 P007 D4707 D4807 P008 D4708 D4808 P009 D4709 D4809 P010 D4710 D4810 P011 D4711 D4811 P012 D4712 D4812 P013 D4713 D4813 P014 D4714 D4814 P015 D4715 D4815 P016 D4716 D4816 P017 D4717 D4817 P018 D4718 D4818 P019 D4719 D4819 P020 D4720 D4820 P021 D4721 D4821 P022 D4722 D4822 P023 D4723 D4823 P024 D4724 D4824 P025 D4725 D4825 P026 D4726 D4826 P027 D4727 D4827 P028 D4728 D4828 P029 D4729 D4829 P030 D4730 D4830 P031 D4731 D4831 P032 ~ P063 D4732 ~ D4763 D4832 ~ D4863

Forced I/O data

App27

Appendix 2 Flag List

(5) System error history(when RTC module is attached) Relay Description

D4900 Error pointer D4901 Year, Month D4902 Day, Time D4903 Minute, Second D4904 Error code

(6) data

Clock

Relay Description

D4990 Year, Month D4991 Day, Time D4992 Minute, Second D4993 Day of week, Century

App28

Appendix 3 Dimensions

External

Appendix 3 External Dimensions (unit: mm)

1) Main unit

Model A B K7M-DR10/14UE 85 95 K7MDR20/30UE K7M-DR(T)20/30U 135 145 K7M-DR(T)40U 165 175 K7M-DR(T)60U 215 225

95 105 115

A B

73

2) module (1) type

Extension Standard

95 105 115

5 95

73

App31

Appendix 3 Dimensions
(2) Slim RD2A)

External

type(G7E-DC08A,G7E-RY08A,G7F-ADHB,G7F-DA2V,G7F-

App32