DC 500 CL-T: Toshiba Machine Co., LTD

DC 500 CL-T
TOSHIBA MACHINE CO., LTD
PREFACE
Electricity is essentially invisible. When the electricity flows in electric wires, it turns on electric lights,
drives, motor, and warms up nichrome wires. We know the great energy of electricity but have little knowledge
about electricity. Unfortunately, most people are apt to give up getting to know electricity. However, change your
mind about electricity, which you have believed to be difficult, and make positive maintenance management. A
little knowledge about electricity enables you to maintain machines increasing the operation rate.
The following explains the fundamentals of electricity for die casting machine :
1.
THEORY OF ELECTRICITY
(1) Current
If you connect a dry cell and a light bulb using a copper wire as shown below, electricity flows in the direction
from the positive terminal (+) to the negative (-). To take water as an example for the glowing from the positive
terminal (+) to the negative terminal (-), water flowing from high level to a low level is called a water flow.
Similarly, electricity flows from high electric charge level to a low level. This is called a current, which expressed
with the symbol A (ampere).
Dry cell
1.5 V
(2) Voltage
The potential difference between the positive (+) and negative (-) terminals before they are connected by an
electric wire is called a voltage, which is expressed with the symbol V (volt).
(3) Resistance
While the current is flowing from the positive terminal (+) to the negative terminal (-), it encounters the light bulb
which is an obstacle between them. The obstacle is called resistance, which is expressed with the symbol
(ohm). When a voltage of 1V is applied for flowing a current of 1A, the value of resistance is 1.
(4) Ohms law
A ---------- Ampere
V ---------- Volt
R --------- Ohm
A = V / R ------ Formula 1
V = A X R ----- Formula 2
R = V / A ----- Formula 3
The above are the fundamental electricity.
Example 1: When a voltage of 100V is applied to a resistance of 20, the current is obtained from formula 1 as
follows:
A = 100 / 20 = 5 (A)
Example 2: When a current of 2A is flowing into a resistance of 30, the voltage is obtained from formula 2 as
follows:
V = 30 x 2 = 60 (V)
(5) Power and quantity of power
Electricity generates heat when being used with a heater, and works as mechanical power when being used with
a motor. The amount of work per unit hour is called power, which is expressed with the symbol W (watt). In
other words, the work of 1W is the amount per unit time of work done by a current of 1A when a voltage of 1V is
applied.
W = VA --------- Formula 4
W = V / R -------- Formula 5
W = A R -------- Formula 6
Example 3: If the voltage is 200V and the current is 5A, W is obtained from formula 4 as follows:
W = 200 X 5 = 1000 (W) = 1 (kW)
If the resistance is 20 and the current is 5A, W is obtained from formula 6 as follows:
W = 5 X 20 = 500 (W)
One hour work done by a power of 1W is counted as one unit, and the amount of work is measured in the units,
which is expressed with the symbol WH (watt-hour). Horsepower (hp) can be explained just like power. The
work of lifting up a weight of 1 pound by 33 000 feet for 1 minute is expressed as 1 hp. Conversion from 1hp into
W is 0.746 kW. (A unit of power equal to 746 watts)
(6) Grounding ( Earth)
The earth is considered as a huge conductor of which potential is zero. If we connect a charged object and the
earth using an electric wire, electricity flows into the earth through the wire. This connection is called ground
connection, which expressed with the symbol E or .
See the grounding specifications below.
A) Ground the machine through the iron base or iron core of the machine / apparatus, the control unit.
B) A steel frame of the factory may be used as a grounding electrode. However never use a gas pipe or air pipe
for grounding the machine.
C) The sizes of ground wires are defined depending on the main switch and the fuse capacity.
Up to 50A : 3.5 mm
Up to 100A : 5.5 mm
Up to 200A : 14 mm
Up to 400A : 30 mm
Above 400A : 38 mm
(7) Series and parallel connections
A) Series connection of resistors
R1
R2
R3
R = R1 + R2 +R3 ------ Formula 7

Example 1: If R1, R2, and R3 are 10, 15, and 30, respectively, the total resistance is obtained as follows :
R = 10 + 15 + 30 = 55 ()
B) Parallel connection
1
R=
1
1
1 ------ Formula 8
+
+
R1
R2
R3
R1
R2
R3
Example 1: If R1, R2, and R3 are 10, 15, and 30, respectively, the total resistance is obtained as follows :
1
R=
= 5 ()
1
1
1
+
+
10
15
30
(8) Frequencies of direct current and alternating current
Electricity flowing from the positive terminal (+) to the negative terminal (-) of a battery is constant free from any
change. This called current, which expressed with the symbol DC.
In comparison with the direct current, electricity sent to households and factory is called alternating current
which expressed with the symbol AC. Positive (+) voltage and negative (-) voltage are applied alternately as
shown below. This waveform is called frequency, which is expressed with the symbol Hz (hertz).
Positive (+) potential

Negative (-) potential
1 hertz
For alternating current, a voltage of up to 600V is called low voltage, a voltage of 601 to 700V is called high
voltage, a voltage higher than 700V is called extra high voltage. For direct current, a voltage of up to 750V is
called low voltage, and a voltage higher than 750V is called high voltage. The method of electric work is
specified according to the type of voltage. However, the specification does not cover information about
maintenance work for the control circuits of the machine.
2.How to read sequencer circuits

Electric control circuits are necessary for running a die casting machine.
There are various electric circuits, of which main ones are relay circuits and PC (Sequencer) circuits. This
chapter explain how to read the two types of electric circuits.
2.1 Comparison between Relay circuits and Sequencer circuits
(1) What is a relay circuits.
Below Figure is an extended connection diagram of a relay circuit (Ejector circuit). Each selector switch and the
relay contact are connected through the electric wiring, and the coil of the relay or the coil of the solenoid valve
is energized for getting the die casting machine to run.
6
155
EJECTOR
BACK
EJECT
180
DOR SHFR 1CBR EFR

181 182
183
186
EFSOL
Ejector Forward
IR
DOR
187
188
EBR
EFR
189
190
EBSOL
Ejector Backward
CUT
191
ET
Counter
Ejector Time
ET
(1) What is a PC circuits.

Below Figure is an extended connection diagram of a PC circuit. Figure 1 to 3 are hardware circuit diagrams,
and figure 4 is a software circuit diagram. (Ejector circuit).
The signals of the selector switches (fig. 1) and the limit switches (fig. 2) are all input into the program by the
input module in order to make up the electric circuit (fig. 4). When all the conditions are satisfied, (Y04C) in the
program is turned ON. When (Y04C) is turned on, the signals are output externally by the output module (Fig. 3)
which energizes the solenoid valve or the like to get the die casting machine to operation.
Fig. 1 Input Module
Input module
PC-0
4
X10
EJECTOR
X008
BACK
EJECT
X100
Ejector Forward
CEF
X101
Ejector Backward
CEB
Fig. 2 Input Module

7
EFLS
Input module
PC-0
4
X01
X01A
Ejector Forward LS
EFL
EBLS
X01B
B
EBL
Ejector Backward LS
Fig. 3 Output Module

10
Output module
PC-0
Y04
Y04C
Y04D
EFSOL
4
Ejector Forward SOL
EBSOL
Ejector Backward SOL
Fig. 4 Software Circuit

R012
AR
T141 R038 R13A

DT DOCB TEFX
T012
EST
X012 X01C X111

DOL SHFL 1CBL
T012
EST
00010
Ejector Delay Time
R039
EFY
Ejector Auxiliary
Y04C
EFS
Ejector Forward SOL
R010 X100 X101

MR CEF CEB
R039 X01A Y04D

EFY EFL EBS
2-2 How to read Basic Circuits

(1) Relay Circuits
Series Connection
PB1
PB 2
SL-1
PB 1
PB 2
SL-1
The lamp (SL-1) goes on only when you pressed the push buttons (PB1) and (PB2) concurrently. The lamp
Goes off when you release either one of the push button.
Parallel connection
PB 1
SL-1
PB 1
W
PB 2
PB 2
SL-1
The lamp (SL-1) goes on when you pressed either one of the push button (PB1) or (PB2)
Self holding circuit.
PB 1
PB1
PB 2
R1
R1
PB2
R1
Self-holding contact after coil R1 ON
The relay (R1) is turned on when you press the push button (PB1). In series connection, (R1) is turned off when
You release (PB1). By connecting the push button (PB1) in parallel with contact A of (R1), (R1) remains on even
If you release (PB1).
Interlock circuit.
When the circuit of higher priority is turned ON, other circuit are opened and cannot be operated on.
PB 1
R2
PB 1
R1
R1
R1
PB 2
PB2
R2
R2
R2
When you turn on a high priority circuit, the other circuit opens and is unable to work. The relay (R1) is turned on
when you press the push button (PB1) and (PB2) remains on through the self holding feature. However when you
press the push button (PB2), the relay (R2) is turned on, and the contact B of (R2) on the circuit of (R1) opens.
As a result (R1) is turn off. (R2) remains through the self holding feature. Even if you press the push button (PB1)
Again, (R1) is not turned on because the contact B of (R2) id open.
Priority Circuit
PB 1
R1
R1
R2
PB 1
R1
PB2
PB 2
R2
R2
R2
R1
The latest input always has priority over the previous input. The relay (R1) is turned on when you press the push
button (PB1), and (R1) remains on through the self holding feature because (R2) is off. However , the relay (R2)
is turned on when you press the push button (PB2) next, and the contact B of (R2) on the circuit of (R1) opens.
As a result, (R1) is turned off. (R2) remains on through the self holding feature. However, (R2) is turned off when
you press (PB1) again, and (R1) is turn on.
Timer circuit.
A. Delayed operation circuit.
PB 1
R1
R1
PB 1
R1
T
T
T
SL-1
W
Certain time operation circuit.

Actuated simultaneously when the switch is turned ON and stops when the timer set time is up.
PB 1
T
R1
PB 1
R1
R1
T
T
L
Repeated operation circuit.

Two timers are used and the circuits are repeatedly turned ON and OFF according to their set times.
SS
R1
T1
T1
L
T2
SS
T1
R1
R1
T2
R1
T2
L
T1
T2
T1
T2
(2) Sequencer Circuit.

Applied circuit using a basic circuit in a PC circuit.
Clamping start non-repeat circuit (safety interlock).
Common to manual and automatic operations
PBS1
1
X10C
Figure 1
PBS2
Input module
PC-0
4
X10
C
Cycle Start
PBS1
X10D
Cycle Start
PBS2
00205
R000
HPDR
X10C
PBS1
T007
PBT2
00206
Figure 2
00207
00208
R004
PBR1
R000
HPDR
X10D
PBS2
T006
PBT1
R005
PBR2
R004
PBR1
Start Pushbutton 1
00206
T006
PBT1
Start Pushbutton interval 1

/00207
R005
PBR2
Start Pushbutton 2
00208
T007
PBT2
Start Pushbutton interval 2

/00205
1)
Figure 1
Clamping starts only when you press the start push button PBS1 (1)(X10C) and PBS2 (2)(X10D) concurrently
or within 1 second (4)(5) (1 second set to T006 and T007 by the manufacturer
2)
Figure 2
Clamping does not start when you press the two push buttons separately at an interval of 1 second or more.
When 1 second or more has passed after you press PBS1 (3)(X10C), the timer of start pushbutton interval 1 (4)
(T006) has reached the specified time, and (6)(T006, contact B) opens. As a result, the start push button 2 can
not longer be turned on and clamping does not start.
(Similarly, a non-repeat circuit is also incorporated in relay circuit.
2-3
How to read extended connection diagram of electric circuit.
(1)
Relay circuit
The numbers below (1) in the below figure are addresses on the diagram. For example, the numbers above (2)
indicates that the contacts of (ET) are at addresses 34 and 63.
The underlined number (34) indicates contact B, and the non-underline number indicates contact A.
The number (181) indicated by (3) is the wire number (marked on the wire).
181
wire
Wire number
(marked on the wire)
155
EJECTOR
BACK
EJECT
56
DOR SHFR 1CBR EFR

180
181 182
183
58
186
EFSOL
Ejector Forward
IR
59
DOR
60
187
188
EBR
61
62
EFR
189
190
EBSOL
Ejector Backward
CUT
191
ET
Counter
Ejector Time
34 63
ET
63
(2)
Contact B
PC circuit
As is the case with the relay circuit, the numbers below (1) in the below figure are addresses, and the numbers
above (2) are the addresses being used.
Difference from the relay circuit is that slash (/) is prefixed to the address of contact B (/00801). The number with
no slash being prefixed indicates contact A.
1
R012
AR
T141 R038 R13A

DT DOCB TEFX
00718
T012
EST
00719
00721
00722
X012 X01C X111

DOL SHFL 1CBL
T012
EST
00010
Ejector Delay Time

00719
R039
EFY
Ejector Auxiliary
00722 /00800
00804
Y04C
EFS
Ejector Forward SOL

/00801
R010 X100 X101

MR CEF CEB
R039 X01A Y04D

EFY EFL EBS
Contact B
2-4
(1)
(2)
(A)
(B)
(C)
(D)
(E)
(F)
(1)
(2)
(3)
(4)
How to read extended connection diagram of relay circuit.

Example : The ejector cylinder does not move forward (Manual)
Using a multi-meter, check if a voltage is applied to the ejector (forward) solenoid valve.
[Measure the voltage of the wires 186 and 4 at the terminal of the ejector (forward) solenoid valve whether there
is 100V. If voltage OK, then mechanical failure may cause the problem.]
Conditions for turning on the ejector (forward) solenoid valve.
EFR (ejector forward limit switch) OFF
figure 2
1CBR
(core 1 return limit) ON
figure 2
SHFR (safety hook on limit) ON
figure 2
DOR (die open limit) ON
figure 2
Ejector selector switch Forward
figure 2
Cycle selector switch Manual
figure 1
For conditions (A) to (D) above, determined by the movement of the iron core if each relay is ON/OFF.
For condition (E), check if the ejector selector switch is set to Forward.
For condition (F), check if the cycle selector switch is set to Manual.
Example : SHFR (safety hook on limit) is OFF due to a contact failure of the relay.
Using a multi-meter, check if the voltage of wires 4 and 7 are 100V.
Using a multi-meter, check the voltage of each terminal on the circuit of wire 4 to find out where is shut down.
If a multi-meter reads that the voltages of wires 4 and 181 are 100V but the voltage of wires 4 and 182 are 0V, it
is clear that electricity is shut down at the contact A of SHFR.
If there is a free terminal at the contact A of SHFR, move it to another contact. If the check result is still NG,
replace the relay.
Cycle
COS1
Manual Automatic
EBR
Figure 1
COR
IBR
Automatic
AR
AR
Figure 2
6
155
EJECTOR
BACK
EJECT
56
180
58
59
60
61
62
63
DOR SHFR 1CBR EFR

181 182
183
186
EFSOL
Ejector Forward
IR
DOR
187
188
EBR
EFR
189
190
EBSOL
Ejector Backward
CUT
191
ET
Counter
Ejector Time
34 63
ET
10
2-4
How to read extended connection diagram of PC circuit.

Example : The ejector cylinder does not forward.
This section explains how to trouble shoot (read) the circuit when the ejector cylinder does not move forward.
There are two trouble shooting procedures:
> Trouble shooting through the LED of the input and output modules.
> Trouble shooting using the handy programmer to check for the software circuit.
The following explains the trouble shooting procedure through the LED of the input and output modules.
(1)Check the output module LED whether Y04C (ejector forward solenoid) is ON. When the check is OK : Using
multi meter, measure the voltage at the terminal block of the ejector forward solenoid valve.
If the voltage is 100V. Then mechanical failure may causes the problem.
If the voltage is less than 100V. Check for the wiring from the control unit to the solenoid valve.
If the check is NG. according to the software diagram, check the conditions in which Y04C is turned ON, and
identify the cause the problem by the LED of the input and output modules.
(2)Conditions for turning ON Y04C.
(A) X01A (ejector forward limit switch) OFF
figure 2
(B) Y04D (ejector backward solenoid) OFF
figure 3
(C) R039 (ejector forward auxiliary) ON
figure 4
[Check the conditions for R039 according to (3) If both X01A and Y04D are OFF]
Figure 1
R039
EFY
X01A
EFL
Ejector
Backward
Limit sw
Y04D
EBS
Y04C
EFS
Ejector
Forward
Limit sw
Input module
PC-0
4
X01
7
EFLS
EBLS
See the section explaining B200

for how to view the LED of the
input and output modules.
Ejector Forward
EFLS
X01A
Ejector Forward LS
EFL
Figure 2
EBLS
X01B
Ejector Backward LS
EBL
10
Output module
PC-0
Y04
Y04C
Y04D
EFSOL
4
Ejector Forward SOL
Figure 3
R012
AR
EBSOL
Ejector Backward SOL
T141 R038 R13A

DT DOCB TEFX
T012
EST
Figure 4
R010 X100 X101
MR CEF CEB
X012 X01C X111

DOL SHFL 1CBL
T012
EST
00010
Ejector Delay Time

00719
R039
EFY
Ejector Auxiliary
00722 /00800
00804
11
(3)Conditions for turning ON R039 (ejector forward auxiliary)

The conditions for manual ejector forward auxiliary are enclosed in broken line in the circuit in figure 1.
(A) X111 (core 1 return limit) ON
figure 2
(B) X01C (safety hook in limit) ON
figure 3
(C) X012 (die open limit) ON
figure 4
(D) X101 (ejector selector switch: ejector backward) OFF
figure 5
(E) X100 (ejector selector switch: ejector forward) ON
figure 5
As the case with the previous item, check the input module LED whether the conditions above are satisfied.
(F) R010 (manual operation) is ON when another operation (e.g., clamping or injection) is manually performed.
If the cylinder does not move in manual mode when you attempt to perform operation such as injection, check
the conditions for R010.
If the check result show that any of the conditions is not satisfied, check for the hardware (e.g., LS or wiring) in
the conditions.
R012
AR
T141 R038 R13A

DT DOCB TEFX
T012
EST
Figure 1
X012 X01C X111

DOL SHFL 1CBL
T012
EST
00010
Ejector Delay Time

00719
R039
EFY
Ejector Auxiliary
00722 /00800
00804
R010 X100 X101

MR CEF CEB
Figure 2
Safety hook cylinder
Input Module 4
7
MC 1
X11
X111
Core 1 return limit
X111
1CBL
Figure 3
SHFL
S (a)
Input Module 4
7
SHFL
SHBL
S (a)
X01
X01C
Safety hook in limit
X01C
Link Housing
SHFLS
Input Module 4
Figure 4
DCLS
(b)
DHILS
(b)
SHSL
S (a)
DOLS
(a)
DOL
X01
X012
Die open limit
X012
DOLS
Manual
X008
Figure 5
Ejector
COS 4
0 Forward
Backward
Input Module
X100
X10
X100
Ejector forward
X101
Ejector backward
Ejector
0
Backward
Forward
X101
12
(4)Conditions for turning ON R010 (manual operation) in figure 1. to check the manual operation conditions, set all
the selector switches to neutral, turn ON X002, and then set cycle selector switch to Manual whether X008 is
turn ON.
Conditions for turning on R010 (manual operation)
(A) X002 (selector switches neutral) ON
figure 2
(B) X008 (manual) ON
figure 3
(C) X009 (automatic) OFF
figure 4
(D) X00A (full automatic) OFF
figure 5
(E) X012 (automatic operation) OFF
figure 5
(R012 is OFF when both X009 and X00A are OFF)
After conforming that the conditions above are satisfied, set the ejector selector switch to Forward again to get
the machine to run
If the cylinder does not move, probably causes are follows:
(A) A terminal of the electric wiring is loose or the wiring is about to break, and the input is unstable switching back
and forth between ON and OFF.
(B) The PC is in abnormal state. (e.g., module defective)
X008
KSM
Figure 1
X009
KSA
X00A
KSFA
X002
COR
R012
AR
R010
MR
7
Figure 2
Input Module
Manual operation
R010
MR
X00
COR
X002
X002
Selector switches neutral
COR
Figure 2
DIE
COS2
Open 0 Close
20
INJECTION
COS3
Inject 0 Return
EJECTOR
COS4
Eject 0 Return
21
22
CYCLE
KS 2
Man Off Auto Full Auto
X008
CORE 1
COS5
In 0 Out
4
27
Input Module
X00
X008
COR
Selector switches
neutral
Cycle manual
KSM
Figure 3
X009
X009
Cycle auto
KSA
X00A
X00A
Cycle full auto
KSFA
R041
MRBR
X002
COR
X009
KSA
X00A
KSFA
Figure 4
R011
AR1
R00C
MHPR
R012
AR2
R010
MR
X008
KSM
R011
AR1
Automatic operation auxiliary
R012
AR
Automatic operation
13
2-6 Lubrication pump circuit (Relay circuit).

(1) Figures 1 and 2
When hydraulic pump ON is completed, the relay (MLR)(1) is turned on and the lubricant pump run (LBL)(3) is
turned on through (LBX contact B)(2) at the same time. Consequently, the lubricant pump starts running.
(2) Figure 3
When the lubricant pump starts running and the pressure increases to 17 kg/cm, the pressure switch (LBPS)
(4) is turned ON, the lubricant pump stop (LBX)(5) is turned ON, and (LBX contact B)(2) is opens to stop.
Consequently, the lubricant pump stop.
(3) Figure 3
The lubricant pump stop relay (LBX)(5) remains on through the self holding feature. The timer of lubricant pump
stop time (LBT)(6) starts at the same time (LBX) is turned ON.
(4) Figure 4
When the timer of lubricant pump stop time (LBT) has reached the specified time, (LBT contact B)(7) opens to
turns OFF the lubricant pump stop relay (LBX). Consequently, the lubricant pump starts running again.
Fig. 1
1
MLR
LBPS
LBT
LBX
LBX
LBT
LBL
Lubricant pump stop

Lubricant pump stop time
LBOL
Lubricant pump run
LB
PT
Lubricant pressure detect
Fig. 2
R S T
NFB 1
LBL
LBOL
U3
V3
LBM
Motor for lubricant pump
W3
Fig. 3
4
MLR
LBPS
LBT
LBX
LBX
LBT
LBL
Lubricant pump stop

LBOL
Lubricant pump run
LB
PT
Fig. 4
MLR
LBPS
LBT
7
LBX
LBX
LBT
LBL
Lubricant pump stop

LBOL
Lubricant pump run
LB
PT
14
2-7 Lubrication pump circuit (PC circuit).

(1) Figures 1, 2 and 3
When hydraulic pump ON is completed, the relay (R000)(1) is turned on and the output relay (Y038)(2) is turned
ON at the same time. Consequently, the external relay (LBL)(3) is energized through the output module, and the
lubricant pump starts running. The internal timer of lubricant pump run time (T001)(4) starts at the same time.
(2) Figure 4
When the timer of lubricant pump run time (T001) has reached the specified time, (T001contact B)(5) opens,
and the lubricant pump run relay (Y038) is turned OFF. Consequently, the lubricant pump stop.
(3) Figure 5 and 6
When the timer (T001)(6) has reached the specified time, (T001contact A)(7) is turned ON, and the timer of
lubricant pump stop time (T002)(8) starts.
When the timer (T002) has reached the specified time, (T002 contact B)(9) of the circuit of (Y038) opens.
Consequently, (T001 contact B)(10) is reset. When the timer (T002)(8) has reached the specified time, the
lubricant pump starts running.
1
R000
HPDR
Fig. 1
T002
LBST
T001
LBMT
4
R000
HPDR
T001
LBMT
10 Output module
Fig. 2
Y038
LBL
Lubricant pump run
T001
LBMT
Lubricant pump run time
T002
LBST
Y03 Y038
Y038
LBOL
LBL
Lubricant pump on
LBL
R0 S0 T0
LBL
NFB 2
LBOL
U3
V3
Fig. 3
LBM
Motor for lubricant pump
W3
Fig. 4
R000
HPDR
T002
LBST
T001
LBMT
5
6
Fig. 5
R000
HPDR
T001
LBMT
Fig. 6
T002
LBST
Lubricant pump run
T001
LBMT
9
R000
HPDR
Y038
LBL
T002
LBST
Y038
LBL
Lubricant pump run
T001
LBMT
10
T001
LBMT
15
Programmable Logic Control

B200
1. Specification
Power supply
Item
Description
Voltage
100AC only
Regulation
Between 85 and 132 VAC 50 Hz
Primary side
5V 10A
135 VAC or less
5V 5A
80 VAC or less
power
consumption
Ambient temperature used
0 to 55 C
Storage temperature
-20 C to 65 C
Earthing
Earthing in Class 3
Cooling system
Natural cooling
Control system
Stored program system
Program system
Indicated program system

(11 rows x 11 columns + 11 output)
Word length
16 bits/word, 1 to 4 word instruction
Instruction executing time
Basic input instruction : 0.42
Instruction
Basic output instruction : 0.58 (Y, L, SD & MC)

Basic instruction
16 types
Applied
FS 00 ~ FS 63 MOVE,,,,,V,BIN, & BCD
Standard
Instruction FUN instruction

User Defined
User define FU 00 through FU 63 with the
FUN instruction
mnemonic basic language
Program capacity
4kw, 11kw, 18kw, CMOS.RAM, EPROM

Note : The EPROM board is required to use the
EPROM
Number of points of external
2048 points between X000 to XF7F or Y000 to
input / output relay
YF7F (Every 16 input/output points available)
16
Special auxiliary relay
Temporary storage

B200
17

B200
Item
Description
Special
PC operation
Dry contact input, shorting .. PC operates,
input /
input
Disconnecting .. PC stops.
output
Abnormal PC
Contact output : 24 VDC, 250 VAC, 2A;
output
contact close .. When the PC stops due to the

trouble of the PC
Indicating
Power supply
Power On turned ON
function
indicator (green)
Power OFF turned OFF
In operation
During operation turned ON,
indicator (green)
stop turned OFF
Alarm indicator
When a controllable trouble occurs turned ON,
(yellow)
Normal turned OFF
Trouble indicator
When an uncontrollable trouble occurs turned
(red)
ON, Normal turned OFF
Battery
25 C
5 years or longer
life
55 C
2 years or longer
Status holding function

during
The counter, latch and shift register hold the status
interruption
before power failure. To hold the status of the

internal auxiliary relay, assign the storage area with
the programmer.
Battery
Lithium battery brand name :

ER 6 (AA) 3.6 V 1.9 Ah
Battery replacement
Within 5 minutes
Duration
18

B200
19

B200
20

B200
2.1. Programmable Logic Control
Connector for
connecting extended
Input/ Output rack
Basic base board
Input/ Output module
7
6
5
Module slot number
Rack number setting switch
CU module
Maximum 8 pieces of input and out module

Input module indicates -X
Output module indicates -- Y
1 2 3
1 indicates Rack number
2 indicates Module slot number
3 indicates Terminal number
Power module
Connector for peripheral equipment
(Programmer PGM 355)
21

B200
Mode switch
Extension base board
From Basic Board
To another
Extension base
7
6
5
Module slot number
0
Power module
Maximum 8 pieces of input and out module

Input module indicates -X
Output module indicates -- Y
1 2 3
1 indicates Rack number

2 indicates Module slot number
3 indicates Terminal number
*Mode switch setting :

1.
When basic Rack number used only 0 (all I/O module), the extension power module set at 1
2.
When basic Rack number used 0 & 1 (all I/O module), the extension power module set at 2
3.
When basic Rack number used 0, 1, 2 & 3 (all I/O module), the extension power module set at 4
22

B200
3. Configuration and function of module
A. Basic Power Module Used for the basic and remote I/O rack
Model : B200PW110A 100 VAC
Rack Number setting switch (Set 0 at shipping)
Power lamp
(Green)
When 5VDC is supplied turned ON

Turned OFF if voltage is dropped to less than 5 VDC
PC operation input terminal :

When the terminal is turned on, the PC executes the sequence program
PC emergency stop output terminal :
When uncontrollable trouble occurs in the PC, turns off the terminal.
They are normally on. Use them for emergency stop circuit, when the
trouble occurs.
Power terminal : Used to connected from power supply (external)
Common ground terminal and frame ground terminal :
Used to make the ground in the shortest route.
Fuse (glass tube fuse 250V, 4A)
B. Extension Power Module Used for the extension and remote I/O rack
Model : B200PW110B 100 VAC
Rack Number setting switch (From 0 to F)
Power lamp (Green)
Power terminal :
Common ground terminal and frame ground terminal :
Fuse (glass tube fuse 250V, 4A)
23

B200
C. Cu module
Model : B200 CU, B200 CURM

In operation lamp --- During normal operation .. Turned on
(Green)
---During stops .. Turned off
Alarm lamp --- When a controllable trouble occurs .. Turned on
(Yellow)
---During normal operation .. Turned off
Emergency --- When a controllable trouble occurs .. Turned on
(Red)
---During normal operation .. Turned off
Peripheral equipment interfacing connector :
To be interfaced with peripheral equipment including CRT programmer
CU Cover :
Battery and memory card inside
When the front cover is removed

CU board :
Used to executes / operates sequence program
Battery connector : Connect the lithium battery to the CPU board
Lithium battery (Model K21141G 3.6 VDC):
Used for the power supply to hold the memory during service
Interruption. For the EPROM memory, it is used to back up the
data.
Battery replacement :
When the alarm lamp on the PC is turned on and the message
Battery Alarm is output to peripheral equipment or used up to 5 yrs
(base on the date at the Battery replace name plate inside the
CB box).
Notes : Through the battery replacement can be change during the
power on, replace it carefully while the PC is in operated in
particular.
When changing the battery at power off, replacement time
within 5 min after remove the battery connector.
The EPROM memory board
24

B200
PC mode setting switch :

Used to set the working mode of the PC and set as
follow when shipping :-
1 2
3 4
When dismantle and view from the back
ON
Shipping status : All OFF position
Initial clear : Used to set the status on whether to clear the battery back-up area of the
CMOS RAM when the power is turned on.
25

B200
D. 16 points Input Module
Model : B200 16 AI 100 VAC

B200 16 DI -- 24 VDC
Input ON/OFF indicator lamp (red)

ON turned on
OFF turned off
Terminal block
E. 16 points Output Module
Model : B200 16AO 100 VAC

B200 16 DON 24 VDC
B200 16 DOP 24 VDC
Built in blow-fuse indicator lamp (red)

Blown out turned on
Normal turned off
Output ON/OFF indicator lamp (red)

ON turned on
OFF turned off
Terminal block
26

B200
F. 32 points Input Module
Model : B200 32 AI 100 VAC

B200 32 DI -- 24 VDC
Input ON/OFF indicator lamp (red)

ON turned on
OFF turned off
Terminal block
G. 32 points Output Module
Model : B200 32AO 100 VAC

B200 32 DON 24 VDC
B200 32 DOP 24 VDC
Note : The 32 points output module has no built in blow out fuse
Install the 1 common 5A fuse outside the module. Through this fuse
Prevent the module pattern from burning, its protects no internal element.
Output ON/OFF indicator lamp (red)
ON turned on
OFF turned off
Terminal block
27

B200
3. Replace fuse on output module (B200 16AO)
Fuse
blowout
indicator
Screw
2
Fuse
Rear
cover
Output
board
Screw 1
Case
Terminal
block
Fuse
Fuse : 125 V 7.5A

Model : MP 7.5
Fuse : Ordinary blowout type

Model : MF-51 250V 6A
Size : 5.2 X 20 mm
Note : Used recommended fuse or

same ampere fuse only. 28

B200
4. LED display on I/O module (16 points)
AC100V
OUTPUT
Fuse blown
Output module
only
AC100V
INPUT
0
1
2
3
4
5
6
7
8
9
A
B
C
D
E
F
0
1
2
3
4
5
6
7
Y070
Y071
Y072
Y073
Y074
Y075
Y076
Y077
Y078
Y709
Y07A
Y07B
Y07C
Y07D
Y07E
Y07F
(1)
(3)
(a)
Left
side
8
9
A
B
C
D
E
F
(b)
0
1
2
3
4
5
6
7
COM
8
9
A
B
C
D
E
F
COM
Right
Side
Note : For input, the display in the programmer

will indicating X
The part (3) in figure is the close-up of the part (1) of the LED indicator.
The LED indicator of a 16 point output module has a structure of 2 columns listing 8 points in vertical.
The points are re-listed in a single column consisting of (a) and (b) as shown.
When they are re-listed in a single column , they are easy to understand because they are in the same list as for the
terminal block. Each of 2 COM indicates power supply.
29

B200
5. LED display on I/O module (32 points)
AC 100V
INPUT
0
0
1
2
3
4
5
6
7
0
1
2
3
4
5
6
7
0
1
2
3
4
5
6
7
0
1
2
3
4
5
6
7
AC 100V
INPUT
0 1 23
X000
To
X007
0
1
2
3
4
5
6
7
X008
To
X00F
X000
X001
X002
X003
X004
X005
X006
X007
COM
X008
X009
X00A
X00B
X00C
X00D
X00E
X00F
COM
0
1
2
3
4
5
6
7
COM
8
9
A
B
C
D
E
F
COM
0
1
2
3
4
5
6
7
X100
To
X107
0
1
2
3
4
5
6
7
COM
8
9
A
B
C
D
E
F
COM
X108
To
X10F
X100
X101
X102
X103
X104
X105
X106
X107
COM
X108
X109
X10A
X10B
X10C
X10D
X10E
X10F
COM
Note : For output, the display in the programmer

will indicating Y
Figure 1 is the close-up of the part (1) of the LED indicator (fig. 6) of the input module. The indicator is a structure of 4
columns containing 8 points in vertical appears to be complicated, but it can be simplified by dividing as shown.
30

TC200
1. Specification
Power supply
Item
Description
Voltage
AC 100 V 50 Hz
Regulation
Between 85 and 132 VAC
Primary side
5V 10A
120 VAC or less
5V 5A
80 VAC or less
power
consumption
Ambient temperature used
0 to 55 C
Storage temperature
-20 C to 70 C
Grounding
Grounding resistance of 100 ohm or less.
Cooling system
Natural cooling (SEA)
Control system
Stored program system
Program system
Indicated program system

(11 rows x 11 columns + 11 output)
Word length
16 bits/word, 1 to 5 words instruction
Processing time
Basic instruction : 0.09 to 0.18
Instruction
Application instruction : 0.57

Basic instruction
16 types
Applied
127 kinds (Arbitrary setting of argument and
Application
Instruction instruction
User defined
Selection of operating conditions are possible)

127 kinds
A. instruction
Program capacity
Sequence area : 32 kW
User area : 12 kW
Number of points of external
2048 points between X000 to XF7F or Y000 to
input / output relay
YF7F.
31

TC200
Item
Description
Internal relay
1024 points, R000 to R77F
Extension Internal relay 1
2048 points, G000 to GF7F
Extension Internal relay 2
2048 points, H000 to HF7F
Latch relay
128 points, L000 to L07F
Shift register
128 points, S000 to S07F
Edge relay
1024 points, E000 to E77F
General-purpose register 1
2048 points, D000 to DF7F
General-purpose register 2
2048 points, B000 to BF7F
Timer / counter
1024 points, T/C000 to T/C77F
Set value
1024 points, V000 to V77F
Current value
1024 points, P000 to P77F
Alarm flag
A011 - Battery fault

A012 - PC link error
A013 - Cycle time over
A014 - Instantaneous power failure
A015 - Undefined function execution
A016 - Fuse blow-out detection
A017 - Input / output module mismatch
Fuse blow-out alarm
A020 - Rack No. 0 fuse blow-out

to
A02F - Rack No. F fuse blow-out
32

TC200
1 Power module
2 CU module
3 Communication module
4 Remote module
5 Input module
6 Output module
7 Output module
8 Output module
9 Input module
10- Input/output module
( For J type machine only)

( For J-S type machine only)
(For J type machine only)

10
33

TC200
3. Configuration and function of module
A. Basic Power Module Used for the basic and remote I/O rack
Model : TCPW 110A AC 100V (For standard machine)
TCPW 110AL AC 100V (For Toscast machine)
I/O connector (TCPW 110AL model only)
Power indicator LED (Green)
Illuminated when DC 5V power supply normal
Rack No. setting switch
Power wiring terminal block :
INPUT AC 100V terminal
FG (frame ground) terminal
STOP relay out put terminal.
If an uncontrollable trouble occurs, turn off this terminal.
Note : Contact capacity : DC 24V / AC 220 V 2A
OUTPUT DC 5V terminal. Power of 5 VDC is supplied to TCPW5B
EXT. I/O (OUT) connector :
Connector for extension I/O connection. Connect it with the EXT. I/O
IN connector of the next extension I/O power supply module.
B. Extension Power Module Used for the extension I/O rack

Model : TCPW 110B AC 100V
EXT. I/O (IN) connector :
(OUT) connector of the preceding extension I/O power module.
Rack No. setting switch
Power wiring terminal block :
INPUT AC 100V terminal
FG (frame ground) terminal
OUTPUT DC 5V terminal: Power of DC 5V is supplied to TCPW5B
EXT. I/O (OUT) connector :

IN connector of the next extension I/O power supply module.
34

TC200
C. Cu module
Model : TCCUH (Control module with high speed sequence function)
1. RUN lamp
2. ALARM lamp
3. STOP lamp
4. Maintenance Code display
5. RUN / STOP key switch
6. Peripheral equipment interfacing connector
7. RS232 connector
8. Maintenance Code reset push button
9. Lithium battery
10.Battery connector
11. Memory card and connector
12. Memory card ejector
13. PC mode setting switch
35

TC200
1. RUN lamp :
Illuminated during normal PC operation and goes out during stop.
2. ALARM lamp :
Illuminated if a controllable trouble occurs.
3. STOP lamp :
Illuminated if an uncontrollable trouble occurs.
4. Maintenance Code display :
An error message is display by the 3 digit 7 segment LED. It is also possible to display
a user message. (This code cannot be cleared at trouble causing PC stop)
5. RUN switch :
Used to change over the PC start and stop. When this switch is set to RUN the PC start.
6. Peripheral equipment interfacing connector :
To be interfaced with peripheral equipment including the programmer. (PGM 559)
7. RS232 connector :
To be connector with the personal computer or equipment having an RS232 interface.
8. Maintenance Code reset push button :
Press this switch when clearing a maintenance code display.
9. Lithium battery :
RAM backup battery.
10.Battery connector :
Used to connect the lithium battery with the CU module.
11.Memory card and connector :
EEPROM type memory card storing the sequence program. The memory capacity is
128 KB. And connector for inserting the memory card.
12.Memory card ejector :
Eject push button for removing the memory card.
13.PC mode setting switch :
Used to set the PC operation mode. In all the following 8 modes are available.
9
8
7
6
5
4
3
2
1
ON
36
Programmable Logic Control TC200

No. 8. MC BOOT
(memory card boot)
No. 7. MC WRITE
(Memory card write)
When set to ON from OFF, the sequence program is booted

from the memory card. (Also booted when the switch set to
ON at power ON)
When set to ON from OFF, the sequence program is written
into the memory card. (Memory card write protect WP must
switch to ON) See fig. below
WP
No. 6. SEQ. PROTECT

(Sequence protect)
No. 5. DATA REG. PROTECT
(Data register protect)
No. 4. I/O CHANGE
(input / output change)
When set to ON, writing of sequence program is prohibited.

Writing of data register is banned.
When set to ON, the I/O module can be changed during PC

operation. In this condition, I/O processing is not executed.
After replacement, be sure to set the switch to OFF.
No. 3. OUT HOLD
When set to ON, output is held even if the PC stops. When
(Output hold)
set OFF, all number of output are turned off.
No. 2. CONTINUE
When set to ON, the PC operation continues even if
(Resumption of operation) instantaneous power failure or cycle time over is detected.
No. 1. INITIAL
When set to ON from OFF, all contents of sequence program
(Initial clear)
and data register are cleared. (They are also cleared when
the switch is set to ON at power ON)
Note : All dip switches of the PC mode setting switch are set to OFF for spare parts.
As for installed on the machine, usually dip switch No. 5 and 6 are set to ON.
D. Replacement of battery
1. Replace the memory backup and clock battery within the term of
validity. The battery can be replace while the PRIVISOR power is on or
off. When the power off, replace the battery within 5 minutes.
2. Model : ER3V-C
Battery connector
37

D. Input module
Model : TC 32DI DC 24V

TC 32AI AC 100V
Input signal indicator lamp

When the input signal is ON, LED light in red
Terminal block
E. Output module
Model : TC 32DON DC 24V COM - NEGATIVE

TC 32 DOP DC 24V COM - POSITIVE
TC 32AO AC 100V
Fuse blow out indicator lamp
Illuminated in red if the output wiring protection has blown out
Input signal indicator lamp

When the input signal is ON, LED light in red
Terminal block
38

TC200
4. Fuse replacement on Output module
Only the fuse of the output module is changeable by customer. If the fuse has blown out,
identify and remove the case, then replace it with a new fuse.
Through the fuse is also in the Power Module, it is blown out even by an abnormal generated
In the internal circuit and must not be replaced by customer.
Rear
cover
PCB
Case
Terminal block
Fuse
Spare
fuse
Note :
Type of fuse used : Normal blow out fuse 5.2 X 20 mm
TC 32 DON : MF 51, 250V 8A
TC 32 DOP : MF 51, 250V 8A
TC 32 AO : MF 51, 250V 6A
Before replacing the fuse, be sure to turn off the PROVISOR and I/O power supply.
Note : Used recommended fuse or

same ampere fuse only.
39

5. 32 points input module LED display and terminal connection
TC 32DI
0
0
1
2
3
4
5
6
7
0
1
2
3
4
5
6
7
TC 32AI
3
0
1
2
3
4
5
6
7
TC 32DI
0
1
2
3
4
5
6
7
TC 32AI
0 1 23
X000
To
X007
0
1
2
3
4
5
6
7
X008
To
X00F
X001
X003
X005
X007
X008
X00A
X00C
X00E
COM
X101
X103
X105
X107
X108
X10A
X10C
X10E
COM
1
3
5
7
8
A
C
E
C2
1
3
5
7
8
A
C
E
C4
0
1
2
3
4
5
6
7
X100
To
X107
0
2
4
6
C1
9
B
D
F
0
2
4
6
C3
9
B
D
F
X108
To
X10F
X000
X002
X004
X006
COM
X009
X00B
X00D
X00F
X100
X102
X104
X106
COM
X109
X10B
X10D
X00F
40

6. 32 points Output module LED display and terminal connection
TC 32DON
FUSE
1 2
0
1
2
3
4
5
6
7
0
1
2
3
4
5
6
7
Fuse blown out indicator

3
0
1
2
3
4
5
6
7
0
1
2
3
4
5
6
7
TC 32DON
0 1 23
Y000
To
Y007
0
1
2
3
4
5
6
7
Y008
To
Y00F
Y001
Y003
Y005
Y007
Y009
Y00B
Y00D
X00E
N
Y101
Y103
Y105
Y107
Y109
Y10B
Y10D
Y10F
N
1
3
5
7
9
B
D
F
1
3
5
7
9
B
D
F
-
0
1
2
3
4
5
6
7
Y100
To
Y107
0
2
4
6
8
A
C
E
C1
0
2
4
6
8
A
C
E
C2
Y108
To
Y10F
Y000
Y002
Y004
Y006
Y008
Y00A
Y00C
Y00E
COM
Y100
Y102
Y104
Y106
Y108
Y10A
Y10C
Y10E
COM
41

7. 16/4 points input module.
Model : TR 16DIC, TR 16DIE, TR 04DI
Mode switch
Operation monitor LED display
1
2
0
1
LINE
END
CH NO
Input LED display
Main
Unit
DC24V
I/O
supply
DC24V
Terminal connector
X**0
COM
X**1
X**2
COM1
X**3
X**4
COM2
X**5
X**6
COM3
X**7
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A15
A16
B1
B2
B3
B4
B5
B6
B7
B8
B9
B10
B11
B12
B13
B14
B15
B16
A+
B-
FG
FG
X**8
COM4
X**9
X**A
COM5
X**B
X**C
COM6
X**D
X**E
COM7
X**F
42

8. 16/4 points output module.
Model : TR 16AOECE, TR 16AOE, TR 04AO
Fuse
250 VAC 3A
5.2 X 20mm
Input LED display
I/O
supply
AC100V
A3
Terminal connector
Y**0
COM
Y**1
Y**2
COM1
Y**3
Y**4
COM2
Y**5
Y**6
COM3
Y**7
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A15
A16
B4
B5
B6
B7
B8
B9
B10
B11
B12
B13
B14
B15
B16
FG
Y**8
COM4
Y**9
Y**A
COM5
Y**B
Y**C
COM6
Y**D
Y**E
COM7
Y**F
43

9. Input / output module.
X+0
Model : TR 80DIDOPT (64 points input & 16 points output)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
0
1
2
3
4
5
6
7
C3
8
9
A
B
C
D
E
F
C4
OV
OV
24V
24V
X+2
TB2
TB1
0
1
2
3
4
5
6
7
C1
8
9
A
B
C
D
E
F
C2
0
1
2
3
4
5
6
7
C5
8
9
A
B
C
D
E
F
C6
DC 24V Input
I/O LED
display
Led 1 - 16
0
1
2
3
4
5
6
7
C7
8
9
A
B
C
D
E
F
C8
Power LED
Run LED
Error LED
SW2
Channel
SW3
I/O LED indicator
OV
OV
24V
24V
SW1
2 1
2 Line End
1 Channel change
Fuse for output

Y**0 to Y**7
F1
TB3
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Y**0
Y**1
Y**2
Y**3
Y**4
Y**5
Y**6
Y**7
C9
Y**8
Y**9
Y**A
Y**B
Y**C
Y**D
Y**E
Y**F
C10
(-)
24V
0V
FG
A(+)
B(-)
SG
FG
Fuse for output

Y**8 to Y**F
F2
Power Supply Control
F3
Fuse type: for F1 and F2 normal blown out fuse 250V / 1A 5.2 X 20mm
for F3 normal blown out fuse 250v / 3A 5.2 X 20mm
44

9-1. Terminal connector TB 1 and TB 2 (DC24V input)
Common connector C1 to C8 (0V) for 8 points input
C1at TB 1-1-9 pin
Example :
Input contact X000, X00F and X020
X000 to connect at TB 1-1 pin
X00F to connect at TB 1-9 pin
X020 to connect at TB 2-1 pin
Power supply : OV to connect at TB 1-37, TB 1-38, TB 2-37 & TB 2-38.
DC 24V to connect at TB 1-39, TB 1-40, TB 2-39 & TB 2-40.
9-2. Terminal connector TB3
(Included output, communication and control power supply ports)
Example : Output contact Y000 and Y00f
Y000 to connect at TB 3-1 pin
Y00F to connect at TB 3-18 pin
Common connector C9 and C10 (24V) for 8 points output
C9 at TB 3-9 and TB 3-19.
RS485 I/F connection (A+ and B-) Split I/O communication
A+ to connect at TB 3-24 and B- to connect at TB 3-25
For shield FG to connect at TB 3-27
Power supply connection (0V, 24V and FG)
0V to connect at TB 3-21
24V to connect at TB 3-22
FG to connect at TB 3-23
9-3. LED 1-16 (I/O display LED) / SW3 (indicator I/O)
LED 16
LED 15
LED 14
LED 13
LED 12
LED 11
LED 10
LED 9
LED 8
LED 7
LED 6
LED 5
LED 4
LED 3
LED 2
LED 1
F
E
D
C
B
A
9
8
7
6
5
4
3
2
1
0
2 3
4
5
8 7
SW3
0
1
2
3
4
5
6~8
9
OFF
LED display for input signal TB 1-1 to 8 & 10 to 17 connection ports
LED display for input signal TB 1-19 t0 26 & 28 to35 connection ports
LED display for input signal TB 2-1 to 8 & 10 to17 connection ports
LED display for input signal TB 2-19 to 26 & 28 to35 connection ports
LED display for output signal TB 3-1 to 8 & 11 to 18 connection ports
Unused
LED test mode
45

10. Communication module.
Model : TCRMT
TCRMT
RUN
ALARM
STOP
A R
S
B 4
8
FG 5
Operation LED display

Run : ON when CU module switch to run
Alarm : On when RS485 wire trouble
Stop : Module trouble
Terminal connector
Connect the blocks according. These 2 terminal blocks
are connected internally by connecting the same signals.
A R
S
B 4
8
FG 5
Open the cover on the module front lower side, and you can see
switches SW1 and SW2 there.
The function of each switch is as follows. Set these switches according
to the intended use.
SW1 TERMINATING RESISTANCE
Used to turn on and off the 100 terminator. Only when the
module is located on the final end of the transmission line, set
this switch ON.
SW2 MASTER/SLAVE MODE SWITCH
Used to select the master station or slave station for the module.
When the module is used as the master station, set the switch to
MASTER.
When its serve as the slave station, set it to SLAVE.
In the same remote system, only 1 master station is available.
NEVER set 2 or more modules for the master station.
46

Notes :
If the cycle time over or instantaneous power failure is detected, the PC operating condition
and LED status change with the internal setting of the CU module.
Maintenance code display content
. . .
Signifies the related module.

C : CU Module
P : Power Module
U : I/O Module
E : Intelligent Module
Signifies the alarm breakdown.

0 ~ 2 : Replacement of module is needed
3 ~ 5 : If the same alarm is repeated, replacement
module, etc. is needed.
6 ~ 8 : Illegal programming or setting.
. . .
F : Fuse down
H : Remote I/O error
U : I/O error
L.
0 ~ F : Rack number
0 ~ 7 : Card number (If the remote I/O is

generated, the card number is 0)
0 ~ 3 : PC number
(Upper)
0 ~ F : PC number
(Lower)
. .
L : PC link error
Maintenance code display
48
SYMBOL (1)
ELECTRICAL SYMBOL
Name
Symbol
Symbol Name
EE
Fuse
FUSE
MOTOR
M
OVERLOAD RELAY
MOL
3-phase
induction
motor
Bimetal
MOL
Contact
Description
Melts down to protect the circuit when
electric current larger than the flows.
Therefore, do not use fuse greater than
the rated capacity.
This is a 3-phase motor and a symbol for
the location it is used is entered in this part.
The supply voltage must be 10% of the
Rated voltage.
Generates heat when a current larger than
the rated current flows, becoming warped
to break the contact. This action turns off
current in the magnet switch coil to protect
the motor.
MOL
MAGNETIC
SWITCH
Coil
When current flows in the coil, its activates

the motor that has contacts connected.
Normally open contacts operated by above.
Contact
FORWARD /
REVERSE
SWITCH
DF
DB
Coil to move die

height unit
forward and
backward.
When current flows in the coil, it connects

contact DF or DB.
DF
Contacts of DF Contacts connected by DF or DB.
and DB.
DB
SHOT COUNTER
Shot counter
CUT
When current flows in the power section, it

rotates the gear a turn and when current
stops, it simultaneously rotates the gear
turn further to change the indicator number.
SYMBOL (2)
ELECTRICAL SYMBOL
Name
SELECTOR
SWITCH &
KEY SWITCH
Symbol
Symbol Name
COS & KS
1
0
2
A
C
E
G
B
D
F
H
PRS
PRESSURE
SWITCH
PRS
SELECT SWITCH
PS
c
d
FOOT SWITCH
SNAP SWITCH
FS
Standard Close
SS
GROUND
(EARTH)
TRANSFORMER
180 200 220
Contact A
(normally open
contact)
Contact B
(normally close
contact)
Connected when pressure rises above the

set pressure. Disconnected when pressure
is below the set pressure.
Disconnected when pressure rises above
she set pressure. Connected when
pressure is below the set pressure.
100
SL
W
Contact A
Connection when the pedal is stepped on.
Solenoid coil
When the current flows, it is energized to

Switch over the valve.
Shorted for
Standard
Machine.
Discounted in the terminal block section

when using automatic device or safety
equipment.
Contact A
Connected when switch lever push to ON

position. And disconnected when push to
OFF position.
Earth
One side of the transformer secondary

circuit is grounded to earth with green wire.
(wire directly connected to the coil)
Voltage varies in proportion to the number

Of coil windings. The voltage on the
secondary side varies as the tap on the
Secondary side
primary side is changed.
Primary side
Tr
INDICATOR LAMP
Locations where broken line intersect as

marked by are connected from left to
right.
When switch to 0 connection is from C to D
And G to H.
When switch to 1 connection is from A to B
When switch to 2 connection is from E to F
SOLENOID COIL
SHORTING WIRE
Vertical line =
a switch position
,the horizontal
line =
combination, &
the mark =
connection.
When switched over, a to c and d to e are

a b Contact B
connected, a to b are disconnected.
a c Contact A
If is not switch over, the connection as
d e Contact A
shown in the diagram.
Description
Indicator lamp
Also called signal lamp.

Symbol W is white, G is green, R is red &
Y is yellow.
SYMBOL (3)
ELECTRICAL SYMBOL
Name
Symbol
Symbol Name
PB
PUSH BUTTON
SWITCH
LIMIT SWITCH
Contact A
Connected when pushed & disconnected

when release.
Contact B
Disconnected when pushed & connected
(mushroom type) when release.
Contact B
(use at emergency stop)
Contact A
AUXILIARY RELAY
Disconnected when lever was pressed and

connected when release.
Coil
When current flows, it is energized to

switch over the contact.
Contact A
Connected when coil energized.

Disconnected when coil is not energized.
Disconnected when coil is energized.
Connected when coil is not energized.
Coil
T
T
Contact A
KEY SWITCH
Off
Contact B
Key switch
On
KS
MC
b
PUSH BUTTON
WITH
LAMP
BUZZER
When current flows, it time lag operation

start.
Connected when the set time elapses after
flows in the coil. Disconnected when
current stops.
Disconnected when the set time elapses
After current flows in the coil. Connected
when current stops.
This switch cannot be operated unless the
key was inserted. When the key inserted &
turn to ON position, a and b are connected.
a
METAL CONSENT
Connected when lever was pressed and

disconnected when release.
Contact B
Contact B
TIMER
(TIMER LAG
RELAY)
Description
Metal connector Core in/out limit switch is connected when

using a core. And a & b are connected
through the limit switch.
Contact A
Lamp
BZ
Buzzer
The lamp lights when the push button is

pressed.
W is white.
R is red.
When current flows in the coil, its creates

a sound.

DC 500 CL-T: Toshiba Machine Co., LTD

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DC 500 CL-T

TOSHIBA MACHINE CO., LTD

R = R1 + R2 +R3 ------ Formula 7

Positive (+) potential

2.How to read sequencer circuits

DOR SHFR 1CBR EFR

(1) What is a PC circuits.

Fig. 2 Input Module

Fig. 3 Output Module

Fig. 4 Software Circuit

T141 R038 R13A

X012 X01C X111

Ejector Delay Time

Ejector Forward SOL

R010 X100 X101

R039 X01A Y04D

2-2 How to read Basic Circuits

Self holding circuit.

Certain time operation circuit.

Repeated operation circuit.

(2) Sequencer Circuit.

Start Pushbutton interval 1

Start Pushbutton interval 2

How to read extended connection diagram of electric circuit.

DOR SHFR 1CBR EFR

T141 R038 R13A

X012 X01C X111

Ejector Delay Time

Ejector Forward SOL

R010 X100 X101

R039 X01A Y04D

How to read extended connection diagram of relay circuit.

DOR SHFR 1CBR EFR

How to read extended connection diagram of PC circuit.

See the section explaining B200

T141 R038 R13A

X012 X01C X111

Ejector Delay Time

(3)Conditions for turning ON R039 (ejector forward auxiliary)

T141 R038 R13A

X012 X01C X111

Ejector Delay Time

R010 X100 X101

Safety hook cylinder

Core 1 return limit

Safety hook in limit

Die open limit

Selector switches neutral

Man Off Auto Full Auto

Cycle full auto

Automatic operation auxiliary

2-6 Lubrication pump circuit (Relay circuit).

Lubricant pump stop

Lubricant pump run

Lubricant pressure detect

Motor for lubricant pump

Lubricant pump stop

Lubricant pump run

Lubricant pressure detect

Lubricant pump stop

Lubricant pump run

Lubricant pressure detect