electrical (e1)

1TOSHIBA MACHINE CO., LTD

DC 500 CL-T

2

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) CurrentIf 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).

(2) VoltageThe 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) ResistanceWhile 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 Ω (ohm). When a voltage of 1V is applied for flowing a current of 1A, the value of resistance is 1Ω.

(4) Ohm’s lawA ---------- Ampere V ---------- Volt R --------- OhmA = V / R ------ Formula 1 V = A X R ----- Formula 2 R = V / A ----- Formula 3The above are the fundamental electricity.Example 1: When a voltage of 100V is applied to a resistance of 20Ω, 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 30Ω, the voltage is obtained from formula 2 as follows:

V = 30 x 2 = 60 (V)

(5) Power and quantity of powerElectricity 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 = V² / R -------- Formula 5 W = A² R -------- Formula 6Example 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)

Dry cell1.5 V

3

If the resistance is 20Ω 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 mm² Up to 100A : 5.5 mm² Up to 200A : 14 mm²Up to 400A : 30 mm² Above 400A : 38 mm²

(7) Series and parallel connectionsA) Series connection of resistors

R = R1 + R2 +R3 ------ Formula 7Example 1: If R1, R2, and R3 are 10Ω, 15Ω, and 30Ω, respectively, the total resistance is obtained as follows :

R = 10 + 15 + 30 = 55 (Ω)

B) Parallel connection 1

R = ------ Formula 8

Example 1: If R1, R2, and R3 are 10Ω, 15Ω, and 30Ω, respectively, the total resistance is obtained as follows :1

R = = 5 (Ω)

(8) Frequencies of direct current and alternating currentElectricity 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).

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.

1R1

1R2

1 R3+ +

110

115

130+ +

R1

R3

R2

R1 R3R2

Positive (+) potential

Negative (-) potential

1 hertz

4

2.How to read sequencer circuitsElectric 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 7

IR

DOR

4

ET

EFR

EBR

ET

CUT

EBSOL

EFSOL

189

188

186

187

190 191

181 182 183180DOR SHFR 1CBR EFR

0BACK EJECT

EJECTOR

(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

Ejector Forward

Ejector Backward

Counter

Ejector Time

X008X100

X101

Input modulePC-0

0

1

CEF

CEB

Ejector Forward

Ejector Backward

0BACK EJECT

EJECTOR

X104

Fig. 2 Input Module

7X01A

X01B

A

B

EFL

EBL

Ejector Forward LS

Ejector Backward LS

X01

Input modulePC-0

EFLS

EBLS

4

5

Fig. 3 Output Module

Ejector Forward SOL

Ejector Backward SOL

EFSOL

EBSOL

Y04C

Y04D

Output modulePC-0

Y04 C

D

10

4

Fig. 4 Software Circuit

R012 AR

T141 DT

R038DOCB

R13ATEFX

T012EST00010T012

ESTX012 DOL

X01CSHFL

X1111CBL

R039EFY

Y04CEFS

R039EFY

X01AEFL

Y04DEBS

R010MR

X100CEF

X101CEB

Ejector Delay Time

Ejector Auxiliary

Ejector Forward SOL

2-2 How to read Basic Circuits(1) Relay Circuits Series Connection

W

PB1 PB 2 PB 1

PB 2

SL-1

SL-1

The lamp (SL-1) goes on only when you pressed the push buttons (PB1) and (PB2) concurrently. The lampGoes off when you release either one of the push button.

Parallel connection

W

PB 1

PB 2

PB 1

PB 2

SL-1

SL-1

The lamp (SL-1) goes on when you pressed either one of the push button (PB1) or (PB2)

6

Self –holding circuit.

PB1 PB 2

R 1

R 1

Self-holding contact after coil R1 ON

PB 1

R1

PB2

Interlock circuit.When the circuit of higher priority is turned ON, other circuit are opened and cannot be operated on.

R1

PB 1

R 1

R2

R 2

PB 2

R 2PB 1

R1

PB2

R2

Priority Circuit

The relay (R1) is turned on when you press the push button (PB1). In series connection, (R1) is turned off whenYou release (PB1). By connecting the push button (PB1) in parallel with contact A of (R1), (R1) remains on evenIf you release (PB1).

When you turn on a high priority circuit, the other circuit opens and is unable to work. The relay (R1) is turned onwhen you press the push button (PB1) and (PB2) remains on through the self holding feature. However when youpress 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.

R1

R 1 R 2

PB 1

R2

R 2 R 1

PB 2

PB 1

R1

PB2

R2

The latest input always has priority over the previous input. The relay (R1) is turned on when you press the pushbutton (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 whenyou press (PB1) again, and (R1) is turn on.

7

Timer circuit.

A. Delayed operation circuit.

R1

PB 1

W

T

R 1

T

PB 1

R 1

T

SL-1

Certain time operation circuit.

Actuated simultaneously when the switch is turned ON and stops when the timer set time is up.

R1

PB 1

T

R 1

T

L

PB 1

R 1

T

L

Repeated operation circuit.

Two timers are used and the circuits are repeatedly turned ON and OFF according to their set times.

SS R 1

T1

L

R1

T2

T 1T 2

R 1

T1 T2 T1 T2

SS

T 1

R 1

T 2

L

8

(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

7 4PBS1

PBS2

X10C

X10D

Input modulePC-0

X10

C

D

PBS1

PBS2

Cycle Start

Cycle Start

1) Figure 1Clamping 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 2Clamping 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 cannot longer be turned on and clamping does not start.(Similarly, a non-repeat circuit is also incorporated in relay circuit.

Figure 1

Figure 2

1

2

Start Pushbutton 100206

Start Pushbutton interval 1/00207

Start Pushbutton 200208

Start Pushbutton interval 2/00205

R000HPDR

X10CPBS1

T007PBT2

R004PBR1

R000HPDR

X10DPBS2

T006PBT1

R005PBR2

T007PBT2

T006PBT1

R004PBR1

R005PBR2

3

6

4

5

00205

00206

00207

00208

9

2-3 How to read extended connection diagram of electric circuit.

(1) Relay circuitThe 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).

R012 AR

T141 DT

R038DOCB

R13ATEFX

T012EST00010T012

ESTX012 DOL

X01CSHFL

X1111CBL

R039EFY

Y04CEFS

R039EFY

X01AEFL

Y04DEBS

R010MR

X100CEF

X101CEB

Ejector Delay Time00719

Ejector Auxiliary00722 /0080000804

Ejector Forward SOL/00801

6 155 7

IR

DOR

4

ET

EFR

EBR

ET

CUT

EBSOL

EFSOL

189

188

186

187

190 191


0BACK EJECT

EJECTOR

Ejector Forward

Ejector Backward

Counter

Ejector Time34 63

3

1

1

2

2

56

58

59

60

61

62

63

00718

00719

00721

00722

Contact B

Contact B

181

Wire number(marked on the wire)

wire

(2) PC circuitAs is the case with the relay circuit, the numbers below (1) in the below figure are addresses, and the numbersabove (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 withno slash being prefixed indicates contact A.

10

2-4 How to read extended connection diagram of relay circuit.

Example : The ejector cylinder does not move forward (Manual)(1) 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.]

(2) Conditions for turning on the ejector (forward) solenoid valve.(A) EFR (ejector forward limit switch) OFF figure 2(B) 1CBR (core 1 return limit) ON figure 2(C) SHFR (safety hook on limit) ON figure 2(D) DOR (die open limit) ON figure 2(E) Ejector selector switch “Forward” figure 2(F) 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.

(1) Using a multi-meter, check if the voltage of wires 4 and 7 are 100V.(2) Using a multi-meter, check the voltage of each terminal on the circuit of wire 4 to find out where is shut down.(3) 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.(4) 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.

6 155 7

IR

DOR

4

ET

EFR

EBR

ET

CUT

EBSOL

EFSOL

189

188

186

187

190 191


0BACK EJECT

EJECTOR

Ejector Forward

Ejector Backward

Counter

Ejector Time34 63

56

58

59

60

61

62

63

54

AutomaticAR

AR

IBRCOR

EBR7

Cycle COS1Manual Automatic

Figure 2

Figure 1

11

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]

R039EFY

X01AEFL

Y04DEBS

Y04CEFS

Ejector ForwardFigure 1

7

X01A

X01B

A

B

EFL

EBL

Ejector Forward LS

Ejector Backward LS

X01

Input modulePC-0

EFLS

EBLS

4

R012 AR

T141 DT

R038DOCB

R13ATEFX

T012EST00010T012

ESTX012 DOL

X01CSHFL

X1111CBL

R039EFY

R010MR

X100CEF

X101CEB



Ejector Forward SOL

Ejector Backward SOL

EFSOL

EBSOL

Y04C

Y04D

Output modulePC-0

Y04 C

D

10

4

Figure 2

Figure 3

Figure 4

•See the section explaining B200 for how to view the LED of the input and output modules.

EBLS EFLS

EjectorBackwardLimit sw

EjectorForwardLimit sw

12

R012 AR

T141 DT

R038DOCB

R13ATEFX

T012EST00010T012

ESTX012 DOL

X01CSHFL

X1111CBL

R039EFY

R010MR

X100CEF

X101CEB



Figure 1

(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.

Core 1 return limit

47

MC 1X111 X111

1CBL

X11

Input ModuleFigure 2

Safety hook in limit

47

SHFLX01C

X01C

X01

Input Module

Die open limit

47

DOLX012 X012

X01

Input Module

Figure 3

Figure 4

Ejector forward

4ManualX008

X100 X100

X10Input Module

Ejector backwardX101X101

EjectorCOS 4 0Backward ForwardFigure 5

Ejector 0

Backward Forward

Safety hook cylinder

SHFLS (a)

SHBLS (a)

Link

H

ousi

ng

DCLS (b)

DHILS (b)

SHSLS (a)

DOLS (a)

SHFLS

DOLS

13

(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 runIf 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)

KSM

KSA

KSFA

R010 MR

Manual operation

Selector switches neutral

Cycle manual

Selector switches neutral

X008KSM

X009KSA

X00AKSFA

X002COR

R012 AR

R010 MR

Figure 1

Figure 2

Figure 3

Figure 4

Figure 2

CORX002

Input Module

Input Module

X00

X00

X002

COR

COR

7 4

3 4

47

DIECOS2

INJECTION COS3

EJECTOR COS4

CORE 1 COS5

Open 0 Close Inject 0 Return Eject 0 Return In 0 Out20 21 22 27

CYCLE KS 2

Man Off Auto Full AutoX008

X009

X00A

Cycle auto

Cycle full auto

X008

X009

X00A

X008KSM

X009KSA

X00AKSFA

X002COR

R011 AR1

R041MRBR

R011 AR1

R010 MR

R012 AR2

R012 AR

R00CMHPR

Automatic operation auxiliary

Automatic operation

14

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 3When the lubricant pump starts running and the pressure increases to 17 kg/cm², 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 3The 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 4When 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.

MLR LBPS LBT

LBX

LBOL

LBX

LBT

LBL

LBPT

Lubricant pump stop

Lubricant pump stop time

Lubricant pump run

Lubricant pressure detect

MLR LBPS LBT

LBX

LBOL

LBX

LBT

LBL

LBPT

Lubricant pump stop


Lubricant pump run


MLR LBPS LBT

LBX

LBOL

LBX

LBT

LBL

LBPT

Lubricant pump stop


Lubricant pump run


R S TNFB 1 LBL LBOL

LBM

U3

V3

W3Motor for lubricant pump

Fig. 1

Fig. 3

Fig. 4

Fig. 2

1

32

5

4

6

5

7

15

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 4When 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 6When 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.

R0 S0 T0NFB 2 LBL LBOL

LBM

U3

V3

W3Motor for lubricant pump

R000HPDR

T002LBST

T001LBMT

T001LBMT

T002LBST

Y038 LBL

R000HPDR

T001LBMT

Lubricant pump run

Lubricant pump run time


Y038 LBL

LBLLBOLY03

Output module10 4

Lubricant pump onY038

Fig. 1

Fig. 3

Fig. 2

R000HPDR

T002LBST

T001LBMT

T001LBMT

Y038 LBL

Lubricant pump run

R000HPDR

T002LBST

T001LBMT

T001LBMT

Y038 LBL

Lubricant pump run



T002LBST

R000HPDR

T001LBMT


1

3

Fig. 4

Fig. 6

Fig. 5

2

4

6

8

5

7

910

16

Programmable Logic ControlB200

1. Specification

Item Description

Voltage 100AC only

Regulation Between 85 and 132 VAC 50 Hz

Primary side 5V 10A 135 VAC or less

power

consumption 5V 5A 80 VAC or less

Ambient temperature used 0 to 55 ºC

Storage temperature -20º C to 65º 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 : 0.42µ

Basic output instruction : 0.58µ (Y, L, SD & MC)

Basic instruction 16 types

Applied Standard FS 00 ~ FS 63 MOVE,,,,,V,BIN, & BCD

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)

Pow

er s

uppl

yIn

stru

ctio

n

17


DescriptionInternal relay 1024 points, R000 to R77FTimer counter T000 to T17F 0.1 to 3276.7 sec(Totals 512 points) T200 to T37F 0.01 to 327,67T000 to T37FC000 to C37F C000 to C37F 1 to 32767Latch 128 points L000 to L07FShift register 128 points S000 to S07FEdge register 128 points E000 to E07FData register 1024 words D000 to D77F(General purpose register) Timer Set value 512 words V000 to V37F counter Preset value 512 words P000 to P37F Alarm flag A011 : To be turned ON when the battery voltage

of the CPU module is unusual.A012 : To be turned ON when the PC link transmission is unusual.A013 : To be turned ON when the user program execution times exceeds 100ms.A014 : To be turned ON when an instantaneous power failure occurs.A015 : To be turned ON when the undefined FUN instruction is executed.A016 : To be turned ON when the out put module fuse is blown out.A017 : To be turned On when the coil output instruction is used for the 16 point input in the user program.

Dead fuse alarm for A020 : To be turned ON when the output module each rack fuse of the rack No. 0 is blown out.

toA02F : To be turned ON when the output module fuse of the rack No. F is blown out.

Item

Tem

pora

ry s

tora

ge

Spe

cial

aux

iliar

y re

lay

18


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 º C 5 years or longer

life 55 º 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

19


DescriptionTrouble Operation / Trouble of CPU :detecting monitor It is detected that the CPU is uncontrollablefunction mode

Trouble of ROM :It is detected that the system program ROMcontrolling the PC or the usersequence programEPROM is abnormal

Trouble of RAM :It is detected that the system RAM controlling thePC is abnormal

Back up data error :It is detected that the content of the user sequenceprogram CMOSRAM or the data held in serviceinterruption is changed

Instantaneous power failure detection :An intantaneous power failure of the PC powersupply for 10ms or longer is detected. (When theInstantaneous operation stop mode is set)

Trouble of the battery :It is detected that the voltage of the memory backup battery is dropped to approx. 2.8 V or lower

Dead fuse detection :It is detected that the fuse inside the output moduleis blow out

Trouble of I/O bus :Abnormal input/output data of the input/outputmodule are detected

Item

20


DescriptionTrouble Operation / Trouble of I/O mismatch :detecting monitor It is detected that the output instruction is used forfunction mode the input module in the user program

Trouble of PC Link :The trouble of PC Link transmission is detected

Abnormal cycle time :It is detected that an undefined function instructionis processed

Function over :The memory capacity for function instruction isinsufficient

Program Circuit element errormode Memory full

MT PC playback errorPeripheral circuitsPair coil error

Searchec data errorMemory PC < MTPC = MT checking errorNumber of coil circuits errordiscompiling error

Monitored data errorMemory ROMUncompleted circuitDuplicate coil error

Item

21


2.1. Programmable Logic ControlConnector for connecting extended Input/ Output rack

Rack number setting switch

Power module

CU module

Maximum 8 pieces of input and out moduleInput module indicates -- X Output module indicates -- Y

7 6 5 4 3 2 1 0Module slot number

Input/ Output module

1 2 3

1 indicates Rack number 2 indicates Module slot number3 indicates Terminal number

Basic base board

Connector for peripheral equipment(Programmer PGM 355)

22


From Basic BoardMode switch

Power module

7 6 5 4 3 2 1 0Module slot number

Maximum 8 pieces of input and out moduleInput module indicates -- X Output module indicates -- Y

1 2 31 indicates Rack number 2 indicates Module slot number3 indicates Terminal number

To anotherExtension base

*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’

2.2. Programmable Logic Control

Extension base board

23


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 When 5VDC is supplied… turned ON(Green) 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 thetrouble 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.

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)

Fuse (glass tube fuse 250V, 4A)

24


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

Lithium battery (Model K21141G 3.6 VDC):Used for the power supply to hold the memory during serviceInterruption. For the EPROM memory, it is used to back up thedata.

Battery connector : Connect the lithium battery to the CPU board

The EPROM memory board

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.

25

No. PC mode OFF ON4 Test mode OFF ON3 Instantaneous Operation Operation

power failure stop continuingdetection andcycle time over

2 Timer counter Unchangeable Changeableset value

1 Intial clear Unexecuted Executed


When dismantle and view from the back

ON1

2

3

4

PC mode setting switch :Used to set the working mode of the PC and set asfollow when shipping :-

Shipping status : All OFF position

Back up area Address While data While data isis memor- memorized byized by the the EPROMCMOS Timer counterRAM set value SW

Unchan Changgeable eable

Holding area in the R000 - R37F Cleared Cleared Clearedtemporary storageduring interruptionLatch relay L000 - L07F Cleared Cleared ClearedShift relay S000 - S07F Cleared Cleared ClearedGeneral purpose D000 - D77F Cleared Cleared ClearedregisterTimer counter V000 - V37F Cleared ----- Clearedset valuePreset value of P000 - P37F Cleared ----- ClearedcounterProgram ----- Cleared ----- Cleared

Initial clear : Used to set the status on whether to clear the battery back-up area of theCMOS RAM when the power is turned on.

26


D. 16 points Input Module Model : B200 16 AI – 100 VAC B200 16 DI -- 24 VDC

E. 16 points Output Module Model : B200 16AO – 100 VAC B200 16 DON – 24 VDC B200 16 DOP – 24 VDC

Input ON/OFF indicator lamp (red)ON – turned onOFF– turned off

Terminal block

Output ON/OFF indicator lamp (red)ON – turned onOFF– turned off

Terminal block

Built in blow-fuse indicator lamp (red)Blown out – turned onNormal – turned off

27


F. 32 points Input Module Model : B200 32 AI – 100 VAC B200 32 DI -- 24 VDC

Input ON/OFF indicator lamp (red)ON – turned onOFF– turned off

Terminal block

G. 32 points Output Module Model : B200 32AO – 100 VAC B200 32 DON – 24 VDC B200 32 DOP – 24 VDC

Output ON/OFF indicator lamp (red)ON – turned onOFF– turned off

Terminal block

Note : The 32 points output module has no built in blow out fuseInstall the 1 common 5A fuse outside the module. Through this fusePrevent the module pattern from burning, it’s protects no internal element.

28


3. Replace fuse on output module (B200 16AO)

Rearcover

Output board

Case Terminalblock

Fuse

Fuse

Fuseblowoutindicator

Screw 1

Screw2

Fuse : 125 V 7.5AModel : MP 7.5

Fuse : Ordinary blowout typeModel : MF-51 250V 6ASize : 5.2 X 20 mm

Note : Used recommended fuse or same ampere fuse only.

29


4. LED display on I/O module (16 points)

01234567COM89ABCDEFCOM

AC100VOUTPUT

01234567

89ABCDEF

Fuse blownOutput moduleonly

01234567

89ABCDEF

RightSide

Y070Y071Y072Y073Y074Y075Y076Y077Y078Y709Y07AY07BY07CY07DY07EY07F

Leftside

AC100VINPUT

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.

(3)

(a)

(b)

(1)

30

0 1 2 30 01 12 23 34 45 56 67 7



5. LED display on I/O module (32 points)


X000X001X002X003X004X005X006X007COMX008X009X00AX00BX00CX00DX00EX00FCOM

X100X101X102X103X104X105X106X107COMX108X109X10AX10BX10CX10DX10EX10FCOM

AC 100VINPUT

01234567

01234567

0 1 2 3

AC 100VINPUT

01234567

01234567

0 1 2 3

X000ToX007

X008ToX00F

X100ToX107

X108ToX10F

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.

31

Programmable Logic ControlTC200

1. Specification

Item Description

Voltage AC 100 V 50 Hz

Regulation Between 85 and 132 VAC

Primary side 5V 10A 120 VAC or less

power

consumption 5V 5A 80 VAC or less

Ambient temperature used 0 to 55 ºC

Storage temperature -20º C to 70º 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 : 0.09µ to 0.18µ

Application instruction : 0.57µ

Basic instruction 16 types

Applied Application 127 kinds (Arbitrary setting of argument and

Instruction instruction Selection of operating conditions are possible)

User defined 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.

Pow

er s

uppl

yIn

stru

ctio

n

32


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

33


2.1. Programmable Logic Control

7 6 5 4 3 2 1

1 – Power module2 – CU module3 – Communication module ( For “J” type machine only)4 – Remote module ( For “J-S” type machine only)5 – Input module6 – Output module7 – Output module8 – Output module (For “J” type machine only)9 – Input module (For “J” type machine only)10- Input/output module (For “J” type machine only)

8

9

10

34


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 switchPower wiring terminal block :INPUT AC 100V terminalFG (frame ground) terminalSTOP 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/OIN connector of the next extension I/O power supply module.

B. Extension Power Module – Used for the extension I/O rackModel : TCPW 110B – AC 100V

EXT. I/O (OUT) connector :Connector for extension I/O connection. Connect it with the EXT. I/OIN connector of the next extension I/O power supply module.

Power wiring terminal block :INPUT AC 100V terminalFG (frame ground) terminalOUTPUT DC 5V terminal: Power of DC 5V is supplied to TCPW5B

Rack No. setting switch

EXT. I/O (IN) connector :Connector for extension I/O connection. Connect it with the EXT. I/O(OUT) connector of the preceding extension I/O power module.

35


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

36


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.

ON

987654321

No. PC mode98 MC BOOT7 MC WRITE6 SEQ. PROTECT5 DATA REG. PROTECT4 I/O CHANGE3 OUT HOLD2 CONTINUE1 INITIAL

37

Programmable Logic Control TC200

No. 8. MC BOOT When set to ON from OFF, the sequence program is booted (memory card boot) from the memory card. (Also booted when the switch set to ON at power ON)No. 7. MC WRITE When set to ON from OFF, the sequence program is written (Memory card write) into the memory card. (Memory card write protect “WP” must switch to ON) See fig. below

No. 6. SEQ. PROTECT When set to ON, writing of sequence program is prohibited. (Sequence protect)No. 5. DATA REG. PROTECT Writing of data register is banned. (Data register protect)No. 4. I/O CHANGE When set to ON, the I/O module can be changed during PC (input / output change) 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.

WP

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

38


D. Input module Model : TC 32DI – DC 24V TC 32AI – AC 100V

E. Output module Model : TC 32DON – DC 24V COM - NEGATIVE TC 32 DOP – DC 24V COM - POSITIVE TC 32AO – AC 100V

Input signal indicator lampWhen the input signal is ON, LED light in red

Terminal block

Input signal indicator lampWhen the input signal is ON, LED light in red

Terminal block

Fuse blow out indicator lampIlluminated in red if the output wiring protection has blown out

39


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 generatedIn the internal circuit and must not be replaced by customer.

PCB Case

Terminal block

Rearcover

Sparefuse

Fuse

Note : Used recommended fuse or same ampere fuse only.

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.

40


5. 32 points input module LED display and terminal connection

0 1 2 30 01 12 23 34 45 56 67 7

13578ACEC213578ACEC4

0246C19BDF0246C39BDF

X001X003X005X007X008X00AX00CX00ECOMX101X103X105X107X108X10AX10CX10ECOM

X000X002X004X006COMX009X00BX00DX00FX100X102X104X106COMX109X10BX10DX00F

TC 32DI

01234567

01234567

0 1 2 3

TC 32DI

01234567

01234567

0 1 2 3

X000ToX007

X008ToX00F

X100ToX107

X108ToX10F

TC 32AI

TC 32AI

41


6. 32 points Output module LED display and terminal connection

0 1 2 30 01 12 23 34 45 56 67 7

13579BDF-13579BDF-

02468ACEC102468ACEC2

Y001Y003Y005Y007Y009Y00BY00DX00E NY101Y103Y105Y107Y109Y10BY10DY10F N

Y000Y002Y004Y006Y008Y00AY00CY00ECOMY100Y102Y104Y106Y108Y10AY10CY10ECOM

TC 32DON

01234567

01234567

0 1 2 3

TC 32DON

01234567

01234567

0 1 2 3

Y000ToY007

Y008ToY00F

Y100ToY107

Y108ToY10F

FUSEFuse blown out indicator

42


7. 16/4 points input module. Model : TR 16DIC, TR 16DIE, TR 04DI

Mode switch

Input LED display

LINEEND

01

1 2

CH NO

Terminal connector

Operation monitor LED display

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

Main I/O Unit supply DC24V DC24V X**0 COM X**1 X**2 COM1 X**3 X**4 COM2 X**5 X**6 COM3 X**7

X**8 COM4 X**9 X**A COM5 X**B X**C COM6 X**D X**E COM7 X**FFGA+ B- FG

43


8. 16/4 points output module. Model : TR 16AOECE, TR 16AOE, TR 04AO

Terminal connector

A3 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

I/O supply AC100V Y**0 COM Y**1 Y**2 COM1 Y**3 Y**4 COM2 Y**5 Y**6 COM3 Y**7

Y**8 COM4 Y**9 Y**A COM5 Y**B Y**C COM6 Y**D Y**E COM7 Y**FFG

Input LED display

Fuse250 VAC 3A5.2 X 20mm

44


9. Input / output module. Model : TR 80DIDOPT (64 points input & 16 points output)

TB1 TB2

12345678910111213141516171819202122232425262728293031323334353637383940

X+0 X+201234567C189ABCDEFC2

01234567C389ABCDEFC4

OVOV24V24V



OVOV24V24V

Power LEDRun LEDError LED

DC 24V Input

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

Fuse for outputY**0 to Y**7

Fuse for outputY**8 to Y**F

TB3

O OSW2 SW3

SW1

2 1

Channel I/O LED indicator

F1F2

F32 – Line End1 – Channel change

Power Supply Control

I/O LEDdisplayLed 1 - 16

Y**

0Y

**1

Y**

2Y

**3

Y**

4Y

**5

Y**

6Y

**7

C9

Y**

8Y

**9

Y**

AY

**B

Y**

CY

**D

Y**

EY

**F

C10

(-)

24V

0V FG A(+

)B

(-)

SG

FG

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

45


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 pinExample : 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)

FEDCBA9876543210

LED 16LED 15LED 14LED 13LED 12LED 11LED 10LED 9LED 8LED 7LED 6LED 5LED 4LED 3LED 2LED 1

0

12 3

4

56

789

SW30 OFF1 LED display for input signal TB 1-1 to 8 & 10 to 17 connection ports2 LED display for input signal TB 1-19 t0 26 & 28 to35 connection ports3 LED display for input signal TB 2-1 to 8 & 10 to17 connection ports4 LED display for input signal TB 2-19 to 26 & 28 to35 connection ports5 LED display for output signal TB 3-1 to 8 & 11 to 18 connection ports6~8 Unused9 LED test mode

46


10. Communication module. Model : TCRMT

TCRMT

RUNALARMSTOP

RS485

A

B

FG

RS485

A

B

FG

Operation LED displayRun : ON when CU module switch to runAlarm : On when RS485 wire troubleStop : Module trouble

Terminal connectorConnect the blocks according. These 2 terminal blocksare connected internally by connecting the same signals.

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 accordingto the intended use. SW1 TERMINATING RESISTANCE Used to turn on and off the 100 Ω 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.

Power Peripheral Alarm contentsupply equipment & referencemodule error message for remedyPower RUN ALARM STOP MAINTENA-

NCE CODE

O

O O O C.7.0 F Table error The undefined function instruction is used.

C.7.1 I/O mismatch The output instruction is used for the input module.

C.7.2 Link table error The link table data isabnormal.

C.6.0 Cycle time over The processing time of one cycle exceeds thepredetermined time.

C.4.0 Battery fail The battery voltage dropsto 2.8 V or less.

C.4.1 EEPROM Data writing to or readingfrom the memory card isabnormal.

F.0.0 to Fuse down The fuse of the outputF.0.7 module has blown out.

L.0.0 to PC link error Abnormal data L.3.F transmission by PC link.

O O C.0.0 PC CPU error The main PC CPU hasmalfunction.

C.0.1 PC RAM error The operating system RAM is abnormal.

C.0.2 PC ROM error The operating system ROM is abnormal.

P.0.0 EXT. power fail The DC 5V power voltageabnormal.

C.3.0 Back up data The sequence memory error data is abnormal.

L6.0 Link master Two or more link mastermaster are preset.

C.6.1 INT. Prog. over The interruptive programhas not been processed within the predetermined time.

Normal condition

Abnormal condition, operation continues.

Abnormal condition, operation stop.

LED ON / OFF State of Power supply and CU moduleO : LED ON, : LED OFF

LED indication

CU module


48


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 ModuleP : Power ModuleU : I/O ModuleE : Intelligent Module

Signifies the alarm breakdown.0 ~ 2 : Replacement of module is needed3 ~ 5 : If the same alarm is repeated, replacement module, etc. is needed.6 ~ 8 : Illegal programming or setting.

. . .

F : Fuse downH : Remote I/O errorU : I/O error

0 ~ F : Rack number 0 ~ 7 : Card number (If the remote I/O isgenerated, the card number is “0”)

L. . .

L : PC link error 0 ~ 3 : PC number (Upper)

0 ~ F : PC number (Lower)

Maintenance code display

SYMBOL (1)

ELECTRICAL SYMBOL

Name Symbol Symbol Name Description

FUSEEE

MOTOR

M

OVERLOAD RELAY MOL

MOL

MOL

LMAGNETIC SWITCH

DFFORWARD /REVERSESWITCH

DB

DF

CUTSHOT COUNTER

DB

Fuse

3-phaseinductionmotor

Melts down to protect the circuit whenelectric current larger than the flows.Therefore, do not use fuse greater than the rated capacity.

Bimetal

Contact

This is a 3-phase motor and a symbol forthe location it is used is entered in this part.The supply voltage must be ±10% of theRated voltage.

Generates heat when a current larger thanthe rated current flows, becoming warpedto break the contact. This action turns offcurrent in the magnet switch coil to protectthe motor.

Coil

Contact

When current flows in the coil, its activatesthe motor that has contacts connected.Normally open contacts operated by above.

Coil to move dieheight unitforward andbackward.

Contacts of DFand DB.

When current flows in the coil, it connectscontact DF or DB.

Contacts connected by DF or DB.

Shot counterWhen current flows in the power section, itrotates the gear a ½ turn and when current stops, it simultaneously rotates the gear ½ turn further to change the indicator number.

A BC DE FG H

SYMBOL (2)

ELECTRICAL SYMBOL

COS & KS 1 0 2

SELECTOR SWITCH &KEY SWITCH

PRS

PRS

PRESSURE SWITCH

a

d

b

c

e

SELECT SWITCHPS

FSFOOT SWITCH

SOLENOID COIL

Standard CloseSHORTING WIRE

SSSNAP SWITCH

EGROUND(EARTH)

Tr

180 200 220

100

TRANSFORMER

SLINDICATOR LAMP

Name Symbol Symbol Name Description Vertical line =a switch position,the horizontalline = combination, &the • mark =connection.

Locations where broken line intersect asmarked by • are connected from left to right.When switch to 0 connection is from C to DAnd G to H.When switch to 1 connection is from A to BWhen switch to 2 connection is from E to F

Contact A(normally opencontact)Contact B(normally closecontact)

Connected when pressure rises above theset pressure. Disconnected when pressure is below the set pressure.Disconnected when pressure rises aboveshe set pressure. Connected whenpressure is below the set pressure.

a → b Contact Ba → c Contact Ad → e Contact A

Contact A

When switched over, a to c and d to e areconnected, a to b are disconnected.If is not switch over, the connection as shown in the diagram.

Connection when the pedal is stepped on.

Solenoid coilWhen the current flows, it is energized toSwitch over the valve.

Shorted forStandard Machine.

Discounted in the terminal block sectionwhen using automatic device or safety equipment.

Contact A Connected when switch lever push to ON position. And disconnected when push toOFF position.

Earth One side of the transformer secondarycircuit is grounded to earth with green wire.(wire directly connected to the coil)

Primary side

Secondary side

Voltage varies in proportion to the numberOf coil windings. The voltage on the secondary side varies as the tap on theprimary side is changed.

W

Indicator lamp Also called signal lamp.Symbol W is white, G is green, R is red &Y is yellow.

SYMBOL (3)

ELECTRICAL SYMBOL

PBPUSH BUTTON SWITCH

LIMIT SWITCH

RAUXILIARY RELAY

T

T

T

Off OnKS

TIMER(TIMER LAGRELAY)

KEY SWITCH

METAL CONSENT MC

a b

W

PUSH BUTTON WITHLAMP

BZBUZZER

Name Symbol Symbol Name Description

Contact A

Contact B(mushroom type)Contact B

Connected when pushed & disconnectedwhen release.Disconnected when pushed & connectedwhen release.(use at emergency stop)

Contact A

Contact B

Connected when lever was pressed anddisconnected when release.

Disconnected when lever was pressed andconnected when release.

Coil

Contact A

Contact B

When current flows, it is energized toswitch over the contact.

Connected when coil energized.Disconnected when coil is not energized.Disconnected when coil is energized.Connected when coil is not energized.

Coil

Contact A

Contact B

When current flows, it time lag operationstart.Connected when the set time elapses afterflows in the coil. Disconnected when current stops.Disconnected when the set time elapsesAfter current flows in the coil. Connectedwhen current stops.

Key switchThis switch cannot be operated unless thekey was inserted. When the key inserted &turn to ON position, a and b are connected.

a b

Metal connector Core in/out limit switch is connected when using a core. And a & b are connectedthrough the limit switch.

Contact A

Lamp

The lamp lights when the push button ispressed.W is white.R is red.

BuzzerWhen current flows in the coil, it’s createsa sound.

electrical (e1)

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