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.

??? The meaning of each symbol in this manual and on your equipment is as follows

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.

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:

REMARK

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

1-1

Chapter 1 General

1.3 Terminology

The following table gives definition of terms used in this manual.

1-3

Chapter 1 General

1-4

Chapter 2 System Configuration

Chapter 2. System Configuration

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

2.1Overall Configuration

2.1.1Basic system

expansion cable

2-1

Chapter 2 System Configuration

2.1.2 Cnet I/F system

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

1)1:1 Communications system

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

MASTER-K120S

RS-485

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

RS-485

Monitoring Device

RS-232C

2-2

Chapter 2 System Configuration

2.2 Product Functional Model

The following describes functional model of the MASTER-K120Sseries.

2.2.1 Product Functional Block

Product function block for the K120S series is as follows.

2-4

Chapter 2 System Configuration

2.2.2K120S Series System Equipment Product

1)Main Unit ??? Standard type

2-5

Chapter 2 System Configuration

3) Expansion Modules

* External memory G7M-M256 isn???t 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.

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 Names of Parts

Chapter 4. Names of Parts

4.1 Main Unit

-While key switch is on stop mode

-Detecting an error which makes operation stop Indicates operating status of CPU

4 -1

Chapter 4 Names of Parts

4.1.160-points main unit (Standard)

1)K7M-DR60U

4 -2

Chapter 4 Names of Parts

2) K7M-DRT60U

3) K7M-DT60U

4.1.240-points main unit (Standard)

1)K7M-DR40U

4 -3

Chapter 4 Names of Parts

2) K7M-DRT40U

3) K7M-DT40U

4.1.330-points main unit (Standard)

1)K7M-DR30U

4 -4

Chapter 4 Names of Parts

2) K7M-DRT30U

3) K7M-DT30U

4.1.420-points main unit (Standard)

1)K7M-DR20U

4 -5

Chapter 4 Names of Parts

2) K7M-DRT20U

3) K7M-DT20U

4.1.530-points main unit (Economic)

1)K7M-DR30UE

4 -6

Chapter 4 Names of Parts

4.1.620-points main unit (Economic)

1)K7M-DR20UE

4.1.714-points main unit (Economic)

1)K7M-DR14UE

4.1.810-points main unit (Economic)

1)K7M-DR10UE

4 -7

Chapter 4 Names of Parts

4.2 Expansion I/O Module

4.2.2 10points I/O Module

1) G7E-DR10A

4 -8

Chapter 4 Names of Parts

??????

4 -9

Chapter 4 Names of Parts

4.3Special Module

4.3.1A/D??D/A Combination Module

1)G7F-ADHA

??????

4 -10

Chapter 4 Names of Parts

4.3.2D/A Conversion Module

1)G7F-DA2I

??????

2)G7F-DA2V

???

???

4.3.3A/D Conversion Module

??????

??? Expansion Cable

4 -11

Chapter 4 Names of Parts

4.3.4 Analog timer Module

4.3.5RTD Input Module

??????

4 -12

Chapter 4 Names of Parts

4.4Communication I/F Module

4.4.1Cnet I/F Module

1)G7L-CUEB

2) G7L-CUEC

4.4.2Fnet I/F Module

1)G7L-FUEA

4 -13

Chapter 4 Names of Parts

4.4.3Pnet I/F Module

1)G7L-PBEA

4.4.4DeviceNet I/F Module

1)G7L-DBEA

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.

4 -14

Chapter 5 Power Supply / CPU

Chapter 5. Power Supply / CPU

5.1Power Supply Specifications

5.1.1.Standard Type

5-1

Chapter 5 Power Supply / CPU

5.2 CPU Specifications

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

5.2.1. Standard Type

5-2

Chapter 5 Power Supply / CPU

(continued)

5-3

Chapter 5 Power Supply / CPU

5.2.2. Economic Type

5-4

Chapter 5 Power Supply / CPU

(continued)

5-5

Chapter 5 Power Supply / CPU

5.3Operation Processing

5.3.1Operation Processing Method

1) Cyclic operation

A PLC program is sequentially executed from the first step to the last step, which is called scan. This sequential

5-6

Chapter 5 Power Supply / CPU

2) Interrupt operation method

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 re-applied.

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

REMARK

1) Momentary power failure

The PLC defining power failure is a state that the voltage of power has been lowered outside the allowable variation range of it. The momentary power failure is a power failure of short interval (several to tens ms).

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Chapter 5 Power Supply / CPU

5.3.3 Scan Time

The processing time from a 0 step to the 0 step of next scan is called scan time.

1) Expression for scan time

Scan time is the sum of the processing time of scan program that the user has written, of the task program processing time and the PLC internal processing time.

+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)

5.3.4Scan 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.

REMARK

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

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Chapter 5 Power Supply / CPU

5.3.5 Timer Processing

The MASTER-K series use up count timer. There are 5 timer instructions such as on-delay (TON), off-delay (TOFF), integral (TMR), monostable (TMON), and re-triggerable (TRTG) timer.

The measuring range of 100msec timer is 0.1 ~ 6553.5 seconds, 10msec timer is 0.01 ~ 655.35 seconds, and that of 1msec timer is 0.001 ~ 65.53 seconds. Please refer to the ???MASTER-K programming manual??? for details.

Preset value

Timer output relay

Timer type

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.

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.

Chapter 5 Power Supply / CPU

3)Integral timer

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

The current value can be cleared by the RST instruction only.

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.

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Chapter 5 Power Supply / CPU

5)Retriggerable timer

The operation of retriggerable timer is same as that of monostable timer. Only difference is that the retriggerable timer is not ignore the input condition of TRTG instruction while the timer is operating (decreasing). The current value of retriggerable timer will be set as preset value whenever the input condition of TRTG instruction is turned on.

Timer input condition

PT

Timer output relay

Preset value (PV)

(On operation)

Current value

REMARK

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

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Chapter 5 Power Supply / CPU

5.3.6 Counter Processing

The counter counts the rising edges of pulses driving its input signal and counts once only when the input signal is switched from off to on. MASTER-K series have 4 counter instructions such as CTU, CTD, CTUD, and CTR. The followings shows brief information for counter operation. Refer to the ???MASTER-K Instruction Manual??? for details.

1)Up counter (CTU)

-. The counter output relay is turned on when the current value reaches the preset value.

-. 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 Power Supply / CPU

4)Ring counter

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

5)Maximum counting speed

(1)The maximum counting speed of counter is determined by the length of scan time. Counting is possible only when the on/off switching time of the counter input signal is longer than scan time.

(2) Duty

Duty is the ratio of the input signal???s on time to off time as a percentage.

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Chapter 5 Power Supply / CPU

5.4Program

5.4.1Classifications 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.

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

HSCDI program

END processing

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Chapter 5 Power Supply / CPU

1) Scan program

-. The scan program is executed regularly in every scan from 0 step to last step.

-. When interrupts has occurred, CPU pauses scan program and executes corresponding interrupt program first. -. When this interrupt program finished, scan program is to resume.

2) Interrupt program

-. When an interrupt occurs, the CPU module will stop the current operation and execute the corresponding interrupt routine first. 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)

5.4.3Interrupt Programs

1)Usage of interrupt program

(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

Chapter 5 Power Supply / CPU

2) parameter setting

3) Time driven interrupt

TDI occurs periodically with the constant interval assigned in parameter setting. The interrupt routine of TDI starts with the TDINT instruction and ends with the IRET instruction.

When multiple interrupt factors occur simultaneously, interrupt routines are executed according to the priority given to the each interrupt. 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 isn???t 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 Power Supply / CPU

REMARK

Total available interrupt points is 8(In standard type).

-. Time driven interrupt + process driven interrupt + high speed counter driven interrupt ??? 8 points Interrupt signal is ignored when self-interrupt occurs more than 2 times during interrupt processing is executing.

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

???PLC hardware defect

???System configuration error

??? Operation error during execution of the user programs

???External device malfunction

2)Operation mode at error occurrence

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

It the numeric operation error of these errors occurs during execution of the user program, its contents are

5-17

Chapter 5 Power Supply / CPU

REMARK

1) In occurrence of a error, the state is to be stored in the representative system error flag F006. 2) For details of flags, refer to Chapter 11. Troubleshooting.

5-18

Chapter 5 Power Supply / CPU

5.5Operation Modes

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

5.5.1 RUN Mode

In this mode, programs are normally operated.

The first scan start in the RUN mode

Initialize data area according to the preset restart mode.

Check the program and determine it can be executed or not.

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.

2) Operation processing contents

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Chapter 5 Power Supply / CPU

5.5.2 STOP mode

In this mode, programs are not operated.

1) Processing when the operation mode is changed.

The output image area is cleared and output refresh is executed.

2)Operation processing contents

(1)I/O refresh is executed.

(2) Normal or abnormal operation and mounting conditions of the loaded module are checked.

(3)Communications service or other internal operations are processed.

5.5.3PAUSE mode

(3)Communications service or other internal operations are processed.

5.5.4DEBUG mode(Standard type only)

1) Processing when the operation mode changes

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

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Chapter 5 Power Supply / CPU

3) Debug operation conditions

following four operation conditions can be specified.

5.5.5Operation Mode Change

1)Operation mode change methods

The following method is used to change the operation mode.

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.

REMARK

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

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Chapter 5 Power Supply / CPU

3) Mode change Remote operation

Remote operation mode change is available only when the operation mode is set to the remote STOP mode (i.e., the mode setting switch position is in the STOP??? PAU/REM???).

5-22

Chapter 5 Power Supply / CPU

5.6Functions

5.6.1Self-diagnosis

1) Functions

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.

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.

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Chapter 5 Power Supply / CPU

5.6.2 I/O Force On/Off function

It is possible to input/output a designated data regardless of the program operation results. When used with OUTOFF instruction simultaneously, OUTOFF is prior to I/O Force On/Off.

1) Forced I/O setting method.

Click

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

5-24

Chapter 5 Power Supply / CPU

Set ???forced I/O data??? by bit

Set ???forced I/O data enable??? by bit -. When forced I/O set enables, forced I/O function is executing.

Click

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Chapter 5 Power Supply / CPU

2) Special data register for forced I/O

The contents of forced I/O setting is registered to special data register as below.

It is possible to use ???forced I/O function??? to program.

3)Force on/ off Processing timing and method

(1)Forced Input

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.

REMARK

-. For detailed operation, refer to the KGLWIN user???s Manual Chapter 7 ???Force I/O setting.

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Chapter 5 Power Supply / CPU

5.6.3Direct I/O Operation function

This function is useful when reads an input relay???s state directly during execution of a program and uses in the operation, or write the operation result directly to an output relay. Direct input/output is executed by the ???IORF??? instruction. If this instruction is used, the input/output image area will be directly updated and applied to the continuing operations.

REMARK

-. For detailed operation, refer to the ???MASTER-K Manual for instruction???.

5.6.4System 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

3) Clear error data

Use a ???data clear??? function of KGLWIN.

REMARK

Refer to the KGLWIN user???s Manual Chapter 7, for details.

5-27

Chapter 5 Power Supply / CPU

5.7Memory 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.

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Chapter 5 Power Supply / CPU

5.8 I/O Address Allocation

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

Max. 3 expansion module is available in standard type.

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.

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Chapter 5 Power Supply / CPU

5.9Built-in Cnet Selection Switch

5.9.1Structure

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

5.9.2 Usage

* The lower switch is for O/S download setting. Don???t handle this switch.

5-30

Chapter 5 Power Supply / CPU

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

Driver

Dip switch

Terminal block cover

5-31

Chapter 5 Power Supply / CPU

5.10 External Memory Module

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

5.10.1 Structure

Installation connector

5.10.2 Usage

1)Saving the user???s program on the external memory module.

(1)Turn the power of the base unit off.

(2)Install the memory module.

-. When only main unit is used : Connect to the expansion connector of the basic unit.

-. 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)Select Online ???Read Information ??? I/O Information in menu, and the following message box will displayed

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Chapter 5 Power Supply / CPU

(6) Select Online ??? Flash memory ??? Write to external memory in menu, and the following message box will displayed.

(7)Turn the power of the main unit off.

(8)Remove the external memory module.

Through the above steps a user can save a program into the external memory module.

2)Run the PLC with a program of external memory module

(1)Turn the power of the main unit off.

(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.

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Chapter 5 Power Supply / CPU

5.11 RTC Module

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

5.11.1 Structure

Installation connector

5.11.2 Usage

1)Read RTC data

(1)Read RTC data from KGLWIN

-. Select Online ???Write Information ??? Set PLC Clock in menu.

-. Following message box will be displayed

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Chapter 5 Power Supply / CPU

(2) Read RTC data from special register

Example : 2002. 07. 23. 13:50:20, Tuesday

2) Write RTC data

There is two ways to write new RTC data to the CPU.

The first one is using a graphic loader (KGLWIN). For detailed information, refer the user???s 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.

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.

3) Date expression

REMARK

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

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Chapter 6 Input and Output Specification

Chapter 6 Input and Output Specification

6.1 Input / Output Specifications

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

Opening/shutting of electric current

6-1

Chapter 6 Input and Output Specification

6.2Digital Input Specification

6.2.1Main unit

1) Specification

6-2

Chapter 6 Input and Output Specification

3) Input wiring

Main unit???s wiring method is as follows. DC input specifications offered by MASTER-K120S is to be used for both electric current sink and electric current source.

(1) Main unit

6-3

Chapter 6 Input and Output Specification

4) Example of external devices.

To connect with external device of DC output type into DC input module, wire depending on the type of the external device as shown.

Chapter 6 Input and Output Specification

6.2.2 Expansion Module

1) Specifications

2) Circuit diagram

It???s the same with the one for the main unit.

3) Input wiring

6-5

Chapter 6 Input and Output Specification

6.3Digital Output Specification

6.3.1Main unit (Relay Output)

1)Specification

(1)Standard type

6-6

Chapter 6 Input and Output Specification

(2) Economic type

2) Circuit

6-7

Chapter 6 Input and Output Specification

3)Output wiring

(1)Main unit

U

6-8

Chapter 6 Input and Output Specification

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

1) Specification

P40,P41

24V

P42,P43

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 can???t be used for AC load. When used for AC loads, they can be destroyed.

6-9

Chapter 6 Input and Output Specification

2) Output wiring

AC100-240V P40 P41 P42 P

FG COM0 COM1 COM2 P43 COM3

DC12V/24V

6-10

Chapter 6 Input and Output Specification

6.3.3 Expansion Module

1) Specifications

2) Circuit

It???s the same with the output circuit of the main unit.

3) Output wiring

6-11

Chapter 6 Input and Output Specification

???

L L L LL

1) Refer to 7.2 ???Special Functions??? for the special modules

6-12

Chapter 7 Usage of Various Functions

3) Names of wiring terminals

Input pulse

Preset input

< Econnomic Type >

7-2

Chapter 7 Usage of Various Functions

4) External interface circuit

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.

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Chapter 7 Usage of Various Functions

6)Wiring example

(1)Voltage output pulse generator

24V

PulseGenerator

CHSC

A

B

COM

24VG

(2) Open collector output pulse generator

B

24VG

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Chapter 7 Usage of Various Functions

7) Instruction(HSCST)

??? 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 pulse???s rising edge and current value goes ???set value ???1???(in down counter mode)

(2) Error code

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Chapter 7 Usage of Various Functions

8)Parameter Setting

(1)Format setting

(a)Linear counter

???If HSC is designate as Linear counter, it can counts from -2,147,483,648 to 2,147,483,647.

???The carry flag F18*(* is channel number) turns on when the current value of high speed counter is overflow during up counting and HSC stop counting.

???The borrow flag F19*(* is channel number) turns on when the current value of high speed counter is underflow during down counting and HSC stop counting.

???Carry and borrow flags can be reset by preset operation and HSC can re-starts its operation.

(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 value is changed to 0.

???The borrow flag turns on when the current value of high speed counter is reaches 0 during down counting and current value is changed to ???set value ???1???.

???When set value is out of range(2 ~ 2,147,483,647), Ring counter setting error(h???11) 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(h???11) occurs and HSC operates as linear counter.

???The ring counter setting error can be corrected by re-start of instruction(HSCST) only.

Chapter 7 Usage of Various Functions

(2) Mode setting

(a)1-phase operation mode

-Current value increases by 1 at the rising edge of input pulse.

(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.

(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 input pulse

Chapter 7 Usage of Various Functions

(d) 2-phase multiplication mode (MUL4)

-Up or Down is set automatically by the phase difference between A and B phase.

???Up counter

-At the rising edge of A-Phase pulse when B-phase is ???low???.

-At the falling edge of A-Phase pulse when B-phase is ???high???.

-At the rising edge of B-Phase pulse when A-phase is ???high???.

-At the falling edge of B-Phase pulse when A-phase is ???low???.

???Up counter

-At the rising edge of A-Phase pulse when B-phase is ???high???.

-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 input pulse

B-phase input pulse

Current value

(3) Preset setting

(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.

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Chapter 7 Usage of Various Functions

(4) Latch Counter setting

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

Current value

- When power supply is off. - When is ???Stop??? or ???Pause??? - When input condition of

???HSCST??? is off

(5)Comparison Output setting

(a)Comparison set

-When current value of HSC is equal to SV1, corresponding output point turns on.

-P40 ~ P47 are available for comparison output point.

Input pulse

Output Contact

Current value

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Chapter 7 Usage of Various Functions

(b)Zone Comparison Set

-When current value of HSC isn???t less than SV1 and more than SV2. corresponding output point turns on.

-P40 ~ P47 are available for comparison output point.

-If SV2 is less than SV1, SV2 setting error(h???12) occurs and zone comparison set is disabled.

(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 User???s Manual???.

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Chapter 7 Usage of Various Functions

(6)RPM setting

-Can calculates RPM of input pulse

-RPM is stored in designated device.

- The RPM is expressed as:

RPM = (CurrentValue- Last Value)??? 60,000

Pulsesper rotate??? refreshcycle[ms]

(a)Examples of Program

-Refresh cycle : 1000ms, Pulses per rotate : 60, RPM save area : D0

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

??? Last value = 1000, Current value = 2000

RPM = { (2000 ??? 1000) * 60,000} / {60 * 1000} = 1000

??? Last value = 2000, Current value = 4000

RPM = { (4000 ??? 2000) * 60,000} / {60 * 1000} = 2000

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Chapter 7 Usage of Various Functions

9)Programming example

(1)Parameter setting

???Channel : Ch0

???Counter format : Ring counter ( 0 ~ 100,000)

???Counter mode : 2-phase multiplication mode

- P0 : A-phase pulse input, P1 : B-phase pulse input

???Preset

-Preset type : internal preset (M100)

-Preset value : 0

???Last counter setting

-None

???Comparison output

-Output mode : Zone comparison set

- SV1 : 10,000 SV2 : 20,000

-Output point : P43

???RPM setting

-Refresh cycle : 100(*10ms)

-Pulses per rotate : 60

-RPM save area : D100

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Chapter 7 Usage of Various Functions

(2)Programming

???When M0 turns on, HSC starts its operation

???If current value is not less than 50,000, F170 turns on.

???Current value is saved in D0(double word).

Remark

The contact point which is designated as HSC input can???t be used for pulse catch or external interrupt. Duplicated designation may cause faults.

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Chapter 7 Usage of Various Functions

7.1.2. Pulse Catch Function

In the main unit, 4(economic type) or 8(standard type) points of pulse catch input contact points are internalized. Through using this contact point, short pulse signal short can be taken which can not be executed by general digital input.

1) Usage

When narrow width of pulse signal is input, a trouble occurs which can not be detected by general digital input, so the operation does not perform as user's intention. But in this case through pulse catch function even narrow interval of pulse signal as 10 ??? min. can be detected.

3) Operating Explanation

10 ???

input signal

input image data

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.

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Chapter 7 Usage of Various Functions

Remark

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

2)Do not designate HSC input points as pulse catch input.

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Chapter 7 Usage of Various Functions

7.1.3 Input Filter Function

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

1) Usage

Input signal status affects to the credibility of system in where noise occurs frequently or pulse width of input signal affects as a crucial factor. In this case the user sets up the proper input on/off delay time, then the trouble by miss operation of input signal may be prevented because the signal which is shorter than set up value is not adopted.

2) Operating Explanation

Input on/off 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 of 0-1000ms

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Chapter 7 Usage of Various Functions

7.1.4 External Interrupt Function

MASTER-K120S Series can perform max 4(economic) or 8(standard) points of external contact interrupt by using input of main unit without special interrupt module.

1) Usage

This function is useful to execute a high speed execution regardless of scan time.

2) Minimum processing time.

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.

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Chapter 7 Usage of Various Functions

5)Usage

(1)Click twice the parameter on the project window of KGLWIN.

(2)Designate contact point, no. of priority and movement condition of the task program which is moved by interrupt inputting.

Time driven Interrupt

execution periodic set

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

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Chapter 7 Usage of Various Functions

7.1.5 PID control function(Standard type only)

1) Introduction

This chapter will provide information about the built-in PID (Proportional Integral Derivative) function of MASTER-K120S main unit. The MASTER-K120S series does not have separated PID module like MASTER-K300S and MASTER- K1000S 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

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.

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Chapter 7 Usage of Various Functions

2)Specification

(1)Control operation

(a)Proportional operation (P operation)

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

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

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Chapter 7 Usage of Various Functions

(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 The integral action with constant deviation

??? The expression of I action is as following;

MV = KpTi ??? Edt

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.

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Chapter 7 Usage of Various Functions

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

Fig. 7.4 The system response when a long integration time given

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

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

(c)Derivative operation (D action)

???When a deviation occurs due to alteration of SV or external disturbances, D action restrains the changes of the deviation by producing MV which is proportioned with the change velocity (a velocity whose deviation changes at

every constant interval) in order to eliminate the deviation.

??? 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.

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Chapter 7 Usage of Various Functions

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

Fig. 7.6 Derivative action with a constant deviation

??? The expression of D action is as following;

MV = Kp ??? Td dEdt

???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 PID action with a constant deviation

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Chapter 7 Usage of Various Functions

(e)Integral windup

All devices to be controlled, actuator, has limitation of operation. The motor has speed limit, the valve can not flow over the maximum value. When the control system has wide PV range, the PV can be over the maximum output value of actuator. At this time, the actuator keeps the maximum output regardless the change of PV while the PV is over the maximum output value of actuator. It can shorten the lifetime of actuator.

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.

Integral

Term

??????

Fig. 7.8 Example of integral windup

.

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Chapter 7 Usage of Various Functions

(2) Realization of PID control on the PLC

In this chapter, it will described that how to get the digitized formula of the P, I, and D terms.

(a) P control

The digitized formula of P control is as following;

P(n) = K[SV (n) ??? PV (n)]

(b) I control

The continuous formula of I control is as following;

I (t) = K ??? t e(s)ds : integral term

Ti 0

dIdt = TiK e where, e = (SV ??? PV) : deviation value The digitized formula is as following;

(c) D control

The continuous formula of derivative term is as following;

TdN ??? dtd D + D = ???KTd dydt

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.

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Chapter 7 Usage of Various Functions

(4)parameter setting and explanation

(a)PID8 instruction parameter setting and 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 system???s 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)

.

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Chapter 7 Usage of Various Functions

??? Proportional gain

The MASTER-K120S can handle only integer, not the floating point type. Therefore, to enhance the accuracy of PID operation, the PID8 instruction is designed to input the P_GAIN data as the 100 times scaled up. For example, if the designated P_GAIN is 98, actual input data of P_GAIN should be 9800. If the designated P_GAIN is 10.99, input 1099 to the P_GAIN.

??? 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. The range of actual input is 0 ~ 20000. (it is possible that parameter value designates ???D??? area 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.

??? PWM set

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 actual input range is 10 ~ 100. PWM output point is only available for output contact of main unit.

Example) PWM output period : 1s, Output contact : P40, MV limit range : 0~4000

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Chapter 7 Usage of Various Functions

??? SV Ramp

If a large amount of SV changes during PID operation, The deviation(E) changes rapidly. Then manipulation value(MV) is changed rapidly also. This can cause damage on load or actuator. To prevent this situation, SV can be changed step by step by parameter setting.

Setting range is 1~4000(Default value is 1). Setting value represents the number of time which taken from starting set value to last set value.

For example, if SV-ramp is set to 1000 and SV changed from 1000 to 3000 during operation, it changes 2 every scan and reach 3000 after 1000 scan time.

??? Delta MV

This is useful when wants to limit maximum change of manipulation value. Setting range is 0 ~ 4000 and default value is 4000.

??? Bias

The Bias data is used for the compensation of offset in the proportional control. The range of input is 0 ~ 4000. Be cautious that The actual range of Bias is ???2000 ~ 2000. namely, 0~2000 represents 0 ~ +2000 and 2001 ~ 4000 represents -1 ~ -2000.

Example> If offset(SV-PV) is 100 ??? Bias should be 100. If offset(SV-PV) is -100 ??? 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) and offset value.

??? 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 which???s load change is slow like temperature control system, and positioning form is useful for system which???s load change is fast.

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Chapter 7 Usage of Various Functions

(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 : -200 ??C ~ 600 ??C),

and the goal value is 100 ??C. The equivalent digital output of A/D module (current input range : 4 ~ 20mA) is 1500 if the A/D module outputs 0 (4mA) with -200 ??C, and 4000(20mA) with 600 ??C. Therefore, the input of SV should be 1500, not 100.

??? When using sensor and RTD module(G7F-RD2A)

Assume that PID control is used for temperature control with Pt100 (operation range : -200 ??C ~ 600 ??C), and the goal value is 100 ??C. The digital output of RTD module is calculated as below.

DigitalOutput = Temp.???10 + 2000

2

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.

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Chapter 7 Usage of Various Functions

???Relay response method.

???PID parameters are obtained by On/Off operation during 1 cycle of PV variation.

???PID parameters are obtained by amplitude and period of oscillation

???The On/Off operation will be occur at the SV value.

MV

Period

SV

Amplitude

???Process reaction curve method(PRC method).

???PID parameters are obtained by step response of process.

???It is useful fo r time 1st order time delay system expressed as following

KTse +1

???Obtained parameters may not accurate if the process can???t approximated to 1st order system, In this case, use relay response method.??? Ls

Time delay(L)

4000

MV

80% of SV

63% of SV

Time constant(T)

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Chapter 7 Usage of Various Functions

5)instruction

(1)PID8

??? PID8 n S1

a)Usage

???when the condition of execution is on, PID operation executes.

??????n??? is registration No.at parameter( 0 ~ 7)

b)Example 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 b7 b6 b5 b4 b3 b2 b1 b0

D0000

Done : normal execution signal

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Chapter 7 Usage of Various Functions

??? 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)Example program

???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 b7 b6 b5 b4 b3 b2 b1 b0

D0000

Auto tuning end bit

Done : normal execution signal

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Chapter 7 Usage of Various Functions

6)Program Example

(1)System configuration

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Chapter 7 Usage of Various Functions

a)PID operation explanation (without A/T function)

???Measure current temperature (-200~600??C) by RTD module then digital conversion value(0 ~ 4000) is stored to D4780

???PID8 instruction will calculate manipulate value (MV : 0 ~ 4000) based on PID parameter settings (P_GAIN,

I_TIME, D_TIME, etc.) and PV from RTD module. Then, the calculated MV is output to the channel 0 of D/A module.

???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(60??C ),1350(70??C ),1400(80??C ),1500(100??C)

???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 area : D4780

d)D/A module setting

???Channel setting : use channel 0

???output range setting: DC 4 ~ 20 mA

???D/A conversion data registration area : D4980

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Chapter 7 Usage of Various Functions

e)Program Explanation

???When the input condition M0 turns on, PID operation executes at no.0 parameter.

???PID execution status registrate D0000 and the output value of control result registrate D0001

???If SV Ramp is designated, current SV is registrate D0005

???D/A module converts the MV to analog signal and output to the actuator (power converter).

???When the input condition M0 turns off, output 0 to the D/A conversion module.

(3)In case of using combined function of PID operation and Auto tuning.

a)PID operation explanation (with A/T function)

???Measure current temperature (-200~600??C) by RTD module then digital conversion value(0 ~ 4000) is stored 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, MASTER-K120S 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(60??C ), 1350(70??C ),1400(80??C ),1500(100??C)

???Current value setting : D4780(Digital value of RTD module Ch0)

???Identification method setting : Select PRC Method

When selected, the scan time fixed to 1 sec.

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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(60??C ),1350(70??C ),1400(80??C ),1500(100??C)

???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 area : D4780

e)D/A module setting

???Channel setting : use channel 0

???output range setting: DC 4 ~ 20 mA

???D/A conversion data registration area : D4980

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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 off, Output 0 to D4980

When M0002 turns on, auto tuning starts.

Calculated P,I,D parameters are saved to D0002, D0003, D0004

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6)Error code list

(1)PID8AT

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7. 2 Special module

The special module and allocated data registers are as followings.

RTD input module store digital conversion value of temperature value to data registers as below

Remark

1)Offset/gain value can???t be changed, it is fixed.

2)Analog inputting is set the current since this is manufactured.

3)Extend to use max.3 Modules

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2) Names of parts and functions

Explain about names of parts and functions

(1) G7F-ADHA

???RUN LED

Indicate the operating status the G7F-ADHA

???External power input terminal

External voltage 24VDC needs to this terminal.

???Extension cable

This cable is used to connect while analog mixture module is used.. Extension cable connector

???The connector connects extension cable when extended module is used.

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(2) G7F-ADHB

???The connector connects extension cable when extended module is used.

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3) Parameter setting

(1) Scaling function

This function convert automatically range when the inout/output range is not matched.

In case that input/output is current , this function is useful that external equapment??? range is not matched each other. (MASTER-K120S series converts range automatically as following : 0 ~ 20mA ??? 4 ~ 20mA)

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 ???

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4)Wiring

(1)Caution for wiring

???Make sure that external input signal of the mixture module of AC and analog I/O is not affected by induction noise or occurs from the AC through using another cable.

???Wire is adopted with consideration about peripheral temperature and electric current allowance. Thicker than Max. size of wire AWG22 (0.3 ???) is better.

???If wire is put near to high temp. 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 miss-operation and out of order.

(2)Wiring example

a)Analog input

b) Analog output

Voltage output

V+

2K~1 ???

V???

*1

GND

I???

*1

GND

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

* Be careful to use that analog output is 1 channel.

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5)I/O converstion characteristics

(1)Analog input characteristics

a)Voltage input

In voltage input, digital amount 0 is output by 0V input and 4,000 is output by 10V input. Therefore input 2.5mV equals to digital amount 1, but value less than 2.5mV can???t be converted.

b) Current input

A/D conversion characteristics (Current input)

Current input 0mA becomes output 0, 10mA does 2000 and 20mA does 4000. therefore input 5 ??? equals to digital amount 1, but value less tan 5 ??? can???t be converted. So abandon it.

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(2)Analog output characteristics

a)Voltage output

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)Current output

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 ???.

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6)Program example

(1)Distinction program of A/D conversion value

a)Program explanation

-When digital value of channel 0 is less than 2000, P090 is on.

-when digital value of channel 0 is more than 3000, P091 is on.

-When digital value of channel 0 is more or same than 2000 or lesser than 3000, P092 is on.

b)System configuration

I/O allocation

Main unit input : P000 ~ P03F

Main unit output : P050 ~ P07F

Expansion module input : P080 ~ P08F

Expansion module output : P090 ~ P09F

c) Program

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(2)Program which controls speed of inverter by analog output voltage of 5 steps

a)Program explanation

-.When P80 becomes On, 2000 (5V) is output. -. When P81 becomes On, 2400 (6V) is output. -.When P82 becomes On, 2800 (7V) is output. -.When P83 becomes On, 3200 (8V) is output. -.When P84 becomes On, 3600 (9V) is output.

b) System configuration

Main Unit A/D??D/A combination module Expansion module

c) Program

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7.2.2 A/D Conversion module

1) Performance specifications

The performance specifications of the analog input module are following.

Remark

???Offset/Gain value can???t 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

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2) Names of parts and functions

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

???RUN LED

Indicate the operating status the G7F-AD2A Analog input terminal

??????

???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.

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3) Parameter setting

(1) Scaling function

The scaling function is the same that of A/D, D/A combination module.

4)Wiring

(1)Caution for wiring

???Make sure that external input signal of the mixture module of AC and analog I/O is not affected by induction noise or occurs from the AC through using another cable.

???Wire is adopted with consideration about peripheral temperature and electric current allowance. Thicker than Max. size of wire AWG22 (0.3 ???) is better.

???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 miss- operation and out of order.

(2)Wiring

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

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5) Analog/Digital conversion characteristics

In voltage input, digital amount 0 is output by 0V input and 4,000 is output by 10V input. Therefore input 2.5mV equals to digital amount 1, but value less than 2.5mV can???t be converted.

b) 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 ??? equals to digital amount 1, but value less tan 5 ??? can???t be converted. So abandon it.

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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

I/O allocation

Main unit input : P000 ~ P03F

Main unit output : P050 ~ P07F

Expansion module input : P080 ~ P08F

Expansion module output : P090 ~ P09F

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(c) Program

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7.2.3 D/A Conversion module

1)Performance specifications

The performance specifications of the analog output module are following.

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2) Names of parts and functions

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

RUN LED

???

Indicate the operating status the G7F-DA2I

Analog output terminal

???

Current output

???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.

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3) Parameter setting

1) Specify the kind of special module

2) Set Output type of each channel

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5) Scaling function

The scaling function is the same that of A/D, D/A combination module.

6)Wiring

(1)Caution for wiring

???Make sure that external input signal of the mixture module of AC and analog I/O is not affected by induction noise or occurs

from the AC through using another cable.

???Wire is adopted with consideration about peripheral temperature and electric current allowance. Thicker than Max. size of wire AWG22 (0.3 ???) is better.

???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 miss-operation and out of order.

(2)Wiring

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

Remark

The common grounding with other devices is permitted when D/A conversion module is used as current output type.

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7)Digital/Analog conversion characteristics

(1)G7F-DA2I

a)0~20mA output

D/A conversion characteristics(Current output)

Digital amount 0 outputs analog amount 0mA, 4000 does 20mA.Digital input 1 equals to 5 ??? of analog amount.

b) 4~20mA output

D/A conversion characteristics(Current output)

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

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8)Program example

(1)Program which controls speed of inverter by analog output voltage of 5 steps(0 ~ 20mA output)

a)Program explanation

???When P80 becomes On, 2000 (10mA) is output.

???When P81 becomes On, 2400 (12mA) is output.

???When P82 becomes On, 2800 (14mA) is output.

???When P83 becomes On, 3200 (16mA) is output.

???When P84 becomes On, 3600 (18mA) is output.

b)System configuration

I/O allocation

Main unit input : P000 ~ P03F

Main unit output : P040 ~ P07F

Expansion module input : P080 ~ P08F

Expansion module output : P090 ~ P09F

c) Program

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7.2.4Analog timer

1)Performance specification

The performance specification of the analog timer module are following.

2) Names of parts and functions

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3)Program example

(1)Program explanation

Program which controls on-delay time of output contact point within 0 to 20 sec. By analog timer module.

(3) Program

A/T conversion data is moved D000 always

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7.2.5 RTD input module(Standard type only)

1) Performance specification

The performance specification of the RTD input module are following.

2) Names of parts and functions

Explain about names of parts and functions

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3) Parameter setting

4) Digital conversion value register

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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

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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8) Burn-out detection function

The RTD input module has the function of burn-out detection on the Pt100, JPt100 or cable.

???As shown below, if disconnection occurs in the RTD or cable then a voltage outside the measurable range voltage is inputted by the internal burn-out detection circuit and burn-out detection error code is generated.

???The RTD input module can detect disconnection for each channel. But, burn-out detection is possible only in the channels enabled.

???If disconnection is detected in two or more wires, first, disconnection error code is generated by ???b??? and then disconnection error code is generated by ???A??? or ???b??? sequentially. If disconnection is detected simultaneously in ???A??? and ???B???, only disconnection error code is generated by ???b???.

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9)Wiring

(1)Caution for wiring

???Make sure that external input signal of the mixture module of AC and analog I/O is not affected by induction noise or occurs from the AC through using another cable.

???Wire is adopted with consideration about peripheral temperature and electric current allowance. Thicker than Max. size of wire AWG22 (0.3 ???) is better.

???If wire is put near to high temp. 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 miss-operation and out of 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 10 ??? or less per wire.

The same wire (in thickness, length, and kind, etc.) should be used for each channel.

Method of Connection between Pt and RTD Input Module

*1: RTD (Pt100 or JPt1000)

*:2: Shielded wire - The shields of the RTD and shields of wire should be connected to the FG of the RTD input module.

REMARK

The difference between the resistance values of the wires used should be 1 ??? or less, or the accuracy shown in 1) performance specification could not be satisfied.

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10)Program example

(1)A program for output of detected temperature value as a BCD value

a) Program explanation

The present A/D conversion value of the detected temperature value which is detected from the temperature-measuring resistor Pt 100 is displayed on the BCD digital display by use of channel 0 of the temperature-measuring resistor input module. The lamp turns on when the detected temperature value is a negative number and turns off when it is a positive number

b) System configuration and parameter setting

c) Program

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2) Output Specification(P40, P41)

3) Names of wiring terminal

FG COM0 COM1 COM2 P43 COM3

Remark

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

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

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4) Internal circuit and wiring example

R

- +

DC 24V

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7.3.2 Positioning function

1) Positioning function

Positioning Control includes position control, speed control.

(1)Position control

Positioning control from start address (present stopped position) to goal address (transfer amount) for the assigned axis

A)Control by Absolute method (Absolute coordinate)

???Positioning control from start address to goal address (the address assigned by positioning data).

??? Positioning control is carried out based on the address assigned (origin address) by return to origin.

???Transfer direction shall be determined by start address and goal 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=8000-1000).

??? Parameter setting

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

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

??? Parameter setting

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(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 (-)

??? Timing diagram

Deceleration stop command (POSCTR)

Remark

Please refer to the ???7.3.4 Instruction??? for details.

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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

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3)Operation Mode

(1)End Operation

A)With one time start command(rising edge of POSIST command), the positioning to the goal position is executed and the positioning shall be completed at the same time as the dwell time proceeds.

B)This operation mode can be used as last positioning data of pattern operation.

C)Operation direction shall be determined by position address.

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] End operation

??? Parameter setting

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(2)Keep Operation

A)With one time Start command(POSIST), the positioning to the goal position of operation step is executed and the positioning shall be completed at the same time as dwell time proceeds and without additional start command, the positioning of operation step for (current operation step no. +1) shall be done.

B)Keep operation mode is available to execute several operation step in order.

C)Operation direction shall be determined by position address.

[ Example ] Keep operation

??? Parameter setting

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(3)Continuous Operation

A)With one time Start command, the positioning for operation step set by continuous operation mode is executed to the goal position without stop and the positioning shall be completed at the same time as dwell time proceeds.

B)If you want to operate with the position and speed of next step before the operation step that is active currently reaches the goal position, the operation by Next Move continuous operation command is available.

C)With Next Move continuous operation command, the operation in the acceleration, constant speed, deceleration section of Continuous operation is 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 ] Continuous operation

Speed

Operation step 2

On

Start command

(POSIST)

??? Parameter setting

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4)Operation Method

(1)Repeat Operation

A)With one time start command, the positioning to the goal position is executed and the positioning shall be completed at

the same time as the dwell time proceeds.

B)The operation type of Repeat operation mode is same as that of Single operation but the different thing is to determine next operation by operation step no. assigned by repeat step no. change command after positioning completion of Repeat operation mode.

C)Operation direction shall be determined by position address.

??? Parameter setting

??? In this case, Operation step 3, 4 does not start.

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5)Positioning start

(1)Direct start(POSDST)

???This is used to operate directly by setting the axis, goal position address, operation speed without parameter setting.

???Refer to the ???7.3.4 Instruction??? for details.

(2)Indirect start(POSIST)

???This is used to operate by setting the operation step no. by parameter.

???Refer to the ???7.3.4 Instruction??? for details.

(3)Speed control start(POSVEL)

???This is used to operate directly by setting the axis, direction, operation speed without parameter 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 current operation step again by Start command and operation step

???In case of deceleration stop by deceleration stop command in deceleration speed section, starts to operate ???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

???Refer to the ???7.3.4 Instruction??? for details.

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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

(B)Origin detection after deceleration when approximate origin turns on

(C)Origin detection by approximate origin

???The items that effects to the origin return from parameter are as follows.

(A)Origin return speed (high speed, low 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.

(B)In this case, if approximate origin as external input is entered, it decelerates and acts by origin return low speed.

(C)If origin signal as external input is entered after the approximate origin signal has changed from ???On??? to ???Off???, it stops.

Speed

Origin return low speed

Time

Transfer amount after approximate origin ???ON???

Origin return command

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(3) Origin Detection after Deceleration when Approximate origin turns on

This is the method using the approximate origin and origin signal and the action by origin return command is as follows.

(A)It accelerates to the setting origin return direction and acts by origin return high speed.

(B)In this case, if approximate origin as external input is entered, it decelerates and acts by origin return low speed.

(C)If encounters the origin signal as external input signal while the origin return low speed is active, the origin shall be determined and it stops.

Speed

Origin return command

(4) Origin Detection by approximate origin

This is the method using the approximate origin signal only.

External input high limit

Origin return command

Origin determined state

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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 time from parameter setting.

???Jog high speed operation : operation pattern with acceleration/deceleration

Speed

Time

??? Jog low speed operation : operation pattern without acceleration/deceleration

Speed

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.

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.

Remark

If POSSOR is executed in deceleration section, error code H44 will occur and continues operation

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10)External Input Stroke High/Low Limit

???External input stroke limit includes External input high limit signal and External input low limit signal.

???This is used to stop the positioning function promptly before reaching Stroke limit/Stroke End of the Driver by installing the stroke limit inside Stroke limit/Stroke end of the Driver.

???If it deviates the high limit, Error H53 will occur and if it deviates the low limit, Error H54 will occur.

???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.

???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.

-F284(Ch0) Off : External input stroke Low limit has not detected, On : External input stroke Low limit has 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 immediately, Then, changes direction and continues origin return operation.

11) M Code function(After Mode)

This function made to set ???M Code Set??? bit, if ???M Code Enable??? bit was ???On??? when positioning was completed. And Then ???M code Set??? bit must reset for run to the next step.

??? Used special relay.

Chapter 7 Usage of Various Functions

???Timing diagram

1)Unused the M Code Output

Positioning

Indirect start

Completed Flag

2) Use the M Code

Positioning

Indirect start

Completed Flag

M1911

M1912

12)Error and Output Prohibition

???Error includes Light failure error and Heavy failure 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 heavy failure error occurs during operation, the operation will stop.

???If external high/low limit, external emergency stop during the positioning operation are detected during the positioning operation, it stops promptly and becomes the pulse output prohibition status. Thus it is required to release the pulse output prohibition by Error reset command(POSCTR)

???For further information, please refer to Error code list .

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(B)Backlash Compensation Amount

???The tolerance that the machine does not work by the wear when the rotation direction changes in case that a gear, screw etc is combined to run at the motor axle, is called as ???Backlash???.

Therefore, when you change the rotation direction, it is required to add the backlash compensation amount to the

positioning amount for output.

??? The setting range is 0 ??? 1,000(unit: Pulse) at each axis.

???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)

Direction change

Transfer amount including Backlash compensation amount

Backlash

(C)Bias Speed

???As the stepping motor has unstable torque near zero speed, the start speed shall be set in the beginning of 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 return operation,

??? JOG operation.

(D)Speed Limit

???max. 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 limit and if they are set as higher value than speed limit, error will occur.

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(2) Origin return parameter

(A) Origin return method

??? For the details, please refer to ???7) Return to Origin??? in chapter 7.3.2

(B) DOG, origin signal

(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 section via acceleration section by origin return command.

???Origin return-high speed setting range : 5 ??? 100,000(unit: 1pps)

???Origin return-Low speed

???The speed that acts to the constant speed section via deceleration section by origin return command.

???Origin return-low speed setting range : 5 ??? 100,000(unit: 1pps)

Remark

When setting the origin return speed, it is recommended to set the origin return-low speed as low speed as possible. If setting the low speed as ???too fast???, it may cause the incorrect origin signal 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 of positioning and especially Dwell time when returning to the origin is called as ???origin return dwell time???.

???Setting range of Origin return dwell time : 0 ??? 10,000(unit: 1 ???)

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(3) JOG speed

(A)JOG High Speed

???JOG high speed operation has operation pattern as acceleration, constant speed, deceleration section. Therefore,

acceleration section and deceleration section is controlled by JOG acceleration/deceleration time.

???JOG high speed setting range : 5 ??? 100,000(unit: 1pps)

(notices when setting the high speed : Bias speed ??? Jog high speed ??? Speed limit)

(B)JOG Low Speed

???JOG low speed operation has only constant speed operation pattern.

???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.

Remark

If step No. set to 0, operating step increase to next step automatically when current operation step finished

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(2) Coordinate

???The coordinate of position data includes Absolute and 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

(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

(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

(5)Positioning Address

???This is the area to set the transfer amount of position data as ???positioning 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 Usage of Various Functions

(6) Speed

???Operation speed can be assigned for each operation step No.

???Setting range of operation speed : 5 ~ 100,000( Setting unit: 1pps )

???The change of speed value is available when assigned by D area

(7)Dwell Time

???This is the waiting time before carrying out the next positioning operation after completing one positioning operation.

??? Setting range is 0 ??? 10,000 (setting unit : 1 ???).

???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.

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2) JOG Operation(POSJOG)

Flag setDesignation

??? 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 can???t 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.

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5) PWM output (PWM)

Flag setDesignation

??? 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

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9) Return to origin(POSORG)

??? 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.

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7.3.5 Flag list and Error codes

1) Flag list

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7.3.6 Wiring with servo and stepping motor driver (Open Collector)

1) Wiring with stepping motor driver(DC 5V)

Stepping Motor Driver

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

Remark

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 they???re 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.

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

49 +24VIN

Remark

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 they???re 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.

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Chapter 8. Communication Functions

8.1Dedicated Protocol Communication

8.1.1Introduction

MASTER-K120S???s built-in Cnet communication uses only MASTER-K120S main unit for a dedicated communication. That is, it doesn???t need a separate Cnet I/F module to facilitate the user-intended communication system by utilizing reading or writing of any area in CPU, and monitoring function.

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-K???s) system configuration (MASTER-K120S main unit : RS-232C)

Remark

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 master-slave 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 can???t be used without any treatment. For the detailed wiring method, refer to 8.1.2.

It???s possible to set baud rate type and station No. in KGLWIN.

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Chapter 8 Communication Functions

8.1.2 System configuration method

According to the method of connection, the system using MASTER-K120S built-in communication can be composed.

1)Connecting system configuration (link between MASTER-K???s)

(1)1:1 connection with general PC

a)Communication program made by C or BASIC computer language on the user???s computer, or utility program like FAM or CIMON can be used.

MASTER-K120S main unit

RS-232C interface

b) Wiring method

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Chapter 8 Communication Functions

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

RS-485 interface

RS-232C interface

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Chapter 8 Communication Functions

.

(3) 1:1 connection with other MASTER-K120S

RS-232C interface

RS-485 interface

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Chapter 8 Communication Functions

8.1.3 Frame Structure

1)Base Format

(1)Request frame(external communication device ??? MASTER-K120S main unit), (Max. 256 Bytes)

Remark

1)Used control codes are as follows. Be familiar with the following control codes. Because they are importantly used for communication.

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Chapter 8 Communication Functions

Remark

1)The numerical data of all frames are ASCII codes equal to hexadecimal value, if there???s no clear statement. The terms in hexadecimal are as follows.

???Station No.

???When the main command is R(r) or W (w) and the command type is numerical (means a data type)

???All of the terms indicating size of all data in the Formatted data area.

???Monitoring registration and command registration number of execution commands.

???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

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Chapter 8 Communication Functions

8.1.4 List of commands

Remark

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

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Chapter 8 Communication Functions

8.1.5 Data type

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

1)Data type of variable

???Available types of device

??? When variable is used, attach ???%???(25H) in front of the marking characters.

Remark

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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Chapter 8 Communication Functions

8.1.6 Execution of commands

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

(1) Introduction

This is a function that reads PLC device specified in accord with memory data type. Separate device memory can be read up to 16 at a time.

(2) PC request format

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

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Chapter 8 Communication Functions

(3) Response format (ACK response)

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.

Remark

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 format (NAK response)

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.

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Chapter 8 Communication Functions

??? For NAK response after execution of command(PC ??? MASTER-K120S main Unit)

2) Continuous reading(R(r)SB) of device

(1) Introduction

This is a function that reads the PLC device memory directly specified in accord with memory data type. With this, data is read from specified address as much as specified continuously.

(2) PC request format

Remark

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.

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

Ex.1

When memory type included in variable name of computer request Format is W(Word), and data number of computer request Format is 03, data number of PLC ACK response after execution of command is indicated by H06(2*03 = 06 bytes)Byte and ASCII code value 3036 is entered in data area.

Ex.2

In just above example, when data contents of 3 words are 1234, 5678, and 9ABC in order, actual ASCII code converted values are 31323334 35363738 39414243, and the contents are entered in data area.

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(4) Response format (NAK response)

(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

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Chapter 8 Communication Functions

3) Individual writing of device(W(w)SS)

(1) Introduction

This is a function that writes the PLC device memory directly specified in accord with memory data type.

(2) PC request format

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.

Remark

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).

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(3) Response format (ACK response)

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Chapter 8 Communication Functions

(5) Example

This example supposes that "HFF" is written in M230 of station No. 1 and BCC value is checked.

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Chapter 8 Communication Functions

4) Continuous writing of device(W(w)SB)

(1) Introduction

This is a function that directly specifies PLC device memory and continuously writes data from specified address as much as specified length.

(2) Request format

Remark

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).

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(3) Response Format (ACK response)

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Chapter 8 Communication Functions

(5) Example

This example supposes that 2 byte H???AA15 is written in D000 of station No. 1 and BCC value is checked.

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Chapter 8 Communication Functions

5) Monitor register(X##)

(1) Introduction

Monitor register can separately register up to 10 in combination with actual variable reading command, and carries out the registered one through monitor command after registration.

(2) PC request Format

??? Register Format : Register Format of request Formats must select and use only one of the followings.

??? Individual reading of device

1 block(max. 16 blocks)

??? Continuous reading of device

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(3) Response Format (ACK response)

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(5) Example

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Chapter 8 Communication Functions

6) Monitor execution(Y##)

(1) Introduction

This is a function that carries out the reading of the variable registered by monitor register. This also specifies a registered number and carries out reading of the variable registered by the number.

(2) PC request Format

(3)Response Format(ACK response)

??? In case that the register Format of register No. is the Individual reading of device

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Chapter 8 Communication Functions

(4) Response Format (NAK response)

(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.

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7) Reading PLC Status(RST)

(1) Introduction

This is a function that reads flag list including operating status of PLC and error information.

(2) PC request Format

???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.

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(4) Response Format ( NAK response)

*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 ??? MASTER-K120S Main Unit)

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8.1.7 1:1, 1:n Built-in communication between MASTER-K120S's

1) Introduction

1:1 built-in communication between MASTER-K120S's is that which constitutes a built-in communication system with the method of 1(master) : 1(slave). Setting Base parameter and communication parameter in KGLWIN can easily constitute this system. Communication protocol currently applied is the same with Cnet I/F used for MASTER-K. Main functions are following.

???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.

1:1 built-in communication between MASTER-K120S

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)Parameter setting

(1)Communication Parameter Setting

???Open a new project file from KGLWIN

-MASTER-K120S must be selected as PLC type.

???After selecting communication parameter from KGLWIN and clicking twice, this window comes up.

(a) When uses Ch.0 : Built-in RS-232C or External Cnet I/F module

(b) When uses Ch.1 : Built-in RS-485

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??? Set according to the following table

(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

??? 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:

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Chapter 8 Communication Functions

3)Flag related with operating status

(1)Sending/receiving error count for each station (total 32 stations) Error code is saved following area according to station

Error code

(2)Sending/receiving error contents of each station (total 32 stations)

Error count number is saved following area according to station

(3)Slave PLC mode and error contents of each station (total 32 stations)

Error Information of PLC is saved following area according to station

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??? Error bit

(5)Max/min/current sending/receiving cycle of set parameter Contents: the interval between after sending and before receiving

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4) Example

1:1 built-in communication between MASTER-K120S

???Device M000 is increased by program per 1 second.

???Writing M000 to output area P004 of slave

???Reading slave???s output area P004

???Writing it to master???s output area P009

The following example uses the above diagram to explain the operation of MASTER-K120S main unit.

???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, G7E-DR10A.

(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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and mode

??? 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.

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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.

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(2) Program

(2)Parameter setting for slave station.

???Set parameters as the following table.

???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

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8.2User Defined Protocol Communication

8.2.1Introduction

User Defined Protocol Communication allows users who do communication between MASTER-K120S main unit and other kind of device to define the other company???s protocol at MASTER-K PLC. There???re a number of kinds of protocols made by many companies, that it???s difficult to have all protocols in it. 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 power???s 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.

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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

???Header

-Used in [Header] type.

-Possible characters, as headers are 1 alphabet letter, 1 numeric number, or control characters as below.

Available Control Code

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???Send / Receive

-Not defined : It is the initial value that doesn???t declare a frame format.

-Send : It is that declares send frame.

-Receive : It is that declares receive frame.

-When Frame 0 window is activated, Tx/Rx term is set as ???Not defined,??? and all the segments are not in activation.

???Segment (1-8): Enter segment by segment to separate fixed sending data area (CONSTANT) and device

If the segment is declared as ARRAY type, designate transmitting device (P,M,L,K, F,T,C,D) and number of transmitting. The unit is byte

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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If ARRAY is set, it asks whether it would convert data to ASCII to send (at send frame), or convert to hexadecimal to receive(at receive frame).

If ARRAY is set, the size of area is to be set by byte. The unit is a byte.

???Tail

-Used in [Tail] type.

-It???s possible to use BCC that can detect errors. BCC must be set as [BCC] to be used. To set BCC contents, click ???BCC Setting??? button on the right side.

Example 5)

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??? BCC setting: set BCC when it is needed.

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???Frame size

-ASCII communication : max. 128 bytes

-Hex communication : max. 256 bytes

???Link relay (L)

-It???s a flag to indicate whether a user defined frame is received in the order set by the user.

-If the received frame is matched with the declared frame in frame list number 3, L003 starts blinking (0 ??? 1 ??? 0).

???When frame receiving is done, MASTER-K120S main unit check if there???s any match between the received frame and the declared frame in frame list. If there is, let the Link relay L(n) flag blink and save the received data in the assigned area.

BCC calculation example> When frame is set as below, the result of calculation is as follow.

(1) Default setting

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

??? SUM 1

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8.2.3 Instruction

1) User defined communication instruction(SNDCOM)

??? SNDCOM Ch n1 D

(1)Function

???When the execution condition is on, the communication starts with protocol at parameter which is designated early.

??????Ch??? is communication channel and ???n??? is a frame number at parameter which is designated

??????D??? is a device which the communication status is stored.

(2)example of program

???When input condition is on, channel 1 stars communication with protocol at user defined parameter rnumber 3.

???The communication state is stored M000 and the format of M000 Iis as below

???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) Error code

8.2.4 Example of Usage

This example is supposed that there???s a communication between MASTER-K120S???s by the user-defined protocol. The system configuration is as follows and the cable is the same with the one of 1:1 dedicated protocol communication.

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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??? Program

???When the data is received at frame no. 1, link relay L001 turns on during 1 scan. At that moment, M000 increases and the value of M000 moves output relay P004.

???The new value of M000 is sending again every 1 second period (F092 is 1second period flag)

???The number of sending normally stores D000.

???When error occurs, the number of sending error stored in D001.

2)Setting and program of slave station

???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

??? Program

???When the data is received at frame no. 0, link relay L000 turns on during 1 scan. At that moment P004 increases and the value of P004 moves M000.

???The new value of P004 is sending again every 1 second period (F092 is 1second period flag)

???The number of sending normally is stored in D000.

???When error occurs the number of sending error is stored in D001.

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8.3Modbus Protocol Communication

8.3.1Introduction

MASTER-K120S built-in communication supports Modbus, the Modicon product???s communication protocol. It supports ASCII mode, using ASCII data and RTU mode using Hex data. Function code used in Modbus is supported by instruction and especially function code 01, 02, 03, 04, 05, 06, 15 and 16. Refer to "Modicon Modbus Protocol Reference Guide"

8.3.2 Basic Specification

1) ASCII mode

REMARK

1)The size constituting 1 letter is 1 character. So 1 character is 8 bits that is 1 byte.

2)1 character time means the time lapsed for sending 1 character. Ex) Calculation of 1 character time at 1200 bps.

1200 bps means that it takes 1 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)Address area

(1)Setting range is available from 1 to 247, but MASTER-K120S supports from 0 to 31.

(2)Address 0 is used for broadcast address. Broadcast address is all slave device recognize and respond to like the self- address, which can't be supported by MASTER-K120S.

4)Function code area

(1)MASTER-K120S supports only 01, 02, 03, 04, 05, 06, 15, and 16 among Modicon products' function codes.

(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.)

It returns as it sets the 8th bit of function code of request frame.

5)Data area

(1)It sends data, using ASCII data(ASCII mode) or hex (RTU mode).

(2)Data is changed according to each function code.

(3)Response frame uses data area as response data or error code.

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.

REMARK

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#0111, 2#1010

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7) Function code types and memory mapping

??? MASTER-K120S Mapping

8) Modbus addressing rules

MASTER-K120S main unit starts its address from 0 and matches with 1 of Modicon products' data address. So MASTER- K120S'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 MASTER-K120S.

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."

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10)Map of wiring

8.3.3 Parameters Setting

1)Setting communication parameter

(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.

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8.3.4Instruction and example

1)MODBUS communication instruction(MODCOM)

??? 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 is as below.

???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

-. In MASTER-K120S series, the ???MODBUS??? command which has been used in MK80S series can be used. In this case, communication channel is fixed to channel 0.

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