EC20 Series PLC User Manual.pdf

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EC20 Series PLC

User Manual

Version V1.1

Revision date

June 26, 2006

BOM 31011166

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

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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:

z 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.

z For the safe operation of the equipment and output signals of the serious accident, please design the external protection circuit and the safety mechanism.

z 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.

z 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.

z 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

z 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.

z 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. z 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.

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z Do not wire, inset or pull out the cable plug with power applied. Otherwise there is a danger of electric shock or circuit damage.

z Installation and wiring must be fastening and reliable. Bad contact may result in faulty operation of equipment.

z The input/output cable of high frequency signal should use the shielding cable to improve the interference rejection of the system.

Notes for wiring

z 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.

z 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.

z 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.

z Don’t power +24V port of the main module by the external power supply. Otherwise the PLC will be damaged.

z Do not lay I/O signal cables of the PLC next to other power cables or strong interference circuits. z 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

z Do not touch the ports when the power is applied, otherwise there is a danger of an electric shock or faulty operation of equipment.

z 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.

z 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.

z Do not disassemble the PLC. Otherwise it may destroy the inner electrical components.

z 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.

z 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:

z Explosive of the electrolytic capacity: The capacities on the circuit board may explode when burning. z Exhaust gas when burning: The main body of the PLC is plastic, and it may produce poisonous gas when

burning.

z Disposal of button cell battery: Classified collecting and disposing, and separating from the daily-life rubbish.

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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.

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2 Chapter 2 Product Introduction

Chapter 2 Product Introduction

2.1 Outline

The outline of EC20 main module is shown in Figure 2-1.

1

2

3

4

5

6

7

8

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12

13

14

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Figure 2-1 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 Internal Memory Capacity Of User Program

The user program is 8K words (16K byte) at most and supports 8,000 data blocks of D register.

2.4 Resource Configuration Of System Soft-device

Component Name Quantity Serial No. Note

X Input relay 256 X000~X377 The soft-device numbering is octal code

Y Output relay 256 Y000~Y377 The soft-device numbering is octal code

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Chapter 2 Product Introduction 3

Component Name Quantity Serial No. Note

SM Special auxiliary relay 256 SM0~SM255

S State relay 992 S0~ S991 T Timer 256 T0~T255 100ms precision: T0~T209 10ms precision: T210~T251 1ms precision: T252~T255 C Counter 256 C0~C255

16 bit common increasing counter: C0~C199 32 bit common decreasing counter: C200~C235 32 bit high-speed counter: C236~C255

D Data register 8000 D0~D7999

V Local data register 64 V0~V63

Z Indexed addressing

register 16 Z0~Z15

SD Special data register 256 SD0~SD255

2.5 High-speed Input/Output Function

High-speed port

name High-speed port type Input/output mode Max. frequency of input/output signal

X0, X1 Input High-speed pulse count Single input: 50KHz;

X0~X5 input at the same time: frequency sum is 80KHz

X2~X5 Input High-speed pulse count Single input: 10KHz

Y0, Y1 (only suitable

for transistor output) Output High-speed pulse output Two ports output independently: 100KHz

2.6 Filter Function Of Input Port

Function Description

Digital filter function X0~X17 provide digital filter function, and filter time is within 0~60mS, set by user’s program

Hardware filter function Other X input ports

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 Reinforced Debugging Function

Provide register-forced function, convenient for debugging and analyzing the user program, improving debugging efficient. Permit the most 128 bit-registers and 16 word-registers.

2.10 Support Online Modification

Users can modify the program online during operation, which is greatly convenient for modifying and upgrading the user program in important production situation.

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4 Chapter 2 Product Introduction

2.11 Multiple Password Protection Function

The product provides three password authorities, which is convenient for user program access control and protecting the intelligence property.

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 RUN And STOP Control

RUN or STOP of the EC20 can be controlled through the following methods: the RUN/STOP switch, ControlStar program system, communication port (i.e. Modbus), and standard input ports X0~X7, which are convenient for controlling system operation

2.14 User Program Developing And Debugging

Provide the integrated ControlStar program system compatible with IEC61131-3 standard, and uses ladder diagram, instruction list, and sequential function diagram to program. The unit has such functions as monitoring, debugging, and modifying on-line. The program system also provides strong instruction guide and on-line help.

2.15 Communication And Networking

The main module has two asynchronism serial communication ports (COM1 provides RS232 and RS485 level), for communication with personnel computer, HMI and other equipment; and the main module has an inner standard Modbus protocol to compose 1:N network; and supports freedom protocol.

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Chapter 3 Installation 5

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 Requirements For Installation Position

To prevent a rise in temperature, mount the PLC up and down to the backboard of thecabinet horizontally. Never mount them to the floor or ceiling of an enclosure or other directions, as shown in the Figure 3-1. You must provide a clearance of at least 15 mm, both above and below the units, for proper cooling. No heat generating equipment

should

exist around the PLC.

Figure 3-1 Requirements for installation position

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.

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6 Chapter 3 Installation

Pull out the Clip of DIN rail

Snap the clip of the DIN rail DIN rail with 35mm width

DIN rail stop DIN rail stop

Figure 3-2 Installing a PLC onto a standard rail

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 Φ4 mounting holes on the enclosure of the PLC (while EC20-2012BR/BT has only two Φ4 fix screws) to fix the PLC on the back panel of the electric cabinet, as shown in the Figure 3-3.

4 mounting holes

M3 fix screw

Figure 3-2 Installing a PLC onto a panel with fix screws

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:

DIN rail (35mm)

Figure 3-4 Dimensions of outline and mounting holes of EC20-2012BR and EC20-2012BT

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 Dimensions of outline and mounting holes of EC20-3232BR and EC20-3232BT

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.

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Chapter 3 Installation 7

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8 Chapter 4 Product Specifications

Chapter 4 Product Specifications

4.1 Model Legend

Addition (A: AC 220V input power) D: DC 24V input power N: No power

EC 2 0 - 20 12 B R D

Output mode (R: relay; T: transistors)

Module type (B: main module; E: expansion module) Output points

Input points Version

Series No. (1:micro-type; 2:minitype; 3:medium-sized; 4:large-sized Emerson PLC

Figure 4-1 Model Legend of PLC

4.2 Product Model And Configuration

4.2.1 Main Module

Table 4-1 Model and I/O configuration of EC20 series PLC,

Model Power voltage

Vac Input / output points Input signal voltage Output type Input port/ common port Output port/ common port Interrupt/ pulse input Pulse output

EC20-2012BRA 90~264 20/12 DC24V Relay 20/1 12/5 Yes No

EC20-2012BTA 90~264 20/12 DC24V Transistor 20/1 12/5 Yes Yes

EC20-3232BRA 90~264 32/32 DC24V Relay 32/1(2)☆ 32/6 Yes No

EC20-3232BTA 90~264 32/32 DC24V Transistor 32/1(2)☆ 32/6 Yes Yes

☆ “ 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 I/O Expansion Module

Table 4-2 I/O expansion module and configuration of EC20 series PLC

Model Power Supply Vac Input/output points Output type Inner power supply

EC20-0808ERN - 8/8 Relay No

EC20-0808ETN - 8/8 Transistor No

EC20-1616ERA 220Vac 16/16 Relay Yes

EC20-1616ETA 220Vac 16/16 Transistor Yes

EC20-1600ENN - 16/00 - No

EC20-0016ERN - 00/16 Relay No

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Chapter 4 Product Specifications 9

4.2.3 Special Function Module

Table 4-3 Special function module of EC20 series

Model Function

EC20-4AD 4-channel analog signal input module

EC20-4DA 4-channel analog signal output module

EC20-4TC 4-channel thermocouple temperature input module

EC20-4AM 2-channel analog signal input module, 2-channel analog signal output module

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 Product size

Model Length (mm) Width (mm) Height (mm) Net weight

EC20-2012BR 158 90 82 680g

EC20-2012BT 158 90 82 680g

EC20-3232BR 227 90 82 950g

EC20-3232BT 227 90 82 880g

EC20-0808ER, 4AD, 4DA, 4AM, 4TC 58 90 82 240g

4.4 Environmental Requirements

Table 4-5 Requirements of operation, storage, and transport environments of EC20 series PLC Environmental parameters

Type Parameter Unit

Environmental conditions for operation

Environmental conditions for transport

Environmental conditions for storage

Low temperature °C -5 -40 -40

Temperature

High temperature °C 55 70 70

Humidity Relative humidity % 95 (30 ± 2°C) 95 (40 ± 2°C) /

Low pressure kPa 70 70 70

Climate

Air pressure**

High pressure kPa 106 106 106

Bit shift mm 3.5 (5-9HZ) / / Sinusoidal vibration acceleration M/s2₁₀_(9-150HZ) _/ _/ acceleration spectra density m2_/s3 (dB/Oct) / 1.92 (5-20Hz) -3db (20-200Hz) / Frequency range Hz / 5-200 / Random vibration

Vibration direction / X/Y/Z /

Type / Half-sine wave /

Impact

acceleration m/s2_/ ₁₈₀ _/

Mechanical stress

Drop Drop height m / 1 /

4.5 Electric Insulation Specifications

Table 4-6 Electric insulation specifications of EC20 series PLC

Type Value Test conditions

AC input to case ≥ 5%106_Ω

AC input to DC output ≥ 5%106_Ω

Insulation resistance

DC output to case ≥ 5%106_Ω

Ambient temperature: 25 ± 5°C; relative humidity 90% (no condensing); test voltage: 500Vdc

AC input to case (PG port)

AC input to the port between the user input and output AC input to expansion busbar

User output (relay board) to expansion busbar User input to user output (relay)

Insulation voltage

Between user output ports (relay board)

Capable of withstanding 2830Vac/50Hz AC voltage (or equivalent DC voltage) 1 minute, with leakage current ñ30mA, and no breakdown or flashover

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Type Value Test conditions

Insulation voltage

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 MTBF of EC20 series PLC

Output type Time Conditions

200,000 hours Fix on the floor , mechanical stress is almost close to zero, with temperature and humidity control Relay

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 Transistor

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 Use life of EC20 series output relay

Load capacity Action frequency Life-span of contactors

220Vac, 15VA, inductive load 1sec. ON / 1sec. OFF 3,200,000 times

220Vac, 30VA, inductive load 1sec. ON / 1sec. OFF 1,200,000 times

220Vac, 60VA, inductive load 1sec. ON / 1sec. OFF 300,000 times

4.7 Power Supply Specifications

4.7.1 Inner Power Supply Of Main Module

Table 4-9 Power supply circuit character of EC20 series PLCs

Item Unit Min. Typ. Max. Note

Input voltage Vac 90 220 264 Normal start and operating range

Limiting input voltage Vac 85 - 280

Operating at 280V for 3 hours and not damaged

Each circuit can power 70% rated load at 85-100Vac, and power 55% rated load at 264-280Vac

Input current A / / 1.5 90Vac input, full load output

5V/GND V 4.75 5 5.25 Output1 24V/GND V 21.6 24 26.4 Output2 Output voltage 24V/COM V 21.6 24 26.4 Output3 5V/GND mA 1000 24V/GND mA 650 Output rated current 24V/COM mA 600

The capacity is the sum of the main module inner consumption and the expansion module load. The maximum output power is 35W, which is the sum of each circuit output with full load. The module is natural cooling

4.7.2 Use Of Each Circuit Output Power

1. Output1 (5V/GND): Output1 is the working power of the PLC main module logic circuit, and provides power supply to the expansion module logic circuit through the expansion port of the module at the same time. And this power will not be used for the expansion module with self-carried power source.

2. Output2 (24V/GND): Output2 is the working power of the PLC main module relay output circuit, and provides power supply to the expansion module relay output circuit through the expansion port of the module at the same time. Output1 and output2 share the common ground. And this power will not be used for the expansion module with self-carried power source.

3. Output3 (24V/COM): Output3 is the 24V power supply, which is provided to users by the PLC main module. Also it can be used as an auxiliary power to other user circuits, sensors or expansion modules through the “24V” and “COM” ports of the main module. Output3 is electrical isolated with Output1 and Output2.

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Chapter 4 Product Specifications 11

4.7.3 Power Specifications Provided By Main Module To Expansion Module

Table 4-10 Power capacity consumption and load current provided

Logic circuit power supply Auxiliary power supply output

5V/GND 24V/GND 24V/COM Model Inner consumption* Capacity provided* Inner consumption Capacity

provided Inner consumption Capacity provided

EC20-2012BR 250mA 750 mA 70 mA 580 mA

EC20-2012BT 400 mA 600 mA 0 650 mA 140mA 460 mA

EC20-3232BR 480 mA 520 mA 240 mA 410 mA

EC20-3232BT 650 mA 350 mA 0 650 mA 240mA 360 mA

*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 25°C. If input voltage is out of rated voltage range or the working temperature exceeds +50°C, 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 Derating Design Of Power Supply Circuit

1. Relation between power supply output capacity derating and power supply input voltage

When the input voltage of the PLC is beyond the rated voltage range, users should consider decreasing the main module’s output power to the expansion module. The derating relation is shown in Figure 4-2.

Power load %

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 %

Operation ambient

temperature °C

-5°C 50°C 55°C

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4.7.5 Power Consumption Of Expansion Module

Table 4-11 Power consumption of each expansion module Max. current consumption Model

5V/GND 24V/GND 24V/COM

EC20-0808ER 30mA 50mA 50mA

EC20-0808ET 80mA 0 50mA

EC20-4AD 50mA 0 25mA

EC20-4DA 50mA 0 120mA ☆

EC20-4AM 50mA 0 90mA ☆

EC20-4TC 50mA 0 25mA

☆: 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 Power Capacity Calculation In Expansion Connection

Before the PLC connects with an expansion module, users should calculate the current sum of each power supply of the expansion module, and ensure the current sum is less than the output current provided by the corresponding power supply of the main module to avoids the over loading of the main module power supply.

Example 1: the main module is EC20-2012BR, at 25°C ambient temperature, two EC20-0808ET, two EC20-4AD, one EC20-4DA and one EC20-4TC shall be connected to, verifying the feasibility.

Checking computations as following:

Power circuit Current provided by the main module Actual consumed current conclusion

5V/GND 750mA (80×2+50×2+50+50) = 360mA Pass

24V/GND 580mA (0×2+0×2+0+0) =0 mA Pass

24V/COM 460mA (50×2+25×2+110+25) = 285mA Pass

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 25°C 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 Current provided by the main module Actual consumed current conclusion

5V/GND 350mA (80×3+50×2+50+50)=440mA Un-passed

24V/GND 650mA (50×3+0×2+0+0)=150mA Pass

24V/COM 360mA (50×3+25×2+120+25)=345mA 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 Programming Tool Of User Program

ControlStar programming system provides the programming, up/down-loading, debugging and monitoring the user program of the EC20 series PLC. The system also provides abundant help information, which can use ladder diagram, instruction list and sequence functional diagram to program.

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Chapter 5 Input Characteristic 13

Chapter 5 Input Characteristic

5.1 User Ports Of Main Module

The outline and the ports of EC20-2012BR and EC20-2012BT are the same. Their port wirings are shown in Figure 5-1:

PG COM X0 X2 X4 X6 X10 X12 X14 X16 X20 X22 L N X1 X3 X5 X7 X11 X13 X15 X17 X21X23

Wiring of EC20-2012BR and EC20-2012BT

+24V Y0 Y1 Y2 Y4 Y6 Y10 Y12 Y13 Y5 Y7 Y11 COM COM 0 COM 1 COM 2 Y3 COM 3 COM 4

Figure 5-1 The outline and the port of EC20-2012BR and EC20-2012BT

The pin definitions of EC20-2012BR and EC20-2012BT are listed in Table 5-1:

Table 5-1 Pin functions of EC20-2012BR and EC20-2012BT

Pin Function Note

L/N 220Vac AC power input port, L is live line, N is neutral line

PG Earth port

● Null port, used for isolation and not wiring

X0~X23 User input signal ports, used together with COM can produce input signal

COM 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

+24V The auxiliary power to user external equipment , used together with COM

Y0, COM0 Control output port, group 0

Y2, Y3, COM2 Control output port, group 2

Y4~Y7, COM3 Control output port, group 3

The COMx (COM0 ~ COM4) of each output group are electrical isolated one another

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:

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14 Chapter 5 Input Characteristic PG COM X0 X2 X4 X6 X10 X12 X14 X16 X20 L N +24V X1 X3 X5 X7 X11 X13 X15 X17 X21 X24 X23 X33 X37 X22 COM X25 X27 X31 X26 X30 X32 X34 X36 X35

Wiring of EC20-3232BR and EC20-3232BT

Y0 COM₂ Y5 Y7 Y11 Y13 Y15 Y17 Y21 Y6 COM Y12 Y14 Y16 Y20 Y22

3

Y25

Y24 Y34

Y23 Y3

Y26 Y30 Y32

Y27 Y31 Y33 Y35 Y37 Y36 Y1 COM 0 COM1 Y2 Y4 Y10 COM 4 COM5

Figure 5-2 Outline and port layout of EC20-3232BR and EC20-3232BT Table 5-2 Pin definition

Pin Function Note

L/N 220Vac AC power input port, L is live line, N is neutral line

PG Earth port

● Null port, used for isolation and not wiring

X0~X37 User input signal ports, used together with COM can produce input signal

COM 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.

+24V The auxiliary power to user external equipment , used together with COM.

The COMx (COM0~COM4) of each output group are electrical isolated one aother.

5.2 Input Port Characteristic And Signal Specification

Table 5-3 Input port characteristic and signal specification

Item High-speed input port X0~X7 General input port

Signal input mode Leak mode, users only need to connect dry contact with Xn and COM ports.

Test voltage 24Vdc

Input impedance 3.3k 4.3k

Input ON External circuit resistance < 400Ω

Electric parameters Electric

parameters _{Input OFF} _{External circuit resistance > 24kΩ}

Digital filter X0~X17 have digital filtering function, the filtering time can be set within 0~60ms

Filtering

function Hardware filter Except for X0~X17, other I/O ports are hardware filtering, filtering time is about 8mS.

High-speed function

X0~X7 have high-speed counting, interrupt, and pulse catching function. The highest counting frequency of X0 and X1 port is high up to 50KHz The highest counting frequency of X2~X5 port is high up to 10KHz

Input Only has one common port: COM

Common port

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5.3 Inner Equivalent Circuit Of Input Port

There is a user switch status detecting power supply (24Vdc). Users only need to connect to the switching signal of the dry contact. If the output signal of active transistor sensor is connected to, an OC output signal is needed. Figure 5-3 shows the signal input and inner equivalent circuit of the PLC, and user’s circuit connects with PLC inner circuit through the connecting port.

24Vdc auxiliary power supply Logi c pr ocessi ng ci rc ui t

Working power for inner logic circuit

24V+ 24V -24V+ COM X0 X1 X2 Xn Sensor

User signal wiring Inner equivalent circuit of PLC main module

24V/5V/GNG Var ious si gnal input equi pme n t

Figure 5-3 Inner equivalent input circuit of the main module (upon delivery)

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 Screen print illustration

JP0 JP1 JP2

Source input mode % %

Drain input mode (default setting) %

The equivalent input circuit changed to the SOURCE input mode is as Figure 5-4:

COM X2 24V-X0 Xn 24V+ 24V+ X1

User signal wiring

24Vdc auxiliary

power supply Working power for_{inner logic circuit} 24V/5V/GND Logic p rocessing cir cuit V ar ious signal input e quipment

Inner equivalent circuit of SOURCE input mode of the main module

For equipment w ith self -carried power source (24 V dc)

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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, you’d 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:

Logi c ci rc ui t Provided by extension cable To 24V+ of main module To COM of main module

X0 X1 X2 Xn Sensor Si gnal input equi pmen t

User signal wiring _{Internal equivalent circuit of the}

PLC extension module Power supply of logic_{circuit : 24V/5V/GND}

24V+

Figure 5-5 Inner equivalent input circuit of the I/O expansion module

5.4 Input Connection Of High-speed Counter

Table 5-5 the counter connection method and characteristic realized by X0~X7 Counter Input point X0 X000 X001 X002 X003 X004 X005 X006 X007 Max. Fre. (KHz) Counter C236 Up/down 50 Counter C237 Up / down 50 Counter C238 Up / down Counter C239 Up / down Counter C240 Up / down Counter C241 Up / down

Counter C242 Up/down Reset

Counter C243 Up / down Up / down

Counter C244 Up/down Reset Reset

Single-phase single-end count input mode

Counter C245 Up / down Up / down Reset

10

Counter C246 Up Down 50

Counter C247 Up Down Reset

Counter C248 Up Down Reset

Counter C249 Up Down Reset Start

Single-phase up/down count input

Counter C250 Up Down Reset Start

10

Counter C251 Phase A Phase B 30

Counter C252 Phase A Phase B Reset

Counter C253 Phase A Phase B Reset

Counter C254 Phase A Phase B Reset Start

Two-phase up/down count input

Counter C255 Phase A Phase B Reset Start

5

Among which:

Phase A: phase-A input port of the two-phase counter; Phase B: phase-B input port of the two-phase counter.

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5.5 Interrupt Input Connection

For the system that responds promptly to the input signal, it can use the interrupt to process the signals. The input ports of X0~X7 have interrupt function and corresponds to the eight external interrupt sources.

If the input port is used as interrupt process mode, the corresponding interrupt control identification should be enabled when programming and the corresponding interrupt routine should be programmed (for details, refer to

Programming Reference Manual). When using interrupt, the digital filter function of corresponding X port will be disabled and the filter time of the corresponding port is set as zero automatically.

z When used as high-speed count input or interrupt input, the corresponding input port should use shielding wire, and the shielding wire should connect to earth line (same as PG port) to improve the interference rejection. z Some counters require multiple X input ports to realize (for example, C242, C244, and C254 consist of 2, 3, 4

ports separately). After using this kind of counter, the used ports cannot be used as input of other counters and the common input mode.

z The input port of the counter has the limitation for the maximum frequency. Beyond the limitation, it may result the incorrect counting or normal operation of the system. You should use the input port reasonable and select the suitable external sensors.

5.6 Input Signal Status Indication

The input status LEDs indicate the status of the user input port. When the input port is closed (“ON” state), the LED is on; otherwise the LED is off. When the X0~X7 ports input high frequency signal, the flashing frequency of the LED may be lower than that of the actual input signal, which is for the convenience of the user to observe the

characteristics of the port signals.

Output terminal status LEDs Working status LEDs Input terminal status LEDs

Figure 5-6 Status LEDs of EC20 series main module

5.7 Analog Potentiometer And Application

The analog potentiometer provides external channel for users setting inner soft-device, which is within 0~255 and read by user program.

When adjusting the setting value, users can use a small Philips screwdriver to rotate the potentiometer clockwise to increase the setting value, and counter clockwise to decrease it. The maximum angle of rotation is 270°. Do not energize excess.

5.8 Example Of Input Connection

Figure 5-7 shows an example: an EC20-3232BT connects with an EC20-0808ER to realize a simple position control. The high-speed counting ports of X0 and X1 detect the position signal from the encoder. The high-speed ports of X3~X7 connect to the travel switch which needs quickly response, other user signals can be distributed with input ports.

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18 Chapter 5 Input Characteristic L PG N 24V COM AC-L AC-N X0 X1 +24V +5V GND EC20-3232BT 0808ER Xm Xn 24V X3 X2 X4 X5 Xn Xm S ensor X7 X6 X10X11 X36 X37 A B Z +24V VG ND PG Switch power supply

Using terminal block connects to COM

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Chapter 6 Output Characteristic 19

Chapter 6 Output Characteristic

6.1 Output Port Application

1. The output type of EC20 series PLC can be divided into relay type and transistor type. Both types are greatly different in the operation parameters. You should distinguish the difference before using them to avoid the damage by the misuse.

2. To protect the contacts of the PLC output relay, when the drive DC circuit is inductive (such as relay coil), a fly-wheel diode shall be connected to the user circuit; when the drive AC circuit is inductive, a RC surge absorber shall parallel connect to the user circuit. In principle, the relay output port does not connect to the capacitive load. If there is necessary to use, its surge current must be less than the maximum current in the specification list (see Table 6-1).

3. The transistor output port should be within the limitation of the allowable maximum current (see Table 6-1) to ensure the thermal value of the output port is limited in the allowable range. If output currents of multiple transistors are bigger than 100mA, they should be distributed equally in the output ports. Distributed adjacent will affect the heat dissipation.

4. It is recommended the output points which are in the ON (conducting) state at one time shall not exceed 60% total output points for a long time.

Table 6-1 Comparison of relay output and transistor output

Item Relay output Transistor output

Output

action Dry contact output, output state is “ON” (conducting) , contacts are closed; output state is ”OFF”, contacts are open. Common

port

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.

Voltage 220Vac; 24Vdc, no polarity requirement 24Vdc, polarity requirement Current Accord with output electric specifications (see Table 6-2)

Difference High drive voltage, high current Low drive current, high frequency, long lifespan Application To drive the load with low action frequency such

as: intermediate relay, contactor coil, and LEDs

To apply in the situation with high frequency and long life, such as control servoamplifier and electromagnet with frequent action

6.2 Electric Specifications Of Output Port

Table 6-2 Electric specifications of output port

Item Relay output port Transistor output port

Loop power supply voltage Below 250Vac, 30Vdc 5~24 Vdc Output current

Single point: 2.0A /250Vac The total current of the 8 points sharing COM port is less than 8A.

0.5A 24Vdc

The total current of the 8 points sharing COM port is less than 2A.

Circuit insulation mechanical insulation Optical coupling insulation Act indication Relay output contacts closed, LED

on Optical coupling is driving, LED on Leakage current at open

circuit - Less than 0.1mA/30Vdc

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20 Chapter 6 Output Characteristic

Item Relay output port Transistor output port

Resistive load

2A/1 point;

8A/4 points, using a COM 8A/8 points, using a COM

Y0, Y1: 0.3A/1 point; Others: 0.3A/1 point; 0.8A/4 point; 1.6A/8 point;

Above 8 points, total current increases 0.1A at 1 point increase Inductive load 220Vac，80VA Y0, Y1: 7.2W/24Vdc

Others: 12W/24Vdc

Max. output curr

ent

Electric light load 220Vac，100W Y0, Y1: 0.9W/24Vdc Others: 1.5W/24Vdc ON response time 20ms Max

OFF response time 20ms Max

Y0, Y1: 10uS ; Others: 0.5ms Y0,Y1 max. output

frequency - Each channel : 100KHz

Output common port 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. Fuse protection No

6.3 Output Port Connection

The inner equivalent circuit of the output part of the relay output PLC is shown in Figure 6-1:

Y0 Y2 Y3 COM0 COM1 Y1 COM2 Y4 Y5

Inner equivalent circuit of PLC Working power of inner logic circuit Logi c pr oc es si ng c irc ui t Output dr iv e ci rc ui t Output group o Output group 1 Output group 2 24Vdc power

Figure 6-1 Inner equivalent circuit of output part of relay output PLC

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:

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Chapter 6 Output Characteristic 21 Inductive load 24V -24V + 1N4004 Y7 Fly-wheel diode Inductive load 24V -Y1 Fly-wheel diode 24V + 1N4004 R=200Ω, 2W R AC - N C Y11 AC - L C=0.022uF , 250Vav Inductive load

Figure 6-2 Protective circuit of PLC output contact

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.

5Vdc power Logi c pr oc es si ng c irc ui t

Working power of inner logic circuit

Y0

Y2

Y3

Inner equivalent circuit of PLC

Output dr iv e ci rc ui t COM0 COM1 Y1 COM2 Y4 Y5 Output group 0 Output group 1 Output group 2

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22 Chapter 6 Output Characteristic

6.4 Output Port Status Indication

The status of the control output port is indicated by the output status LEDs. When the output port is closed (ON) state (the status between Yn and COMn is closed), the LED is on; otherwise the LED is off. When the Y0 and Y1 port of the transistor output PLC output high frequency signal, the flashing frequency of the LED may be lower than the actual output signal frequency, which is convenient for user observation.

6.5 Example Of Output Connection

Figure 6-4 shows the connection between one EC20-3232BR and one EC20-0808ER, different output group can connect to the different signal voltage loop. Some output group (i.e. Y0-COM0) can connect to +24Vdc circuit and be powered by 24V/COM of EC20 PLC. Some output group (i.e. Y1-COM1) can connect to +5Vdc low voltage signal circuit. Other output groups (i.e. Y2~Y7) can connect to 220Vac signal circuit. That is to say, different output group can work at different voltage level.

L PG N 24V COM AC-L AC-N X0 X1 +24V +5V GND _EC20-3232BR 0808ER X1 X0 24V X3 X2 X4 X36X37 X7

Y0 COM0 Y1 COM1 Y2 Y3 Y4 Y5 Y6 Y7 COM2 Y30 Y31 Y32 Y33 COM5 Y0 Y1 Y2 COM

AC-L AC-N +5V +24V AB AB AB AB AB AB AB AB AB AB AB AB AB Various low-voltage

signal circuit 220Vac control loadcircuit Switch

power supply

Using terminal block connects to COM

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Chapter 7 Expansion Module 23

Chapter 7 Expansion Module

7.1 Model

The expansion module is used to increase the point configuration of the main module, or to realize expansion part with special function. It must use together with the main module. At present, expansion modules provided by EC20 series are shown in Table 7-1.

Table 7-1 Expansion module provided by EC20 series

Type Model Function

EC20-0808ERN Digital signal 8-channel input, 8-channel relay output I/O expansion

module EC20-0808ETN Digital signal 8-channel input, 8-channel transistor output EC20-4AD 4-channel analog signal input

EC20-4DA 4-channel analog signal output

EC20-4AM 2-channel analog signal input, 2-channel analog signal output Special module

EC20-4TC 4-channel electric couple temperature input

7.2 Expansion Busbar Connection

Power off the main module, remove the cover of the extension port at the right end of the main module, insert the extension cable of the extension module into this port, and replace the cover. Multiple expansion modules can be connected to one by one using this method.

Removing extension port cover before connection

Main module _{Extension cable} Extension module

Figure 7-1 Cascade connection of expansion module

7.3 Expansion Module Addressing

EC20 series main module can automatically recognize the expansion module connected to, and be sequential addressing automatically without user interference.

When the system is normal after power on, the module conducts auto addressing once. Hereafter the address of each expansion module keeps unchanged during operation. Do not connect or disconnect any I/O expansion module or special function modules when the PLC is operating; otherwise the PLC may be damaged and cannot operate normally.

You should power on the expansion module with self-carried power source and the main module at the same time, or power on the expansion module before the main module to ensure the reliable addressing of the expansion module.

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24 Chapter 7 Expansion Module

7.3.1 I/O Point Addressing Number Principle

I/O point numbering uses octal numbering system, and the serial number is as following: 0, 1, 2, 3, 4, 5, 6, 7, 10, 11, 12, 13, 14, 15, 16, 17, 20, 21…, without the figure 8 and 9.

The numbering of the input port of the main module and I/O expansion module is: X0, X1, X2, …X7, X10, X11…; the output port is: Y0, Y1, Y2, …Y7, Y10, Y11…, and so on. Eight point numbers are a group. Insufficient section will be vacant.

For example: EC20-2012BR module, the input port has 20 points, with serial number X0~X23. The port with serial number X24~X24 will be vacant; the X port of the subsequent expansion module is numbering from X30. In the same way, the output port has 12 points, the serial number is Y0~Y13, the port with serial number Y14~Y17 will be vacant and the Y port of the subsequent expansion module is numbering from Y20.

According to the connection sequence to the main module, the numbering of X and Y ports of the I/O expansion module is in the increasing order.

The example for the port logic numbering of the main module and the expansion module is as following:

EC20-2012BR 0808ER 0808ER 4AD 4AD 4DA 0808ER

X0 -X23 X30-X37 X40-X47 0 1 2 X50-X57 3

Y0 -Y13 Y20-Y27 Y30-Y37 Y40-Y47

4TC

7.3.2 Special Function Module Addressing Number Principle

The addressing number of the special function module is according to the unit of the module and independent of I/O expansion module addressing. Its address numbering is as following: 1, 2, 3, …6, 7; the minimum address number is 0; the maximum is 7. Eight special function modules can be connected to at the same time, and the number of the I/O expansion module added later will not affect the special function module addressing number. Take the module addressing number as the distinguishing identification upon call on. The software read-writing the corresponding data buffer memory (BFM) of the module with assigned address can call on the different channel inside the expansion module. More details refer to programming reference manual.

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Chapter 8 Communication And Networking 25

Chapter 8 Communication And Networking

8.1 Communication Port

The main module of EC20 series PLC has two series asynchronous communication ports: COM0 and COM1, supporting baud rate: 38400, 19200, 9600, 4800, 2400, and 1200bps. The feature and the function are shown in Table 8-1.

Table 8-1 Characteristic of communication port of EC20 series main module

Port Socket Signal Work mode Protocol provide Purpose Special programming

protocol

Users programming, debugging and monitoring Supporting 9600bps and 19200bps only

ModBus slave station Can connect to HMI for operation, also network as slave station equipment

COM0 Mini DIN8 RS232 Full-duplex

Free protocol User-defined protocol

ModBus master station network as master station to control other equipment. ModBus slave station Network as slave station equipment and connect to HMI

to operate COM1 EK500V RS232 and can be selected RS232 Full-duplex RS485

half-duplex 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.

ON/OFF confrot and protocol conversion

COM0 port

COM1 port

RS232 RS485

Figure 8-1 Communication port and operation switch

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

ON/TM/OFF switch position status COM0 port operation protocol

ON Operation Decided by user program and system configuration, it may be programming protocol, Modbus protocol, and free-port protocol.

TM(ON TM) Operation

TM(OFF TM) Stop Compulsorily converted to programming protocol . OFF Stop

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.

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26 Chapter 8 Communication And Networking

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

Item Lowest configuration Recommended configuration

CPU Equivalent to Intel Pentium 233 or above Correspond to Intel Pentium 1G CPU or above

Memory 64M 128M

Video card 640×480, 256 800%600 resolution, 65535 color mode Communication port A DB9 output RS232 serial communication port

Others A mouse, PLC program cable produced by Emerson Network Power Co., Ltd., an EC20 series main module, ControlStar programming software.

Detailed information refers to ControlStar Programming Software User Manual.

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

Programming cable B2053RASL1

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Chapter 9 Cable Specification And Wiring 27

Chapter 9 Cable Specification And Wiring

9.1 Connecting Power Supply Cable

Warning

z EC20 series PLC module have two kinds of input power supply: 220Vac and 24Vdc. You should check and identify before the wiring and powering on the module to avoid the equipment damage and other damages due to misoperation.

z The PLC is designed for use in control circuit. There should have SPD in its AC power circuit, and its power circuit should be separated from the power circuit to avoid the overvoltage.

z Do not connect AC power supply with 24Vdc output port of the main module, or connect DC power with 24Vdc output port of the main module.

z Do not connect or disconnect the cable with power on. Otherwise it may get an electric shock or equipment damage. L PG _N 24V COM AC - L AC - N X0 X7 Switch Power supply COM 24V PG 24V Xn Xm 0808ER 4AD 4DA 4AM 4TC +24V +5V GND EC20-2012BR

Figure 9-1b Connection example of AC power and auxiliary power

9.2 Connecting Ground Cable

The reliable connection of an earth line can strengthen the safety and improve the PLC immunity to electromagnetism. When installing, connect PG port of the PLC power supply with the earthing object. It is recommended to use the AWG12~16 connection cable, as short as possible, and use an independent earthing device. A common route with the earthing line of other equipment (especially for the equipment with strong interference) should be avoided. As shown in Figure 9-2: PLC Other equipment PLC PLC

Best Better Worst

Other equipment

Figure 9-2 Earthing wiring example of PLC and other equipment

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:

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28 Chapter 9 Cable Specification And Wiring Better Worse PLC main module Expansion

module 1 Expansion module 2 PLC main _module Expansion module 1 Expansion module 2

Figure 9-3 Earthing wiring example of PLC main module and expansion module

9.3 Connecting Common Port

When wiring PLC system, there may be multiple cables connecting with the same port, such as +24V, COM, output common port COMn (refer to the figures in Section 5.9 and 6.5). The proper wiring method is to use an extension terminal bar with corresponding identification, which is convenient for wiring.

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

Wire Cross-sectional area Recommended model Wiring terminal and heat-shrink tube to be connected AC power wire (L, N) 1.0~2.0mm² AWG12, 18 H1.5/14 terminal, or terminal tin-plated

Earthing line (PG) 2.0mm² AWG12 H2.0/14 terminal, or terminal tin-plated Input signal line (X) 0.8~1.0mm² AWG18, 20

Output signal line (Y) 0.8~1.0mm² AWG18, 20

UT1-3 or OT1-3 cold-pressed terminal, Φ3 or Φ4 heat-shrink tube

The recommended cable preparation is shown in Figure 9-4:

<5.0 <5.0

UT cold-pressed terminal Heat-shrink tube Line

Line number

OT cold-pressed terminal Heat-shrink tube

H-type pre-insulation cold-pressed terminal

Terminal tin-coat Line

Figure 9-4 PLC connection cable preparation recommended

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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Chapter 10 First Operation And Maintenance 29

Chapter 10 First Operation And Maintenance

10.1 Notes For Application

All the notes of the manual should be read prior to using the product. Users should install, wire and check before power on strictly according to the requirements mentioned in this book. Only everything is identified to be okay, can the PLC be powered on.

10.2 Check Before Power On

1. Make sure the power supply input voltage is in complaint with the PLC rated input voltage, the power supply cable connects with the right connectors. Note: 220Vac power ports are L and N; but 24Vdc power ports are ⊕ DC24V Θ, and do not confuse with +24V and COM port.

2. Check to ensure that user signal input line connects with the ports of the PLC input line, and the signal character complies with the input port electric criterion.

3. Check the output port. If the output circuit has different voltage level, the different level should distribute different output groups to avoid short circuit and equipment damage.

4. Make sure the wiring and the specification of the earthing line are in compliant with the requirement. 5. Make sure irrelevant objects falls inside the PLC and the heat dissipation channel is free.

6. Make sure the insulating paper on the holder of the button lithium cell is removed. 7. Make sure the communication signal cable connects correctly if the host or HMI is needed. 8. After checking the items mentioned above one by one, then power on the PLC.

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).