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EC20 Series PLC User Manual
EC20 Series PLC User Manual
Emerson Network Power provides customers with technical support. Users may contact the nearest Emerson local sales office or service center.
Copyright 2005 by Emerson Network Power Co., Ltd. All rights reserved. The contents in this document are subject to change without notice.
Emerson Network Power Co., Ltd. Address: No.1 Kefa Rd., Science & Industry Park, Nanshan District 518057, Shenzhen China Homepage: www.emersonnetworkpower.com.cn E-mail: support@emersonnetwork.com.cn
Safety Precautions
To reduce the chance of accident, please read the safety precautions very carefully before operation. The "Caution, Notice, Warning, Danger" symbols in this manual do not represent all the safety points to be observed, and are only used as a supplement to various operation safety points. Therefore, the installation and operation personnel must be strictly trained and master the correct operations and all the safety points before actual operation. When operating Emerson PLC products, the safety rules in the industry, the general safety points and special safety instructions specified in this manual must be strictly observed. These notices are highlighted in the manual by a warning triangle and are marked as follows according to the level of danger: Danger: indicates that death, severe personal injury, or substantial property damage will result if proper precautions are not taken. Warning: indicates that death, severe personal injury, or substantial property damage could possibly result if proper precautions are not taken. Caution: indicates that minor personal injury or property damage can result if proper precautions are not taken. Notes for designing The programming must include safety circuit to ensure the safe application of the PLC (Programmable Logic Controller) system upon power off or the PLC malfunction. Note the following when programming: The external circuit of the PLC must include the emergency braking circuit, protection circuit, mutual interlock circuit of forward/reverse rotation, and the interlock switch of position upper/lower limit for preventing equipment from damage. For the safe operation of the equipment and output signals of the serious accident, please design the external protection circuit and the safety mechanism. All the outputs may be shutdown when the CPU of the PLC detects the abnormity of the system; the failure of part PLC circuit may result in uncontrolled PLC output. A suitable external control circuit must be designed to ensure the normal operation of the equipment. When the PLC output unit such as the relay or the transistor is damaged, the PLC output cannot be controlled as ON or OFF state. The PLC is designed to be used in the electrical environment of indoor area B and C. However, to prevent the high lightning voltage from damaging the equipment through the ports of power input, signal input or control output, a SPD should be installed in the power supply system. : According to IEC61131-2, section 8.3.1 classification declaration Notes for installation Units should not be installed in areas subject to the following conditions: excessive or conductive dust, corrosive or flammable gas, moisture or rain, excessive heat, regular impact shocks or excessive vibration. Electric shock, fire hazard and mishandling may also damage the product. Take special care not to allow metal debris and wire lead to fall inside the vent of the PLC during the screw hole processing and wiring. Otherwise there is a danger of fire, damage or faulty operation of equipment. Once the installation of the new PLC is complete, remove everything on the surface of the vent, including packing goods such as protective paper. Otherwise the poor ventilation during the operation may result in fire, damage or faulty operation of equipment.
Do not wire, inset or pull out the cable plug with power applied. Otherwise there is a danger of electric shock or circuit damage. Installation and wiring must be fastening and reliable. Bad contact may result in faulty operation of equipment. The input/output cable of high frequency signal should use the shielding cable to improve the interference rejection of the system. Notes for wiring Installation and wiring can be done only after the external power supplies are all disconnected. Otherwise there is a danger of electric shock or equipment damage. Once the installation and wiring of the PLC is complete, cleanup the spot at once. To prevent the electric shock, replace the port cover of the product before power is on. When wiring AC supplies, the Live cable should be connected to the L terminal and the Neutral cable should be connected to the N terminal. Otherwise the PLC will be damaged. Dont power +24V port of the main module by the external power supply. Otherwise the PLC will be damaged. Do not lay I/O signal cables of the PLC next to other power cables or strong interference circuits. Do not make the earth port (PG) of the main module and the heavy current power system share the same earthing. Notes for operation and maintenance Do not touch the ports when the power is applied, otherwise there is a danger of an electric shock or faulty operation of equipment. The cleaning and the fastening work can be done only after the power supply has been disconnected; otherwise there is a danger of electric shock. Only after the power supply has been disconnected, can the communication signal cables and the cables of the expansion module or control unit be connected or removed. Otherwise there is a danger of equipment damage or faulty operation of equipment. Do not disassemble the PLC. Otherwise it may destroy the inner electrical components. Read through this manual carefully before operating the PLC. Safe and efficient operation of the product, such as program alternation, trial operation, start and stop, is only based on correct operation and maintenance. Do not replace the button cell battery with power applied. If the battery replacement is indeed to be done with power applied, it shall always be carried out by adequately trained electric technical personnel wearing insulated gloves. Notes for the product disposal Note the following when disposing the PLC: Explosive of the electrolytic capacity: The capacities on the circuit board may explode when burning. Exhaust gas when burning: The main body of the PLC is plastic, and it may produce poisonous gas when burning. Disposal of button cell battery: Classified collecting and disposing, and separating from the daily-life rubbish. Follow the local environmental regulations to dispose the PLC or dispose it as industrial waste.
Contents
Chapter 1 Preface ............................................................................................................................................................ 1 Chapter 2 Product Introduction......................................................................................................................................... 2 2.1 2.2 2.3 2.4 2.6 Outline................................................................................................................................................................ 2 Maximum Configuration ..................................................................................................................................... 2 Internal Memory Capacity Of User Program ...................................................................................................... 2 Resource Configuration Of System Soft-device ................................................................................................. 2 Filter Function Of Input Port ............................................................................................................................... 3
2.5 High-speed Input/Output Function...................................................................................................................... 3 2.7 Interrupt Source.................................................................................................................................................. 3 2.8 Subroutine Call................................................................................................................................................... 3 2.9 Reinforced Debugging Function ......................................................................................................................... 3 2.10 2.11 2.12 2.14 2.15 Support Online Modification ............................................................................................................................. 3 Multiple Password Protection Function ............................................................................................................ 4 Expansion Module............................................................................................................................................ 4 User Program Developing And Debugging ...................................................................................................... 4 Communication And Networking ...................................................................................................................... 4
Chapter 3 Installation........................................................................................................................................................ 5 3.1 3.2 3.3 3.4 Notes For Installation ......................................................................................................................................... 5 Requirements For Installation Position............................................................................................................... 5 Installation Method ............................................................................................................................................. 5 Installation Dimensions ...................................................................................................................................... 6
Chapter 4 Product Specifications ..................................................................................................................................... 8 4.1 Model Legend..................................................................................................................................................... 8 4.2.1 4.2.2 Main Module ........................................................................................................................................... 8 I/O Expansion Module............................................................................................................................. 8
4.2.3 Special Function Module......................................................................................................................... 9 4.3 Product Size ....................................................................................................................................................... 9 4.4 Environmental Requirements ............................................................................................................................. 9 4.5 Electric Insulation Specifications ........................................................................................................................ 9 4.6 4.7 Reliability .......................................................................................................................................................... 10 Power Supply Specifications ............................................................................................................................ 10 4.7.1 Inner Power Supply Of Main Module .................................................................................................... 10 4.7.2 Use Of Each Circuit Output Power........................................................................................................ 10 4.7.3 Power Specifications Provided By Main Module To Expansion Module................................................ 11 4.7.4 Derating Design Of Power Supply Circuit ............................................................................................. 11
4.7.5 Power Consumption Of Expansion Module........................................................................................... 12 4.7.6 Power Capacity Calculation In Expansion Connection.......................................................................... 12 4.8 Programming Tool Of User Program................................................................................................................ 12
Chapter 5 Input Characteristic ........................................................................................................................................ 13 5.1 User Ports Of Main Module .............................................................................................................................. 13 5.2 Input Port Characteristic And Signal Specification ........................................................................................... 14 5.3 5.4 Inner Equivalent Circuit Of Input Port ............................................................................................................... 15 Input Connection Of High-speed Counter ........................................................................................................ 16
5.5 Interrupt Input Connection................................................................................................................................ 17 5.6 Input Signal Status Indication ........................................................................................................................... 17 5.7 5.8 Analog Potentiometer And Application ............................................................................................................. 17 Example Of Input Connection .......................................................................................................................... 17
Chapter 6 Output Characteristic ..................................................................................................................................... 19 6.1 Output Port Application .................................................................................................................................... 19 6.2 Electric Specifications Of Output Port .............................................................................................................. 19 6.3 Output Port Connection.................................................................................................................................... 20 6.4 6.5 Output Port Status Indication............................................................................................................................ 22 Example Of Output Connection........................................................................................................................ 22
Chapter 7 Expansion Module ......................................................................................................................................... 23 7.1 Model ............................................................................................................................................................... 23 7.2 7.3 Expansion Busbar Connection ......................................................................................................................... 23 Expansion Module Addressing ......................................................................................................................... 23 7.3.1 I/O Point Addressing Number Principle................................................................................................. 24 7.3.2 Special Function Module Addressing Number Principle........................................................................ 24 Chapter 8 Communication And Networking.................................................................................................................... 25 8.1 Communication Port......................................................................................................................................... 25 8.2 Programming Environment............................................................................................................................... 26 8.3 Programming Cable ......................................................................................................................................... 26 Chapter 9 Cable Specification And Wiring...................................................................................................................... 27 9.1 Connecting Power Supply Cable...................................................................................................................... 27 9.2 Connecting Ground Cable ................................................................................................................................ 27 9.3 Connecting Common Port ................................................................................................................................ 28 9.4 Cable Specification........................................................................................................................................... 28 Chapter 10 First Operation And Maintenance ................................................................................................................ 29 10.1 Notes For Application ..................................................................................................................................... 29 10.2 10.4 Check Before Power On................................................................................................................................. 29 RUN/STOP Switchover .................................................................................................................................. 29 10.4.1 How To Startup (STOP RUN) ....................................................................................................... 30 10.3 Startup............................................................................................................................................................ 29
10.4.2 How To Stop (RUN STOP) ........................................................................................................... 30 10.5 Routine Maintenance ..................................................................................................................................... 30 Chapter 11 Troubleshooting ........................................................................................................................................... 32 Chapter 12 Instruction List.............................................................................................................................................. 33 Chapter 13 Special Register........................................................................................................................................... 38 13.1 Special Intermediate Register ........................................................................................................................ 38
Chapter 1 Preface
Chapter 1 Preface
Thank you for using EC20 series Programmable Logic Controller (PLC) made by Emerson Network Power Co., Ltd. This book contains text, diagrams and explanations that will guide the reader in the correct installation and operation of the EC20 series PLC and should be read and understood before attempting to install or use the product. The book describes the hardware, features and applications of the EC20 series PLC, also includes the options introduction, troubleshooting guide and instruction quick reference. For the information about how to setup an EC20 programming system and the customer programming application, please refer to ControlStar Programming Software User Manual or EC20 series PLC Programming Manual printed by Emerson Network Power Co., Ltd. For ordering the above user manuals, contact your Emerson distributor or sales office. This manual is designed for the engineer who is studying, programming, installing, or servicing the EC20 series PLC. Definitions of specific terms PLC: Programmable Logic Controller Main module: Refer to basic module or CPU module; it is the basic unit of the PLC. It includes master CPU, I/O ports and power supply. Expansion module: Generally refer to the modules except for the main module. I/O expansion module: The expansion module for the digital signal input/output. Special function module: Other function expansion modules except for the I/O expansion module, such as analog signal input/output module, and busbar module. Points: The sum of channel number of the input/output digital signal. Digital signal: Refer to the input/output signals that only have two states: ON and OFF. Analog signal: Continuously changed electric signal, such as 4~20mA output signal of pressure transmitter. Unipolar signal: Generally refer to the continuously changed signal with positive polarity. Bipolar signal: Generally refer to the continuously changed signal, which may be positive polarity or negative polarity. High-speed pulse: Refer to the square-wave signal with higher frequency. Counter: Refer to the counter whose counting value increases or decreases by per pulse input according to the increasing/decreasing control signal. Two-phase counter: refer to the counter that has two-pulse input ports, one is for counting up, and the other is for counting down. AB-phase counter: refer to the counter that has two input ports of quadrature phase pulse, and counts up or down according to the frequencies and phase differences of the two signals.
15 14 13
5 6 7 8 12 11
Figure 2-1
10
Outline of EC20 main module
The name and function of the components in the figure are as follows:
1. The installation position of a button cell battery (CR2032 lithium battery) for data backup. 2. Power supply input ports 3. Signal input ports 4. Input signal status LEDs 5. 26pin busbar socket, used for connecting the expansion module 6. Output signal status LEDs 7. Fix screws, used for tightening the top/bottom cover of the PLC 8. Mounting holes, used for installing screws 9. Locking device of 35mm DIN, used for DIN rail installation mode. 10. Signal output ports 11. System operation status LEDs 12. Communication port COM1, providing RS485 and RS232 at the same time 13. Communication port COM0, RS232, Mini DIN8 socket 14. System operation control switch, with three positions: ON, TM and OFF. 15. Analog potentiometers (two)
2.2
Maximum Configuration
The main module and the I/O expansion modules can achieve the most 512 logic points (256 in/256 out maximum). And eight special function modules can be expanded at most.
2.3
2.4
C D V Z SD
Counter Data register Local data register Indexed addressing register Special data register
2.5
2.6
2.7
Interrupt Source
Provide eight external interrupt inputs, the interrupt edge can be set by users and is corresponding to X0~X7 ports; six high-speed counter interrupts; three inner timing interrupt sources.
2.8
Subroutine Call
At most 64 subroutines and 6-level subroutine nesting can be used. Support local variables and variable-alias, and every subroutine can provide 16 parameters to be called at most.
2.9
2.10
2.11
2.12
Expansion Module
The expansion module such as I/O module, analog signal input/output module, network expansion module, and position control module can be connected to the PLC main module. Every module is address allocation automatically and identification automatically.
2.13
2.14
2.15
Chapter 3 Installation
Chapter 3 Installation
3.1 Notes For Installation
The PLC is designed to be used in the environments meeting with standard II installation ambient, and Class 2 pollution. So the unit should be installed in such environment free of dust, conductive dust, corrosive or flammable gas, excessive heat, moisture or rain; Besides, shocks and vibrations will also affect the reliability of the PLC and shorten its service life, and should therefore be avoided. Usually, the user should mount the PLC and the associated switches, contactors to the inside wall of the electric cabinet and keep adequate natural convection. If the ambient temperature is a little high, or a heat generating equipment is nearby, then a forced convection device should be installed on the top or the side of the cabinet to prevent the overheat of the unit. Take special care not to allow metal debris and wire lead to fall inside the vent of the PLC during the screw hole processing and wiring. Otherwise there is a danger of fire, damage or faulty operation of equipment. Once the installation of the new PLC is complete, remove everything on the surface of the vent, including packing goods such as protective paper. Otherwise the poor ventilation during the operation may result in fire, damage or faulty operation of equipment. Do not wire, inset or pull out the cable plug with power applied. Otherwise there is a danger of electric shock or circuit damage. Installation and wiring must be firm and reliable; bad contact may result in faulty operation of equipment.
3.2
Figure 3-1
3.3
Installation Method
Generally you can mount the PLC onto a standard rail (DIN) with 35mm width. Follow these steps: 1. Fix the DIN rail to the backboard; 2. Pull out the clip (located on the bottom of the PLC) and hook the back of the PLC onto the rail. 3. Snap the clip closed, carefully checking to ensure that the clip has fastened the PLC securely onto the rail. 4. At last, install two DIN rail stops at the two sides of the PLC to avoid slippage around. Other EC20 series modules can be mounted using the same procedures.
Chapter 3 Installation
DIN rail stop
Figure 3-2
Under the conditions with great impact, you should mount the PLC on a panel using the screw installation. Using four fix screws through the four 4 mounting holes on the enclosure of the PLC (while EC20-2012BR/BT has only two 4 fix screws) to fix the PLC on the back panel of the electric cabinet, as shown in the Figure 3-3.
M3 fix screw
4 mounting holes
Figure 3-2
M3 fix screw
3.4
Installation Dimensions
1. The dimensions for the outline and mounting holes of EC20-2012BR and EC20-2012BT are shown in the Figure 3-4:
Figure 3-4
2. The dimensions for the outline and mounting holes of EC20-3232BR and EC20-3232BT are shown in the Figure 3-5:
Figure 3-5
3. The dimensions for the outline and mounting holes of EC20-0808ER are shown in the Figure 3-6. And the dimensions for the outline and mounting holes of the analog signal expansion module such as EC20-4AD, EC20-4DA, EC20-4AM, and EC20-4TC are the same with that of EC20-0808ER.
Chapter 3 Installation
Figure 3-6
Dimensions of outline and mounting holes of EC20-0808ER and the analog signal expansion module
4.2
4.2.1
32/1(2) in the table: Represent only one common port in logic, but two common ports in structure, and the two are connected inside the PLC.
4.2.2
4.2.3
4.3
Product Size
The main modules of EC20 series PLC have the same height and width, but their lengths are related to the I/O ports. The size of each module is listed in Table 4-4.
Table 4-4 Model EC20-2012BR EC20-2012BT EC20-3232BR EC20-3232BT EC20-0808ER, 4AD, 4DA, 4AM, 4TC Length (mm) 158 158 227 227 58 Product size Width (mm) 90 90 90 90 90 Height (mm) 82 82 82 82 82 Net weight 680g 680g 950g 880g 240g
4.4
Environmental Requirements
Table 4-5 Type Temperature Climate Humidity Air pressure** Sinusoidal vibration Mechanical stress Random vibration Requirements of operation, storage, and transport environments of EC20 series PLC Unit C C % kPa kPa mm M/s2 m2/s3 (dB/Oct) Hz Environmental conditions for operation -5 55 95 (30 2C) 70 106 3.5 (5-9HZ) 10 (9-150HZ) / / / / m/s2 m / / Environmental conditions for transport -40 70 95 (40 2C) 70 106 / / 1.92 (5-20Hz) (20-200Hz) 5-200 X/Y/Z Half-sine wave 180 1 -3db Environmental conditions for storage -40 70 / 70 106 / / / / / / / / Environmental parameters Parameter Low temperature High temperature Relative humidity Low pressure High pressure Bit shift acceleration acceleration spectra density Frequency range Vibration direction Impact Drop Type acceleration Drop height
4.5
10
The insulation resistance and voltage of other circuits are designed according to the requirements of an extra-low voltage circuit
4.6
Reliability
Table 4-7 Output type Relay Transistor Time MTBF of EC20 series PLC Conditions
200,000 hours Fix on the floor , mechanical stress is almost close to zero, with temperature and humidity control 100,000 hours Fix on the floor , mechanical stress is almost close to zero, without temperature and humidity control 300,000 hours Fix on the floor , mechanical stress is almost close to zero, with temperature and humidity control 150,000 hours Fix on the floor , mechanical stress is almost close to zero, without temperature and humidity control
For the PLC with relay output, the life of its contactors is related to the load type and load capacity, as listed in Table 4-8.
Table 4-8 Load capacity 220Vac, 15VA, inductive load 220Vac, 30VA, inductive load 220Vac, 60VA, inductive load Use life of EC20 series output relay Action frequency 1sec. ON / 1sec. OFF 1sec. ON / 1sec. OFF 1sec. ON / 1sec. OFF Life-span of contactors 3,200,000 times 1,200,000 times 300,000 times
4.7
4.7.1
4.7.2
11
4.7.3
*Explanation: The current of Inner consumption in Table 4-10 is the average current consumed when the module inner circuit works. Users cannot change it directly. The current of capacity provided in Table 4-10 is the part capacity of the main module that can be used for the external control module. The data listed in Table 4-10 is under the stable ambient condition with 25C. If input voltage is out of rated voltage range or the working temperature exceeds +50C, users should consider the derating design, which is mainly obtained by decreasing the value of capacity provided, to ensure the reliable operation of the PLC.
4.7.4
Input voltage Vac 85 Vac 100 Vac 264 Vac 280 Vac
Figure 4-2
Derating curves of power supply output capacity and power supply input voltage
2. Power output capacity derating vs. work temperature relationship When the work temperature is higher than the upper limit of the specification, the power capacity provided (including 5V/24V/GND and 24V/COM) by the main module to the expansion module must be derating. The derating relation is shown in Figure 4-3.
Power load %
Figure 4-3
12
4.7.5
: Refer to the power consumption when the analog output channel port connects with the output. If the current output port (0~20mA) is not used, the current can be decreased to 50mA.
4.7.6
It is obvious that the total power consumption of above expansion module is less than the permission load of the main module, and the designing scheme is feasible. Example 2: the main module is EC20-3232BT, at 25C ambient temperature, three EC20-0808ET, two EC20-4AD, one EC20-4DA shall be connected to, using 20mA output port and one EC20-4TC. Checking computations as following:
Power circuit 5V/GND 24V/GND 24V/COM Current provided by the main module 350mA 650mA 360mA Actual consumed current (803+502+50+50)=440mA (503+02+0+0)=150mA (503+252+120+25)=345mA conclusion Un-passed Pass Pass
The sum of the 5V/GND power consumption of the expansion module is 440mA, it is larger than 350mA which is the upper limit of 5V power supply; although the power consumption of 24V/GND and 24V/COM is less than the permitted current of the main module, the designing scheme is unfeasible. The solution to solve the insufficient of power supply capacity is to select the expansion module with self-carried power source. It can power by itself, also its outputs of 5Vdc/GND, 24Vdc/GND, and 24Vdc/COM can power to the expansion module added later.
4.8
13
+24V COM
Y0
Y1
Y2
Y4
Y6 Y7
Figure 5-1
The pin definitions of EC20-2012BR and EC20-2012BT are listed in Table 5-1:
Table 5-1 Pin L/N PG X0~X23 COM +24V Y0, COM0 Y1, COM1 Y2, Y3, COM2 Y4~Y7, COM3 Y10~Y13, COM4 Earth port Null port, used for isolation and not wiring User input signal ports, used together with COM can produce input signal Common port, it is the negative pole of the +24Vdc auxiliary power and the common port of input as well. Two COMs connect inside the PLC The auxiliary power to user external equipment , used together with COM Control output port, group 0 Control output port, group 1 Control output port, group 2 Control output port, group 3 Control output port, group 4 The COMx (COM0 ~ COM4) of each output group are electrical isolated one another Pin functions of EC20-2012BR and EC20-2012BT Function 220Vac AC power input port, L is live line, N is neutral line Note
The outline, port layout and function definition of EC20-3232BR and EC20-3232BT are the same. The port layout is shown in Figure 5-2:
14
+24V X1
Y0
Y1
COM 2 Y3
Y5 Y4
Y7
Y21
Y23 Y25 Y27 Y31 Y33 Y35 Y37 Y24 Y26 Y30 Y32 Y34 Y36 COM 5
COM COM Y2 0 1
Figure 5-2
Outline and port layout of EC20-3232BR and EC20-3232BT Table 5-2 Pin definition Note
Pin L/N PG X0~X37 COM +24V Y0, COM0 Y1, COM1 Y2~Y7, COM2 Y10~Y17, COM3 Y20~Y27, COM4 Y30~Y37, COM5 Earth port
Function 220Vac AC power input port, L is live line, N is neutral line Null port, used for isolation and not wiring User input signal ports, used together with COM can produce input signal Common port, it is the negative pole of the +24Vdc auxiliary power and the common port of input as well. Two COMs connect inside the PLC. The auxiliary power to user external equipment , used together with COM. Control output port, group 0 Control output port, group 1 Control output port, group 2 Control output port, group 3 Control output port, group 4 Control output port, group 5
The COMx (COM0~COM4) of each output group are electrical isolated one aother.
5.2
Leak mode, users only need to connect dry contact with Xn and COM ports.
Common port
15
5.3
Inner equivalent circuit of PLC main module 24Vdc auxiliary power supply Working power for inner logic circuit 24V/5V/GNG
COM
24V -
Sensor
X1
X2
Xn
Figure 5-3
As shown in Figure 5-3, the external signal input is a SINK input. You may need a SOURCE input in some special application, and you can change the soldering of the three jumper terminals of JP0, JP1, and jp2 on the interface board inside the PLC to reset the input mode, according to the screen-printing on the board ( represents soldering; represents disconnection). As shown in Table 5-4:
Table 5-4 Source input mode Drain input mode (default setting) % Screen print illustration JP0 JP1 % JP2 %
The equivalent input circuit changed to the SOURCE input mode is as Figure 5-4:
User signal wiring
Inner equivalent circuit of SOURCE input mode of the main module
24V+
24V+
COM
24V-
X0
X1
X2
Xn
Figure 5-4
16
Chapter 5 Input Characteristic Note: in the main module, all the input ports can but use the same input mode (SOURCE input mode or SINK input mode); if you have any requirement, please contact your supplier and ask for the technical support before purchasing the product. To avoid damage, youd better not change the circuit by yourself. The inner equivalent power supply and input signal connection of the I/O expansion module are shown in Figure 5-5:
User signal wiring To 24V+ of main module To COM of main module Sensor Provided by extension cable Internal equivalent circuit of the PLC extension module
24V+
X0
X1
X2
Xn
Figure 5-5
5.4
Among which: Phase A: phase-A input port of the two-phase counter; Phase B: phase-B input port of the two-phase counter.
Logic circuit
17
5.5
5.6
Figure 5-6
5.7
5.8
18
PG
AC-L
PG
Sensor
AC-N
VGND
+24V
24V Xn Xm Xn Xm
EC20-3232BT
Figure 5-7 electric connection of EC20-3232BT and EC20-0808ER
0808ER
19
Relay output
Transistor output
Dry contact output, output state is ON (conducting) , contacts are closed; output state is OFF, contacts are open.
Divided into multiple groups, each group has a common port COMn, suitable for the control circuit with different potential, and all common ports are insulated one another. 220Vac; 24Vdc, no polarity requirement 24Vdc, polarity requirement Accord with output electric specifications (see Table 6-2) High drive voltage, high current Low drive current, high frequency, long lifespan To drive the load with low action frequency such To apply in the situation with high frequency and long life, such as Application as: intermediate relay, contactor coil, and LEDs control servoamplifier and electromagnet with frequent action
6.2
Item
Relay output port 5~24 Vdc Single point: 2.0A /250Vac The total current of the 8 points sharing COM port is less than 8A. mechanical insulation Relay output contacts closed, LED on 2mA/5Vdc
Transistor output port 0.5A 24Vdc The total current of the 8 points sharing COM port is less than 2A. Optical coupling insulation Optical coupling is driving, LED on Less than 0.1mA/30Vdc 5mA (5~24Vdc)
Loop power supply voltage Below 250Vac, 30Vdc Output current Circuit insulation Act indication Leakage current at open circuit Min. load
20
Resistive load
ON response time OFF response time Y0,Y1 max. output frequency Output common port Fuse protection
Y0-COM0; Y1-COM1; Y2, Y3-COM2; Y4~Y7-COM3; Every 8 ports use one common port after Y8, and all the common port are isolated one another. No
6.3
Output group o
Output group 1
Y2
Y3
Output group 2
Y4
Y5 COM2
Figure 6-1
Figure 6-1 shows, output ports are divided into multiple groups, and each group is electrical isolated from others. Output contacts of different group can connect to the different power loop. For the inductive load in AC loop, the external circuit should be RC transient voltage absorbing circuit; for the inductive load in DC loop, it should consider to add a fly-wheel diode. As shown in Figure 6-2:
21
24V -
24V + Y1
Fly-wheel diode
1N4004
24V -
Inductive load
AC - L Y11
Inductive load
AC - N
R
Figure 6-2
The inner equivalent circuit of the output part of the transistor output PLC is shown in Figure 6-3. We can see that, output ports are divided into multiple groups, and each group is electrical isolated from others. Output contacts of different group can connect to the different power loop. Transistor output can but be used in DC 24Vdc load circuit, and you should pay attention to the polarity of the power supply. When driving the inductive load, it should consider adding a fly-wheel diode.
Inner equivalent circuit of PLC 5Vdc power Working power of inner logic circuit
Y0
Output group 0
COM0 Y1
Output group 1
COM1
Y2
Y3
Y4
Output group 2
Y5 COM2
Figure 6-3
22
6.4
6.5
L PG
24V X0 X1 X7
0808ER EC20-3232BR
Y6 Y7 COM2 Y30 Y31 Y32 Y33 COM5 Y0 Y1 Y2 COM
Y0 COM0
Y1 COM1
Y2 Y3 Y4 Y5
AC-L
A B A B A B A B A B A B A B A B A B A B A B A B A B
+24V
+5V
AC-N
23
Function Digital signal 8-channel input, 8-channel relay output Digital signal 8-channel input, 8-channel transistor output 4-channel analog signal input 4-channel analog signal output 2-channel analog signal input, 2-channel analog signal output 4-channel electric couple temperature input
7.2
Main module
Figure 7-1
Extension cable
Cascade connection of expansion module
Extension module
7.3
24
7.3.1
X0 -X23 Y0 -Y13
X30-X37 Y20-Y27
X40-X47 Y30-Y37
X50-X57 Y40-Y47
7.3.2
25
Port
Socket
Signal
Work mode
Full-duplex
COM1 EK500V
Purpose Users programming, debugging and monitoring Supporting 9600bps and 19200bps only Can connect to HMI for operation, also network as slave ModBus slave station station equipment Free protocol User-defined protocol ModBus master station network as master station to control other equipment. Network as slave station equipment and connect to HMI ModBus slave station to operate Free protocol User-defined protocol
Among of which, the communication protocol of COM0 is selected by the operation control switch (ON/TM/OFF) on the side of the port. Refer to Figure 8-1.
COM1 port
RS232
RS485
Figure 8-1
Used as special port of user programming, COM0 can be compulsorily converted to programming protocol through ON/TM/OFF switch. The conversion relation between PLC operating status and the protocol used by COM0 refers to Table 8-2.
Table 8-2 COM0 protocol conversion by switch
COM0 port operation protocol Decided by user program and system configuration, it may be programming protocol, Modbus protocol, and free-port protocol. Compulsorily converted to programming protocol . If the system configuration of user program is free-portprotocol, it converts to programming protocol automatically after stop; otherwise the system configured protocol keep unchanged.
COM1 port is suitable to connect with the equipment that have communication function, such as variable speed drive, and uses Modbus protocol or RS485 port free protocol to control multiple equipment through network. COM1 port is fixed by screws. You can use a twisted pair line to make the communication signal cable by yourself. Note: you should not use RS232 port and RS485 port at the same time, and do not connect the cable to the ports that are not used; otherwise the communication may be interrupted. EC20 Series PLC User Manual
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8.2
Programming Environment
The user program of EC20 series PLC is running on ControlStar integrated software development environment
developed by Emerson Network Power Co., Ltd. The operating system should support Microsoft Windows 98, Me, NT 4.0, Windows 2000 or XP. The basic system configuration is shown in Table 8-3:
Table 8-3 Program environment basic configuration of EC20 series PLC
Lowest configuration Equivalent to Intel Pentium 233 or above 64M 640480, 256
800%600 resolution, 65535 color mode A DB9 output RS232 serial communication port A mouse, PLC program cable produced by Emerson Network Power Co., Ltd., an EC20 series main module, ControlStar programming software.
8.3
Programming Cable
Emerson Network Power Co., Ltd provides a serial communication cable for download program. The model of the cable is B2053RASL1, and the two connectors at the cable ends are Mini-DIN8 and DB9. The cable is non-isolated. Users should not insert or pull out the cable with power on to avoid the equipment damage. Also our company provides an isolated RS232 cable for PLC, which can be hot swappable.
ControlStar
Figure 8-2
27
PG
24V COM X0 X7
24V Xn Xm
24V COM PG
EC20-2012BR
0808ER
9.2
Best
Better
Worst
Figure 9-2
When using a PLC expansion module, you should connect the earthing line of each module with earthing object separately, as shown in Figure 9-3:
28
Better
Worse
Figure 9-3
9.3
9.4
Cable Specification
When wiring PLC system, it is recommended to use the multi-strand copper wire and ready-made isolated terminals to ensure the wiring quality. The recommended cross-sectional area and the model of the wire see Table 9-1.
Table 9-1 Recommended cable model of PLC
Wiring terminal and heat-shrink tube to be connected H1.5/14 terminal, or terminal tin-plated H2.0/14 terminal, or terminal tin-plated UT1-3 or OT1-3 cold-pressed terminal, 3 or 4 heat-shrink tube
OT cold-pressed terminal
<5.0 <5.0
Heat-shrink tube
Terminal tin-coat
Line
Figure 9-4
Fix the prepared cable head on the connector of the PLC using a screw. The screw position should be right, and its moment strength should be within 0.5~0.8NM which ensures the connection is reliable and no damage to the screw.
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10.2
10.3
Startup
1. Switch on the PLC, the POWER indicator of the PLC should be on. 2. Startup the Controlstar software, download the compiled user program to the PLC; 3. After checking the download program, switch the operation switch to RUN position, the RUN indicator should be on; if the ERR indicator is on, it indicates that the user program or the system has mistake, then remove the mistake referring to the programming reference manual. 4. Then switch on the circuit breaker of the PLC external system to carry through system debugging.
10.4
RUN/STOP Switchover
The operation statuses of the main module include RUN and STOP. RUN When the main module operation status is ON, user program will be executed by the system, which is a scan period including four tasks (executing the user program communicating housekeeping refreshing I/O). STOP When the main module operation status is STOP, the system does not execute the user program, but still execute other three tasks in a scan period (communicating housekeeping refreshing I/O).
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10.4.1
10.4.2
10.5
Routine Maintenance
The routine maintenance should check the following: Ensure the clearance of the PLC operation environment, and avoid the impurity and the dust falling inside the PLC. Keep the ventilation and heat dissipation of the PLC in good condition. All the wiring and the terminals are reliable fixed and in the normal state.
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Observe the PLC BATT indicator and know the capacity state of the standby battery. When the BATT indicator flashing, it indicates that the battery capacity is insufficient and the new button lithium cell should be replaced during a month; when the BATT indicator is on, it indicates that the battery voltage is severe insufficient or battery lost, and a new button lithium cell should be replaced as soon as possible. Only trained personnel can replace the cell; the power must be disconnected; the shorter the replacement time the better; the replacement should be within one minute to avoid losing the backup data and the real time clock data.
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Chapter 11 Troubleshooting
Chapter 11 Troubleshooting
When the PLC works abnormally, first check the wiring of the power supply line and the status of the relative switches and protective device; if PLC is power on, check whether the user ports are fastness, the position of the run control switch is right; if all the conditions are normal but the PLC still does not work, you can analyze the problem according to the PLC operation state and the I/O state LEDs in Table 11-1.
Table 11-1 Faults and actions
Cause Power off or power source voltage too low Power source switch or fuse disconnected Power source wiring abnormal Power source board damaged Bad contact of power source circuit Too many expansion module connected to result in current limit 24V/COM auxiliary power source output short circuit and result in current limit User program mistake
Actions Check power source Check switch, line, and fuse state Check: 1) the voltage between L and N terminal is within the normal range 2) whether a short circuit or overload occur between 24V and COM port
Use ControlStar to re-compile the user program and download again Actual run time exceeds the WDT setting time Increase the WDT setting time BATT LED blinking Cell low voltage alarm Replace button cell BATT LED is on Cell voltage low or no stand-by cell ON/TM/OFF is not in ON position Toggle the switch to ON position Set the run control mode as port mode, but Close the setting control run port RUN LED is off the port is in OFF position The host remote control power off Make the host remote control power on Power off due to system mistake Check PLC application system Modify the electric parameters of the external circuit to the Input state LED Conducting resistance of user line toobig suitable value, shorten the wire length and do not use thin inconsistent with the wire input port state Bad contact of the signal circuit Check wiring Can not shutdown the Bad contact of the external wiring output (OFF) Relay contactors damaged The relay port with frequently action can exchange with the Status LED idle port inconsistent with output Relay aging or LED damaged port state Can not download / Bad contact of cable wiring, the position of Use the specialized communication cable of Emerson to upload / monitor ON/TM/OFF switch wrong download Bad contact of cable wiring, or the signal characteristic mistake, such as confusing TXD Connect signal wire correctly with RXD Serial port can not Communication parameters of slave/master control other computer are inconsistent, such as baudrate, Set the communication parameters consistent equipment checking, data bit and address Communication protocols used by Set the communication parameters consistent slave/master computer are inconsistent I/O expansion board or Power off , check and get rid of the problem, then power on special expansion Bad contact of expansion wire again. board no response In most conditions, input signal waveform has Parallel connecting a 22uF50V capacitor with the counter much bigger interference input port (note the capacitor polarity) Low-speed counting If the user program executing time is too long, the counter inaccuracy In few conditions, the cycle of detected signal signal should connect with the high speed counting port. If is shorter than the executive cycle of the PLC. the setting is constant scan, the scan time should be set reasonably. ERR LED blinking
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Basic instructions
SFC instructions
34
Shift/rotate instructions
35
36
37
38
SM7
SM8 SM9
Clock bit
Address SM10 SM11 SM12 SM13 SM14 SM15 10ms clock 100ms clock 1s clock 1min clock 1hour clock Scan period oscillation bit Title Action and function Clock oscillation period is 10ms (turn over per half period, and the half of the first run period of the user program is 0) Clock oscillation period is 100ms (turn over per half period, and the half of the first run period of the user program is 0) Clock oscillation period is 1s (turn over per half period, and the half of the first run period of the user program is 0) Clock oscillation period is 1min (turn over per half period, and the half of the first run period of the user program is 0) Clock oscillation period is 1hour (turn over per half period, and the half of the first run period of the user program is 0) The bit turns over once per scan period ( the first period of the user program is 0) R/W R R R R R R
Interrupt control
Address SM40 SM41 Title X0 input rising/falling edge interrupt enable flag bit X1 input rising/falling edge interrupt flag bit Action and function Set as 1, enable entering X0 rising edge (falling edge) interrupt Set as 1, enable entering X1 rising edge (falling edge) interrupt R/W R/W R/W
Chapter 13
Address SM42 SM43 SM44 SM45 SM46 SM47 SM65 SM66 SM67 SM68 Title X2 input rising/falling edge interrupt enable flag bit X3 input rising/falling edge interrupt enable flag bit X4 input rising/falling edge interrupt enable flag bit X5 input rising/falling edge interrupt enable flag bit X6 input rising/falling edge interrupt enable flag bit X7 input rising/falling edge interrupt enable flag bit High-speed counting interrupt enable flag bit Timing interrupt 0 enable flag bit Timing interrupt 1 enable flag bit Timing interrupt 2 enable flag bit Action and function
Special Register
39
R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W
Set as 1, enable entering X2 rising edge (falling edge) interrupt Set as 1, enable entering X3 rising edge (falling edge) interrupt Set as 1, enable entering X4 rising edge (falling edge) interrupt Set as 1, enable entering X5 rising edge (falling edge) interrupt Set as 1, enable entering X6 rising edge (falling edge) interrupt Set as 1, enable entering X7 rising edge (falling edge) interrupt Set as 1, enable entering Set as 1, enable entering timing interrupt 0 Set as 1, enable entering timing interrupt 1 Set as 1, enable entering timing interrupt 2
When STOP RUN, reset. When the port has HCNT high speed count drive instruction and SPD pulse density detecting instruction, the pulse catch of the port is invalid; and it is valid in other situations. Detailed information refers to SPD and HCNT instructions. The total input number of X0~X7 pulse in the hardware mode ( pulse catch, SPD instruction, no high-speed compare instruction for HCNT) is less than 60K; and is less than 30K in the software process ( using DHSCS, DHSCI, DHSZ, DHSP and DHST instructions in driving high-speed counter).
Free-port (COM 0)
Address Title Action and function When using XMT instruction, the bit is set; and the bit is cleared after sending is finished. When the bit is cleared, the current sending task of the Port 0 is paused; and it continues to send when the power-flow conducts. When using CRV instruction, the bit is set; and the bit is cleared after receiving g is finished. When the bit is cleared, the current receiving task of the Port 0 is paused; and it continues to receive when the power-flow conducts. The bit is set when the sending is finished. The bit is set when the receiving is finished. The flag bit is set when the serial port doesnot have communication task. R/W R/W
SM111 Port 0 receiving enable flag SM112 Serial port 0 sending END flag SM113 Serial port 0 receiving END flag SM114 Serial port 0 idle flag
40
MODBUS communication
Address SM135 SM136 Title MODBUS communication finished MODBUS communication mistake Action and function The bit is set when the communication is finished . The bit is set when the communication is mistake. R/W R/W R/W
SM190
SM191
General module bus mistake flag bit Special module bus mistake flag bit
SM192
Special Register
41
R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W
When SM2 _ _ is high level, its corresponding C2_ _ changes to counting down. When SM2 _ _ is low level, its corresponding C2_ _ changes to counting up.
When corresponding SM2 _ _ is high level, its corresponding C2_ _ changes to counting down. When corresponding SM2 _ _ is low level, its corresponding C2_ _ changes to counting up.
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When the C2_ _ of the dual-phase single-end and the dual-phase dual-end counters are counting down mode, the corresponding SM2_ _ changes to high level; when they are counting up mode, SM2_ _ changes to low level.
13.2
SD05
10-100ms
Expansion I/0 module number Special module number Setting run control input point, using decimal system (such as X0 displays as 0, X10 displays as 8, the maximum number is 15). (Only configured through the system block). Main module I/O point High byte: input; Low byte: output Expansion module I/O High byte: input; Low byte: output point
R R R R R 0-15
Save the latest 5 run error type codes according to queue sequence; SD20 always saves the latest occurring error type code.
FROM/TO error
Address SD25 SD26 Title When using FROM/TO instruction, the mistaken special module numbering occurs ( starting from 0). When refreshing I/O, the mistaken I/O chip numbering occurs (starting from 0). R/W R R Range Initial value: 255 Initial value: 255
Scan time
Address SD30 SD31 SD32 Title Current scan value Minimum scan time Maximum scan time Action and function Current scan time (unit: ms) Minimum value of scan time (unit: ms) Maximum value of scan time (unit: ms) R/W R R R Range
Chapter 13
Address Title
Special Register
R/W Range
43
SD33
SD34
Action and function Initial value: 0ms, unit: 1ms. When the constant scan time is longer than the setting value of user monitoring overtime, user program gives overtime alarm. When some scan cycle of user program is Constant scan time longer than the constant scan time, the cycle constant scan mode is setting value invalid automatically and no alarm. When the setting value of SD33 is bigger than 1000ms, process it according to 1000ms. (Only configured through the system block). Initial value: 100ms, can be modified by user program and will be effective in the next scan cycle. User program When SD34 value is less than 100, process it according to 100. overtime setting value When the SD34 value is bigger than 1000, process it according to 1000. (Only configured through the system block).
0-1000ms
100-1000ms
Real-time clock
Address Title Register content SD100 Year For real-time clock SD101 Month For real-time clock SD102 Date For real-time clock SD103 Hour For real-time clock SD104 Minute For real-time clock SD105 Second For real-time clock SD106 Week For real-time clock Users can but set through TWR instruction or the host. R/W R R R R R R R Range 2000~2099 1~12 months 1~31 days 0~23 hours 0~59 minutes 0~59 seconds 0(Sunday)~6(Saturday)
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SD110.3 Stop bit SD110.4 parity check SD110 SD110.5 parity check permission SD110.6 Character data bit SD110.7 SD110.8 free-port receiving start mode SD110.9 free-port receiving end mode SD110.10~SD110.11 SD110.12-SD110.15 Start word End word Word overtime time Frame overtime time
SD115
SD116 SD117
Default 0ms (ignoring word-space overtime) Default 0ms( ignoring frame overtime) Bit 0: set when user stop receiving Bit 1: set when receiving specified end word Bit 2: set when receiving maximum character No. Receiving end message code Bit 3: set when word-space overtime Bit 4: set when (frame) receiving overtime Bit 5: set when parity check error Bit 6~15: reserved. Users can ignore it. Current receiving character Current receiving character total number
1~32767ms 1~32767ms
R R
SD120
SD120.3 Stop bit SD120.4 parity check SD120.5 parity check permission SD120.6 Every character data bit
Chapter 13
Address SD120 Title SD120.7 SD120.8 free-port receiving start character mode SD120.9 free-port receiving end character mode SD120. 10-SD120.15 Start character End character Word-space overtime time Frame overtime time Register content Reserved 1=have specified start character 0=no specified start character 1-have specified end character 0-no specified end character Reserved
Special Register
R/W Range
45
SD125
Default 0ms (ignoring word-space overtime) Default 0ms( ignoring frame overtime) Bit 0: set when user stop receiving Bit 1: set when receiving specified end word Bit 2: set when receiving maximum character No. Bit 3: set when word-space overtime Bit 4: set when (frame) receiving overtime Bit 5: set when parity check error Bit 6~15: reserved. Users can ignore.
0-32767ms 0-32767ms
SD126 SD127
R R
MODBUS setting
Address SD130 SD135 SD136 SD137 SD139 Title Station number setting (COM0) Station number setting (COM1) Max. overtime setting (after sending and before receiving) (COM1) Retry times (COM1) MODBUS main station error code (COM1) R/W R/W R/W R/W R/W R range
0-100