686 Programmable Logic Controllers

1. Outline
TE CHNICAL GU IDE
Conventional systems for industrial machine control have been constructed with hard-wired relays, timers and counters. With this method, however, operators cannot test the control elements until all wiring has been completed. It takes a lot of time to make any changes. The greatest disadvantage of this type of system is that it requires frequent maintenance because of the short service life of each component. Programmable logic controllers were developed to eliminate such problems. Since the control processes of PLCs are software based, control elements can be easily modified. PLCs also perform arithmetic operations and can control high-speed lines, which cannot be performed using a combination of relays, timers and counters. Since semiconductor devices and microcomputer technology have been rapidly advancing in recent years, PLCs now have a much longer service life. Therefore, little maintenance is required.

2. Configuration
Programmable logic controllers are considered to be a large group of relay contacts (N.O., N.C.), timers and counters. These elements are combined with various instructions to make sequential circuits. The sequential circuits are software-based logic, not hard-wired circuits such as electromagnetic relays. Although conventional systems require complicated physical wiring, programmable logic controllers create logic circuits through simple programming.
Programmable logic controller system diagram
External input devices Pushbutton switch Selector switch Limit switch Relay contact Photoelectric sensor Proximity sensor Other sensor
Input processing unit Memory Output processing unit

External output devices Indicator Digital display Solenoid Solenoid valve Electromagnetic clutch Contactor Motor

Control Microcomputer

3. I/O Operations and Response Delay

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A program created and entered in the KV is called a User Program. During operation of the PLC, this program is repeatedly executed. Execution of the program consists of three steps: Input operations, Execution of the program, and Output operations.
Input The ON/OFF status of all input terminals are written into the input memory before execution of the program. The ON/OFF status of specified elements (internal utility relays, timers, and counters) are read for arithmetic operations. Results of such operations are written into the output memory.

Scan time and response delay

I/O response time includes I/O response delays as well as scan time. These delays are caused by the fact that input statuses can be read into the memory only during input operations. If input statuses change after input operations, new input statuses can only be read during the next scan time.

I/O response time

Shortest response time: Input delay + scan time + output delay Longest response time: Input delay + 2 x scan time + output delay
Input statuses are read. Input ON Output OFF Output Input (1) Input statuses are read. (2) (3) Input statuses can only be read at signals (1) and (2), but not at signal (3).

Output

Contents of the output memory are sent to the output terminals.

Output Input

Output Input

Program execution Scan time

Program execution Scan time

Program execution

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Output

The time it takes for one execution cycle to be completed is called the Scan time. Scan time varies depending on the size of the user program and instructions used in the program.

Programmable Logic Controllers

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4. Glossary
Ladder program
A ladder program is based on a sequence diagram (electrical circuit diagram). It uses a programming language that allows easy visualisation of the relationship between input conditions and outputs. For example, the following is a ladder program which turns on output relay 500 when both input relays 000 and 0001 are turned on (AND circuit).
000 001 500

There are two types of interrupt processing: an interrupt by an external input, or by the high-speed counter comparator.

High-speed counter function

The high-speed counter is a hardware-based counter independent of scan time, providing significantly high response frequency of 30 kHz. It can be used for quick counting of phase-differential pulses from a rotary encoder. A high-speed counter includes a high-speed counter comparator with which a preset value can be specified. By using the interrupt processing function, specific output relays can be directly turned on or off when the count value reaches the comparator preset value.

In a ladder program, instruction words are represented by symbols. A relay input is described as and a relay output is described as . PLCs, however, internally process instructions with mnemonics. The ladder program above can be represented by the following mnemonic words. LD AND OUT 000 001 500

Block diagram of high-speed counters

Preset input: 00008 Phase A: 00004 (Phase B: 00006) Count input External input Internal clock Direct clock pulse input 24-bit highspeed counter 0 CTH0 preset value High-speed counter comparator CTH0 input capture function

Control circuit Interrupt function

00500 (Direct clock pulse)

Interrupt processing function

Normally, a PLC processes a ladder program once every scan time. Therefore, signals shorter than the scan time cannot be received. When the interrupt processing function is used, a process can be executed at the instant when the interrupt condition is activated, regardless of the scan time. When the interrupt condition is active, the PLC suspends the normal program processing until the interrupt program completes. The PLC will then resume its program.

Phase A: 00005 (Phase B: 00007)

Count input Direct clock pulse input Internal clock External input

24-bit highspeed counter 1 CTH1 preset value High-speed counter comparator

CTH1 input capture function Control circuit Interrupt function 00501 (Direct clock pulse)

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Preset input: 00009

Output processing Program execution

Input processing Normal scan time Interrupt condition is satisfied. 000 001 002 003 Interrupt program execution

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Programmable Logic Controllers

Positioning pulse output function

This function produces pulses from specific outputs of the PLC independent of the scan time. Sending this pulse output into a pulse-input stepping motor or servo driver enables positioning operation (speed control). The pulse outputs are capable of reaching frequencies up to 50 kHz. It allows ramp-up/down control by setting parameters such as startup speed, operation speed and acceleration/deceleration time.
Frequency (Hz) Moving speed Startup speed (Stop speed) Acceleration/ deceleration time Acceleration/ deceleration time Target value/travel (No. of output pulses)

Time (ms)

5. Hints on Correct Use

1. Precautions for wiring
Make sure that the power supply voltage is within the tolerance range specified below. Power supply voltage: 24 VDC + 10%/- 20% The KV Series is designed to be resistant to general noise. However, to improve noise-resistance, isolate the PLCs cables from AC power lines with an isolating transformer or noise filter as shown below. To prevent voltage drops, use twisted pair cables with a 2 mm2 or more cross section for the basicunit power-supply line. Applicable input device (DC output)
Relay output type
+
Power supply for sensors KV Series 5 mA IN COM

NPN current output type

+
Constantcurrent circuit

Power supply for sensors KV Series IN COM

Output 5 mA 0V

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24 V DC OUT KV-U2 24 V DC OUT

NPN open-collector output type PNP open-collector output type

Base unit +
Power supply for sensors IN COM KV Series

Output
85-264 V AC IN 50-60 Hz POWER OUTPUT 24VDC 0.8A 24 V DC OUT

External equipment (Sensor or others)

5 mA 0V

Twist the cable to prevent undesirable voltage from being produced. Insert an insulating transformer or noise filter to help reduce noise from the power cable. Make all wirings as short as possible. Power cables and signal cables conveying noise must be placed at a safe distance from each of the cables connected to the KV-U2/U3.

Inapplicable input device

Voltage output type
+12 V

Output 0V

2. Precautions for input connections

Only non-voltage (relay or solid-state) input devices can be connected to the KV Series.

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Programmable Logic Controllers

Leakage current When a 2-wire sensor (photoelectric or proximity sensor) or a limit switch with LEDs is connected to the KV Series, leakage current flows through these devices, causing input errors or the LED indicators to light. If the leakage current is 2 mA or more, connect a bleeder resistor in parallel with the PLCs input terminals to reduce the leakage current flowing through the input circuit.
IN 2-wire sensors Bleeder resistor Input power supply COM OUT
KV Series

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If the load and output terminals are short-circuited, the output elements and internal board may burn out. We recommend connecting a protective fuse to the output elements. If the contact protection circuit can prevent sparking, this will also reduce the noise caused by external equipment.
OUT Diode COM Diode

Peak reverse voltage three times or higher than load voltage. Average rectifying current: 1 A Relay

COM

Surge absorber

Current consumption Current consumption of the input circuit varies depending on terminals. (Relays 0000 to 0005: 7 mA, other relays; 5 mA) Select a power supply with enough capacity by calculating the current consumption of the basic unit, expansion unit, handheld programmer and input circuit.
Relay

Resistance: 50 Capacitance: 0.47 F Voltage: 200 V

5. Precautions for using BJT output Connections to TTL input device

Due to a residual voltage (1 V or less), the BJT output cannot be directly connected to a TTL input device. To accomplish this, use another transistor between the BJT output and TTL input device. Connect the second BJT output to another power supply through a pull-up resistor to produce voltage output.
24 VDC 10 k OUT Transistor output COM 22 k 4.7 k Photoelectric Sensors 5V 1 k Equivalent 7400 Safety Light Curtains Proximity Sensors Pressure Sensors PLCs

3. Precautions for output connections

Observe the rated load voltage/current.
Rated load voltage/current for relay output Rated load voltage/current for BJT output Rated load voltage/current for MOS-FET output
250 VAC/30 VDC, 2 A max. 30 VDC, 0.3 A max. 30 VDC, 0.5 A max.

4. Contact protection
When a PLC is connected to a load with a large amount of inrush current (motor, incandescent lamp, etc.), take precautions to protect the output elements. The best solution is to use heavy-duty output relays. When the output terminals are connected to an induction load, connect a diode (when the load has a DC power supply) or a surge absorber (when the load has an AC power supply) in parallel with the load to suppress backward voltage. Use a diode with a peak reverse voltage three times or higher than the load voltage or a surge absorber with approx. 50 resistance, 0.47 F capacitance and 200 V voltage.

6. Installation Mounting environments

Observe the following instructions to get the best result of the KV Series. Locations Do not place a PLC in the following places: - Places directly exposed to sunlight - Places where the relative humidity falls below 35% or exceeds 85%

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Programmable Logic Controllers

Places where corrosive or flammable gas is present Places where the PLC may be subjected to strong vibrations or shock Places exposed to strong magnetic or electric fields Places where the ambient temperature falls below 0C or exceeds 50C Places where condensation occurs Places where airborne dust, salt or metal particles or soot is present Places where water, oil, or chemicals may splash the PLC Inside the panel Ambient temperature Provide enough space for proper ventilation. Do not install the PLC directly above equipment that emits a large amount of heat. Provide convection as required. Wiring Make the cables as short as possible. Separate the PLCs I/O cables from power lines. Do not install the PLC and high voltage equipment in the same control panel. Ensure safe access for operation and maintenance.

6. Examples of Connections to External Equipment

DC 2-wire type proximity sensor
Brown

DC 3-wire (NPN) photoelectric/proximity sensor

Black Output (open-collector) Blue

Blue Example: Proximity sensor EV-118M

Brown Example: Fibre photoelectric sensor FS2-60

24 VDC OUT Photoelectric Sensors Safety Light Curtains Proximity Sensors Pressure Sensors PLCs Counters Barcode Readers Vision Systems Static Elimination Systems Displacement Sensors Optical Micrometers Microscope Enclosure Rating Communication Method Example: Fibre photoelectric sensor FS2-60P

C 000

001 002

003 004

005 006

007 008

009 010

011 012

24 VDC OUT

C 000

001 002

003 004

005 006

007 008

009 010

011 012

KV-40R

KV-40R

DC 3-wire (PNP) photoelectric/proximity sensor

Black Blue Brown

Sensor with relay output

Output Output Power supply AC

Example: Multi-voltage power supply photoelectric sensor

24 VDC OUT

C 000

001 002

003 004

005 006

007 008

009 010

011 012

KV-40R

24 VDC OUT

001 003 005 007 009 011 000 002 004 006 008 010 012

KV-40R

* A PNP open-collector output which requires a separate power supply of 5 VDC/12 VDC cannot be directly connected to the PLC. For 24 VDC power supply, see the DC 3-wire type (PNP).

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Programmable Logic Controllers

Electronic preset counter (Relay output)
INH (Inhibit input) Power supply for sensors Reset IN (Count input) +12 V 0 V 6 7 8 9 10 Example: RC-13/18 5 100 to 240 VAC 4 3 2 1 COM N.C. N.O.

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Electronic preset counter (NPN)

INH (Inhibit input) Power supply IN (Count input) for sensors Reset +12 V 0 V 6 7 8 9 10 Terminals (3) and (6) are unused. 5 12 to 24 VDC 4 3 2 0V 1 NPN output Example: RC-14/19

24 VDC OUT

C 000

001 002

003 004

005 006

007 008

009 010

011 012

24 VDC OUT

C 000

001 002

003 004

005 006

007 008

009 010

011 012

KV-40R

KV-40R

Rotary encoder (NPN)

Output (open-collector) + 12 VDC Rotary encoder 0V

24 VDC OUT

C 000

001 002

003 004

005 006

007 008

009 010

011 012

KV-40R

Photoelectric Sensors Safety Light Curtains

7. General Specifications
Vibration: 10 to 55 Hz, 1.5 mm double amplitude in X, Y, and Z directions, 2 hours respectively. Operating atmosphere: No excessive dust or corrosive gases.

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