LG MASTER-K 120S Series User Manual

Programmable logic controller

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Overall Configuration

MASTER-K 120S series

- When using LGIS equipment, thoroughly read this datasheet and associated

manuals introduced in this datasheet. Also pay careful attention to safety and

handle the module properly.

- Keep this datasheet within easy reach for quick reference

User's Manual

LG Programmable Logic Controller

LG Industrial Systems

Table of Contents

Troubleshooting

Summary of Contents for LG MASTER-K 120S Series

Page 1 User’s Manual LG Programmable Logic Controller MASTER-K 120S series LG Industrial Systems - When using LGIS equipment, thoroughly read this datasheet and associated manuals introduced in this datasheet. Also pay careful attention to safety and handle the module properly. - Keep this datasheet within easy reach for quick reference...
Page 2 SAFETY INSTRUCTIONS To Prevent injury and property damage, follow these instructions. Incorrect operation due to ignoring instructions will cause harm or damage, the seriousness of which is indicated by the following symbols WARNING This symbol indicates the possibility of death or serious injury This symbol indicates the possibility of CAUTION injury or damage to property.
Page 3 SAFETY INSTRUCTIONS Design Precautions Warning Install a safety circuit external to the PLC that keeps the entire system safe even when there are problems with the external power supply or the PLC module. Otherwise, serious trouble could result from erroneous output or erroneous operation. - Outside the PLC, construct mechanical damage preventing interlock circuits such as emergency stop, protective circuits, positioning upper and lower limits switches and interlocking forward/reverse operation.
Page 4 SAFETY INSTRUCTIONS Design Precautions Caution Do not bunch the control wires or communication cables with the main circuit or power wires, or install them close to each other. They should be installed 100mm (3.94inch) or more from each other. Not doing so could result in noise that would cause erroneous operation. Installation Precautions Caution Use the PLC in an environment that meets the general specification...
Page 5 Tighten the terminal screws with the specified torque. If the terminal screws are loose, it could result in short circuits, fire, or erroneous operation. Be sure to ground the FG or LG terminal to the protective ground conductor. Not doing so could result in erroneous operation.
Page 6 SAFETY INSTRUCTIONS Startup and Maintenance Precautions Warning Do not touch the terminals while power is on. Doing so could cause electric shock or erroneous operation. Switch all phases of the external power supply off when cleaning the module or retightening the terminal or module mounting screws. Not doing so could result in electric shock or erroneous operation.
Page 7 Revision History Date Code Revision history 2002.7. 10310000380 First edition is published 2003.5. 10310000380 A revised edition is published Main unit and expansion modules are added – Built-in function are upgraded – 2003.9 10310000380 A revised edition is published. Main units are added Built-in functions are upgraded.
Page 8: Table Of Contents
◎ Contents ◎ Chapter 1. General 1.1 Guide to Use This Manual ················· 1 - 1 1.2 Features ······················· 1 - 2 1.3 Terminology ······················ 1 - 3 Chapter 2. System Configuration 2.1 Overall Configuration ··················· 2 - 1 2.1.1 Basic System································································································...
Page 9 4.4 Communication I/F Module ················· 4 - 13 4.4.1 Cnet I/F Module····························································································4 - 13 4.4.2 Fnet I/F Module ····························································································4 - 13 4.4.3 Pnet I/F Module ····························································································4 - 14 4.4.4 DeviceNet I/F Module ····················································································4 - 14 4.5 Option Module ····················· 4 - 14 Chapter 5.
Page 10 5.9.2 Usage ········································································································5 - 30 5.10 External Memory Module ················· 5 - 32 5.10.1 Structure ···································································································5 - 32 5.10.2 Usage·······································································································5 - 32 5.11 RTC Module ······················ 5 - 34 5.11.1 Structure ···································································································5 - 34 5.11.2 Usage······································································································5 – 34 Chapter 6. Input and Output Modules 6.1 Input / Output Specifications ················...
Page 11 Chapter 8. Communication Function 8.1 Dedicated Protocol Communication ·············· 8 - 1 8.1.1 Introduction ·································································································· 8 - 1 8.1.2 System configuration method ··········································································· 8 - 2 8.1.3 Frame Structure ···························································································· 8 - 5 8.1.4 Lists of Commands ························································································ 8 - 7 8.1.5 Data Type ····································································································...
Page 12 Chapter 10. Maintenance 10.1 Maintenance and Inspection ················ 10 - 1 10.2 Daily Inspection ···················· 10 - 1 10.3 Periodic Inspection ··················· 10 - 2 Chapter 11. Troubleshooting 11.1 Basic Procedure of Troubleshooting ············· 11 - 1 11.2 Troubleshooting ············································································ 11 - 1 11.2.1 Troubleshooting flowchart used when the power LED turns off ·····························11 - 2 11.2.2 Troubleshooting flowchart used when the error LED is flickering ····························11 - 3...
Page 13: Chapter 1. General
Chapter 1 General Chapter 1. General 1.1 Guide to Use This Manual This manual includes specifications, functions and handling instructions for the MASTER-K120S series PLC. This manual is divided up into chapters as follows: Title Contents Chapter 1 General Describes configuration of this manual, unit's features and terminology. Chapter 2 System configuration Describes available units and system configurations in the MASTER-K120S series.
Page 14: Features
Chapter 1 General 1.2. Features 1) MASTER-K120S series is extremely compact, to fit a wide range of applications and have following features. (1) High speed processing High speed processing of 0.1~0.9µs/step with an general purpose processor included . (2) Various built-in functions The main unit can perform many functions without using separate modules.
Page 15: Terminology
Chapter 1 General 1.3 Terminology The following table gives definition of terms used in this manual. Terms Definition Remarks Example) A standard element that has a specified function which configures the CPU module Module system. Devices such as I/O board, which inserted onto the mother board Power Supply module or base unit.
Page 16 Chapter 1 General Terms Definition Remarks Current flows from the switch to the PLC input terminal if a input signal turns on. Sink Input Current flows from the PLC input terminal to the switch after a input signal turns Source Input Current flows from the load to the output terminal and the PLC output turn on.
Page 17: Chapter 2. System Configuration
Chapter 2 System Configuration Chapter 2. System Configuration The MASTER-K120S series has suitable to configuration of the basic, computer link and network systems. This chapter describes the configuration and features of each system. 2.1 Overall Configuration 2.1.1 Basic system expansion Main unit module expansion...
Page 18: System
Chapter 2 System Configuration 2.1.2 Cnet I/F system Cnet I/F System is used for communication between the main unit and external devices using RS-232C/RS-422 Interface. The MK120S has a built-in RS-232C port, RS-485 port and has also G7L-CUEB for RS-232C, G7L-CUEC for RS-422. It is possible to construct communication systems on demand.
Page 19 Chapter 2 System Configuration (3) RS-232C Communication over a long distance via modem by Cnet I/F modules MASTER-K120S G7L-CUEB G7L-CUEB MASTER-K120S Modem Modem MASTER-K120S G7L-CUEB Modem Modem 2) 1:n Communications system This method can connect between one computer and multiple main units for up to 32 stations Can be connected Max.
Page 20: Product Functional Model
Chapter 2 System Configuration 2.2 Product Functional Model The following describes functional model of the MASTER-K120Sseries. 2.2.1 Product Functional Block Product function block for the K120S series is as follows. Main Unit Expansion Modules Power supply Input signal Input signal Power Input Input...
Page 21 Chapter 2 System Configuration 2.2.2 K120S Series System Equipment Product 1) Main Unit – Standard type I/O Point & Items Models Built-in Function Remark Power Supply 12 DC inputs(24VDC) • Program capacity : 10 k steps K7M-DR20U 8 relay outputs •...
Page 22 Chapter 2 System Configuration 3) Expansion Modules Section Items Models Description Remark • 6 DC inputs / 4 relay outputs G7E-DR10A G7E-DR20A • 12 DC inputs / 8 relay outputs Slim Type G7E-DC08A • 8 DC inputs Expansion Digital I/O module module •...
Page 23: Chapter 3 General Specifications
Chapter 3 General Specifications Chapter 3. General Specifications 3.1 General Specifications The following table shows the general specifications of the MASTER-K120S series. Item Specifications References Operating ambient 0 ~ 55 °C Temperature Storage ambient −25 ~ +70 °C Temperature Operating ambient 5 ~ 95%RH, non-condensing Humidity Storage ambient...
Page 24: Chapter 4. Names Of Parts
Chapter 4 Names of Parts Chapter 4. Names of Parts 4.1 Main Unit ④ ⑤ ⑧ BUILT_IN CNET ⑦ PAU/REM STOP ROM MODE ② ① ⑥ ③ ③ ⑨ RS-485 Name Description Indicates status of power supply to the system PWR LED On : When the supplied power is normal Off : When the supplied power is abnormal...
Page 25 Chapter 4 Names of Parts Name Description I/O LED Indicates operating status of I/O ② Built-in RS-485 connector 2-pin connector for built-in RS-485 communications. ③ (Except K7M-DR10/14UE) Designates main unit’s operation mode RUN : Run program operation Key switch for mode creation STOP: Stop program operation ④...
Page 26 Chapter 4 Names of Parts 2) K7M-DRT60U 3) K7M-DT60U 4.1.2 40-points main unit (Standard) 1) K7M-DR40U 4 -3...
Page 27 Chapter 4 Names of Parts 2) K7M-DRT40U 3) K7M-DT40U 4.1.3 30-points main unit (Standard) 1) K7M-DR30U 4 -4...
Page 28 Chapter 4 Names of Parts 2) K7M-DRT30U 3) K7M-DT30U 4.1.4 20-points main unit (Standard) 1) K7M-DR20U 4 -5...
Page 29 Chapter 4 Names of Parts 2) K7M-DRT20U 3) K7M-DT20U 4.1.5 30-points main unit (Economic) 1) K7M-DR30UE 4 -6...
Page 30 Chapter 4 Names of Parts 4.1.6 20-points main unit (Economic) 1) K7M-DR20UE 4.1.7 14-points main unit (Economic) 1) K7M-DR14UE 4.1.8 10-points main unit (Economic) 1) K7M-DR10UE 4 -7...
Page 31: Expansion I/O Module
Chapter 4 Names of Parts 4.2 Expansion I/O Module 4.2.1 20points I/O Module 1) G7E-DR20A ④ ③ Names Input LED ① ① Output LED ② Input contact ③ ⑦ ⑧ Input common terminal ④ Output contact ⑤ Output common terminal ⑥...
Page 32: Point I/O Module
Chapter 4 Names of Parts 4.2.3 8points I/O Module 1) G7E-DC08A ② ③ Names ① Input LED ① Input contact ② ⑤ ④ Input common terminal ③ Expansion cable ④ Expansion Cable Connecting Terminal ⑤ ② ③ 2) G7E-RY08A ③ ②...
Page 33: Special Module
Chapter 4 Names of Parts 4.3 Special Module 4.3.1 A/D·D/A Combination Module 1) G7F-ADHA Names ⑤ ② RUN LED ① Analog Output Terminal ② Analog Input (Voltage/current) selecting jumper pin ③ ⑥ ⑦ Analog Input Terminal ④ External Power Supply Terminal (DC24V) ⑤...
Page 34: D/A Conversion Module
Chapter 4 Names of Parts 4.3.2 D/A Conversion Module 1) G7F-DA2I Names RUN LED ① Analog Output Terminal ② ③ ④ Expansion Cable ③ Expansion Cable Connecting Terminal ④ ① External Power Supply Terminal (DC24V) ⑤ ⑤ ② 2) G7F-DA2V ⑤...
Page 35: Analog Timer Module
Chapter 4 Names of Parts 4.3.4 Analog timer Module ② Names RUN LED ① Analog Timer Volume Control Resistor ② ③ ④ Expansion Cable ③ Expansion Cable Connecting Terminal ④ ① 4.3.5 RTD Input Module ⑤ ② Names RUN LED ①...
Page 36: Communication I/F Module
Chapter 4 Names of Parts 4.4 Communication I/F Module 4.4.1 Cnet I/F Module 1) G7L-CUEB Names RS-232C connector ① Communication status LED ② Expansion cable ③ Expansion cable connecting terminal ④ TM/TC selecting dip switch ⑤ 2) G7L-CUEC Names RS-422/485 connector ①...
Page 37: Pnet I/F Module
Chapter 4 Names of Parts 4.4.3 Pnet I/F Module 1) G7L-PBEA Names Station No. selecting switch ① Pnet cable connector ② Expansion cable ③ Expansion cable connecting terminal ④ Communication status LED ⑤ 4.4.4 DeviceNet I/F Module 1) G7L-DBEA Names Station No.
Page 38: Chapter 5. Power Supply / Cpu
Chapter 5 Power Supply / CPU Chapter 5. Power Supply / CPU 5.1 Power Supply Specifications 5.1.1. Standard Type K7M – K7M – K7M – K7M – Items DR/DRT/DT20U DR/DRT/DT30U DR/DRT/DT40U DR/DRT/DT60U Rated voltage 85 ~ 264 VAC Rated frequency 50 / 60 Hz (47 ~ 63 Hz) Rated current 0.5A(110VAC)/0.25A(220VAC)
Page 39: Cpu Specifications
Chapter 5 Power Supply / CPU 5.2 CPU Specifications The following table shows the general specifications of the MASTER-K120S series 5.2.1. Standard Type Specifications Items Remarks K7M-DR/DRT/DT20U K7M-DR/DRT/DT30U K7M-DR/DRT/DT40U K7M-DR/DR`T/DT60U Program control method Cyclic execution of stored program, Time-driven interrupt, Process-driven interrupt I/O control method Indirect mode(Refresh method), Direct by program command Program language...
Page 40 Chapter 5 Power Supply / CPU (continued) Specifications Items Remarks K7M-DR/DRT/DT20U K7M-DR/DRT/DT30U K7M-DR/DRT/DT40U K7M-DR/DRT/DT60U Controlled by commands, Relay and PRC auto tuning, PID control function PWM output, manual output, adjustable operation scan time, Anti-windup, SV-Ramp, Delta MV, Position and Velocity algorithm Dedicated protocol support MODBUS protocol support RS-232C - 1port...
Page 41 Chapter 5 Power Supply / CPU 5.2.2. Economic Type Specifications Items Remarks K7M-DR10UE K7M-DR14UE K7M-DR20UE K7M-DR30UE Program control method Cyclic execution of stored program, Time-driven interrupt, Process-driven interrupt I/O control method Indirect mode(Refresh method), Direct by program command Program language Instruction list, Ladder diagram Numbers of instructions Basic : 30, Application : 269...
Page 42 Chapter 5 Power Supply / CPU (continued) Specifications Items Remarks K7M-DR10UE K7M-DR14UE K7M-DR20UE K7M-DR30UE Dedicated protocol support RS-485 is available MODBUS protocol support RS-232C - 1port Cnet I/F Function on K7M-DR10/14UE User defined protocol support RS-485 - 1 port only No protocol support 1 phase : 10 kHz-2 channel Capacity...
Page 43: Operation Processing
Chapter 5 Power Supply / CPU 5.3 Operation Processing 5.3.1 Operation Processing Method 1) Cyclic operation A PLC program is sequentially executed from the first step to the last step, which is called scan. This sequential processing is called cyclic operation. Cyclic operation of the PLC continues as long as conditions do not change for interrupt processing during program execution.
Page 44: Operation Processing At Momentary Power Failure Occurrence
Chapter 5 Power Supply / CPU 2) Interrupt operation method If a situation occurs which is requested to be urgently processed during execution of a PLC program, this opera tion method processes immediately the operation, which corresponds to interrupt program. The signal, which infor ms the CPU of those urgent conditions is called interrupt signal.
Page 45: Scan Time
Chapter 5 Power Supply / CPU 5.3.3 Scan Time The processing time from a 0 step to the 0 step of next scan is called scan time. 1) Expression for scan time Scan time is the sum of the processing time of scan program that the user has written, of the task program processing time and the PLC internal processing time.
Page 46: Timer Processing
Chapter 5 Power Supply / CPU 5.3.5 Timer Processing The MASTER-K series use up count timer. There are 5 timer instructions such as on-delay (TON), off-delay (TOFF), integral (TMR), monostable (TMON), and re-triggerable (TRTG) timer. The measuring range of 100msec timer is 0.1 ~ 6553.5 seconds, 10msec timer is 0.01 ~ 655.35 seconds, and that of 1msec timer is 0.001 ~ 65.53 seconds.
Page 47 Chapter 5 Power Supply / CPU 3) Integral timer In general, its operation is same as on-delay timer. Only the difference is the current value will not be clear when the input condition of TMR instruction is turned off. It keeps the elapsed value and restart to increase when the input condition is turned on again.
Page 48 Chapter 5 Power Supply / CPU 5) Retriggerable timer The operation of retriggerable timer is same as that of monostable timer. Only difference is that the retriggerable timer is not ignore the input condition of TRTG instruction while the timer is operating (decreasing). The current value of retriggerable timer will be set as preset value whenever the input condition of TRTG instruction is turned on.
Page 49: Counter Processing
Chapter 5 Power Supply / CPU 5.3.6 Counter Processing The counter counts the rising edges of pulses driving its input signal and counts once only when the input signal is switched from off to on. MASTER-K series have 4 counter instructions such as CTU, CTD, CTUD, and CTR. The followings shows brief information for counter operation.
Page 50 Chapter 5 Power Supply / CPU 4) Ring counter -. The current value is increased with the rising edge of the counter input signal, and the counter output relay is turned on when the current value reaches the preset value. Then the current value and counter output relay is cleared as 0 when the next counter input signal is applied.
Page 51: Program
Chapter 5 Power Supply / CPU 5.4 Program 5.4.1 Classifications of Program All functional elements need to execute a certain control process are called as a ‘program’. In MASTER-K120 series, a program is stored in the EEPROM mounted on a CPU module or flash memory of a external memory module. The following table shows the classification of the program.
Page 52: Interrupt Programs
Chapter 5 Power Supply / CPU 1) Scan program -. The scan program is executed regularly in every scan from 0 step to last step. -. When interrupts has occurred, CPU pauses scan program and executes corresponding interrupt program first. -.
Page 53 Chapter 5 Power Supply / CPU 2) parameter setting 3) Time driven interrupt TDI occurs periodically with the constant interval assigned in parameter setting. The interrupt routine of TDI starts with the TDINT instruction and ends with the IRET instruction. When multiple interrupt factors occur simultaneously, interrupt routines are executed according to the priority given to the each interrupt.
Page 54: Error Handling
Chapter 5 Power Supply / CPU REMARK Total available interrupt points is 8(In standard type). -. Time driven interrupt + process driven interrupt + high speed counter driven interrupt ≤ 8 points Interrupt signal is ignored when self-interrupt occurs more than 2 times during interrupt processing is executing. ignored Interrupt executing time Interrupt signal (ex : rising edge)
Page 55 Chapter 5 Power Supply / CPU (4) External device malfunction The PLC user program detects malfunctions of external devices. If a fatal error is detected the system ent ers into the STOP state, and if an ordinary error is detected the system continues its operation. REMARK In occurrence of a error, the state is to be stored in the representative system error flag F006.
Page 56: Operation Modes
Chapter 5 Power Supply / CPU 5.5 Operation Modes The CPU operates in one of the four modes - RUN, STOP, PAUSE and DEBUG mode. The following describes ope ration processing in each operation mode. 5.5.1 RUN Mode In this mode, programs are normally operated. The first scan start in the RUN mode Initialize data area according to the preset restart mode.
Page 57: Stop Mode
Chapter 5 Power Supply / CPU 5.5.2 STOP mode In this mode, programs are not operated. 1) Processing when the operation mode is changed. The output image area is cleared and output refresh is executed. 2) Operation processing contents (1) I/O refresh is executed. (2) Normal or abnormal operation and mounting conditions of the loaded module are checked.
Page 58: Operation Mode Change
Chapter 5 Power Supply / CPU 3) Debug operation conditions following four operation conditions can be specified. Operation conditions Description executed by one When executed, Stop operation after executing one instruction command. executed by break-point When executed, Stop operation at designated break-point settings.
Page 59 Chapter 5 Power Supply / CPU 3) Mode change Remote operation Remote operation mode change is available only when the operation mode is set to the remote STOP mode (i.e., the mode setting switch position is in the STOP→ PAU/REM’). Mode setting switch Mode change by the Mode change using...
Page 60: Function
Chapter 5 Power Supply / CPU 5.6 Functions 5.6.1 Self-diagnosis 1) Functions (1) The self-diagnosis function permits the CPU module to detect its own errors. (2) Self-diagnosis is carried out when an error occurs during PLC power supply is turned on or operating process. If an error is detected, the system stops operation to prevent faulty PLC operation.
Page 61: I/O Force On/Off Function
Chapter 5 Power Supply / CPU 5.6.2 I/O Force On/Off function It is possible to input/output a designated data regardless of the program operation results. When used with OUTOFF instruction simultaneously, OUTOFF is prior to I/O Force On/Off. 1) Forced I/O setting method. -.
Page 62 Chapter 5 Power Supply / CPU Set ‘forced I/O data’ by bit Set ‘forced I/O data enable’ by bit -. When forced I/O set enables, forced I/O function is executing. Click 5-25...
Page 63 Chapter 5 Power Supply / CPU 2) Special data register for forced I/O The contents of forced I/O setting is registered to special data register as below. It is possible to use ‘forced I/O function’ to program. Items Special Device All Forced I/O enable M1910 Forced I/O enable by bit...
Page 64: Direct I/O Operation Function
Chapter 5 Power Supply / CPU 5.6.3 Direct I/O Operation function This function is useful when reads an input relay’s state directly during execution of a program and uses in the operation, or write the operation result directly to an output relay. Direct input/output is executed by the ‘IORF’ instruction. If this instruction is used, the input/output image area will be directly updated and applied to the continuing operations.
Page 65: Memory Configuration
Chapter 5 Power Supply / CPU 5.7 Memory Configuration The CPU module includes two types of memory that are available by the user. One is program memory, which is used to store the user programs written to implement a system by the user. The other is data memory, which sto res data during operation.
Page 66: I/O Address Allocation
Chapter 5 Power Supply / CPU 5.8 I/O Address Allocation I/O No. allocation means to give an address to each module in order to read data from input modules and output data to output modules. Max. 3 expansion module is available in standard type. Mounting module Max.
Page 67: Built-In Cnet Selection Switch
Chapter 5 Power Supply / CPU 5.9 Built-in Cnet Selection Switch 5.9.1 Structure You can see dip switches as shown when you open I/O terminal block cover. BUILT_IN CNET Terminal block cover ROM MODE 5.9.2 Usage Dip switch position Description upper switch is for Cnet.
Page 68 Chapter 5 Power Supply / CPU Dip switch for Built-in Cnet is placed in deep place to prevent a mistaken operation caused by terminal block cover, etc. Use a small driver to operate it. Driver Dip switch Terminal block cover 5-31...
Page 69: External Memory Module
Chapter 5 Power Supply / CPU 5.10 External Memory Module MK120S series supplies external memory module for the user to save programs safely or download a program on the system and use it in case of a program is damaged. 5.10.1 Structure Installation connector 5.10.2 Usage...
Page 70 Chapter 5 Power Supply / CPU (6) Select Online – Flash memory – Write to external memory in menu, and the following message box will displayed. (7) Turn the power of the main unit off. (8) Remove the external memory module. Through the above steps a user can save a program into the external memory module.
Page 71: Rtc Module
Chapter 5 Power Supply / CPU 5.11 RTC Module MK120S series supplies RTC(Real Time Clock) module for the time-scheduling control. To use RTC function with K120S series, the RTC operation module should be attached to the expansion slot of main unit or expansion module. Clock operation by the RTC function is continued with a super capacitor when the CPU is powered off.
Page 72 Chapter 5 Power Supply / CPU (2) Read RTC data from special register Description Special register Area Data (Word) (BCD format) Upper byte Lower byte F053 Lower 2 digits of year Month H0207 F054 Hour H2313 F055 Minute Second H5020 F056 Higher 2 digits of year Date...
Page 73: Input / Output Specifications
Chapter 6 Input and Output Specification Chapter 6 Input and Output Specification 6.1 Input / Output Specifications Digital input that offers to MASTER-K120S series are made to use both of electric current sink and electric current source. To keep use coil load as an output module, maximum opening and shutting frequency is 1 second on and 1 second off. The following diagram shows maximum life relay for relay output.
Page 74: Digital Input Specifications
Chapter 6 Input and Output Specification 6.2 Digital Input Specification 6.2.1 Main unit 1) Specification Main unit Model K7M- K7M- K7M- K7M- K7M-DR10UE K7M-DR14UE DR/DRT/DT20U DR/DRT/DT30U DR/DRT/DT40U DR/DRT/DT60U Specification K7M-DR20UE K7M-DR30UE K7M-DRT40U K7M-DRT60U Number of input points 6 points 8 points 12 points 18 points 24 points...
Page 75 Chapter 6 Input and Output Specification 3) Input wiring Main unit’s wiring method is as follows. DC input specifications offered by MASTER-K120S is to be used for both electric current sink and electric current source. (1) Main unit DC24V DC24V...
Page 76 Chapter 6 Input and Output Specification 4) Example of external devices. To connect with external device of DC output type into DC input module, wire depending on the type of the external device as shown. External device Input Relay Power for Sensor sensor Output...
Page 77: Expansion Module
Chapter 6 Input and Output Specification 6.2.2 Expansion Module 1) Specifications Expansion Module Model Specification G7E-DR10A G7E-DC08A G7E-DR20A Number of input points 6 points 8 points 12 points Insulation method Photo coupler Rated input voltage DC 24V Rated input current 7 mA Operating voltage range DC 20.4 ~ 28.8V (ripple: less than 5%)
Page 78: Digital Output Specification
Chapter 6 Input and Output Specification 6.3 Digital Output Specification 6.3.1 Main unit (Relay Output) 1) Specification (1) Standard type Model Main Unit K7M-DR20U K7M-DR30U K7M-DR40U K7M-DR60U Specifications (K7M-DRT20U) (K7M-DRT30U) (K7M-DRT40U) (K7M-DRT60U) Output point 8 points(4 points) 12 points(8 points) 16 points(12 points) 24 points(20 points) Insulation method...
Page 79 Chapter 6 Input and Output Specification (2) Economic type Model Main Unit Specifications K7M-DR10UE K7M-DR14UE K7M-DR20UE K7M-DR30UE Output point 4 points 6 points 8 points 12 points Insulation method Relay insulation Rated load voltage/current DC24V / 2A (r/load), AC220V / 2A (COS Ψ = 1)/1 point , 5A / 1COM Min.
Page 80 Chapter 6 Input and Output Specification 3) Output wiring (1) Main unit DC5V DC24V AC110/220V DC24V DC24V...
Page 81: Main Unit (Tr Output :Drt/Dt Type Only)
Chapter 6 Input and Output Specification 6.3.2 Main unit (TR Output : DRT/DT type only) 1) Specification Model Main Unit Specifications K7M-DRT/DT20U K7M-DRT/DT30U K7M-DRT/DT40U K7M-DRT/DT60U Output point 4 points / 8 point 4 points / 12 point 4 points / 16 point 4 points / 24 point Insulation method Photo coupler insulation...
Page 82 Chapter 6 Input and Output Specification 2) Output wiring AC100-240V COM0 COM1 COM2 COM3 DC12V/24V 6-10...
Page 83: Expansion Module
Chapter 6 Input and Output Specification 6.3.3 Expansion Module 1) Specifications Expansion Module Model Specifications G7E-DR10A G7E-DR08A G7E-RY08A G7E-DR20A Output point 4 points 8 points Insulation method Relay insulation Rated load Voltage/current DC24V / 2A (Resistive load), AC220V / 2A (COS Ψ = 1) / 1 point 5A / 1COM Min.
Page 84 Chapter 6 Input and Output Specification Expansion Module Model Specifications G7E-TR10A Output point 10 points Insulation method Photo coupler insulation Rated load Voltage/current DC12V/24V Operating load voltage range DC10.2 ~ 26.4V Max. load current 0.5A/1 point, 4A/1COM Current leakage when off 0.1mA or lower Max.
Page 85: Chapter 7. Usage Of Various Functions
Chapter 7 Usage of Various Functions Chapter 7. Usage of Various Functions 7.1 Built-in Functions 7.1.1 High-speed counter function This chapter describes the specification, handling, and programming of built-in high speed counter of MASTER-K120S. The built-in high speed counter of MASTER-K120S(hereafter called HSC) has the following features; Function Description •...
Page 86 Chapter 7 Usage of Various Functions 3) Names of wiring terminals Input pulse Preset input ① ② ③ ④ ⑤ ⑥ ⑦ ⑧ ⑨ BUILT_IN CNET ROM MODE COM0 COM1 Terminal Names Usage 1Phase 2Phase 1Phase 2Phase Ch0 Input Ch0 A Phase Input Counter input terminal A Phase Input terminal ①...
Page 87 Chapter 7 Usage of Various Functions 4) External interface circuit Termi Signal name Operati Input warranted Internal circuit voltage 1Phase 2Phase Ch0 A 20.4~28.8V 3.3 kΩ Input Phase 6V or lower pulse Input Ch0 B 20.4~28.8V Input Phase 3.3 kΩ 6V or lower pulse Input...
Page 88 Chapter 7 Usage of Various Functions 6) Wiring example (1) Voltage output pulse generator Pulse Generator Pulse Generator CHSC 24VG (2) Open collector output pulse generator CHSC Pulse Generator Pulse Generator 24VG...
Page 89 Chapter 7 Usage of Various Functions 7) Instruction(HSCST) HSCAST High speed counter Flag Available device No. of Instruction Error Zero Carry steps integer (F110) (F111) (F112) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○...
Page 90 Chapter 7 Usage of Various Functions 8) Parameter Setting (1) Format setting (a) Linear counter • If HSC is designate as Linear counter, it can counts from -2,147,483,648 to 2,147,483,647. • The carry flag F18*(* is channel number) turns on when the current value of high speed counter is overflow during up counting and HSC stop counting.
Page 91 Chapter 7 Usage of Various Functions (2) Mode setting (a) 1-phase operation mode - Current value increases by 1 at the rising edge of input pulse. A-phase input pulse Current value (b) 1-phase pulse + direction mode - Current value increases by 1 at the rising edge of A-Phase pulse when B-phase is ‘low’ state. - Current value decreases by 1 at the rising edge of A-Phase pulse when A-phase is ‘High’...
Page 92 Chapter 7 Usage of Various Functions (d) 2-phase multiplication mode (MUL4) - Up or Down is set automatically by the phase difference between A and B phase. • Up counter - At the rising edge of A-Phase pulse when B-phase is ‘low’. - At the falling edge of A-Phase pulse when B-phase is ‘high’.
Page 93 Chapter 7 Usage of Various Functions (4) Latch Counter setting If this function is enabled, Current value of high speed counter is always retained. Current value - When power supply is off. - When is ‘Stop’ or ‘Pause’ - When input condition of ‘HSCST’...
Page 94 Chapter 7 Usage of Various Functions (b) Zone Comparison Set - When current value of HSC isn’t less than SV1 and more than SV2. corresponding output point turns on. - P40 ~ P47 are available for comparison output point. - If SV2 is less than SV1, SV2 setting error(h’12) occurs and zone comparison set is disabled. Input pulse Output point Current value...
Page 95 Chapter 7 Usage of Various Functions (6) RPM setting - Can calculates RPM of input pulse - RPM is stored in designated device. - The RPM is expressed as: × (Current Value Last Value) 60,000 × Pulses rotate refresh cycle[ms] (a) Examples of Program - Refresh cycle : 1000ms, Pulses per rotate : 60, RPM save area : D0 Input pulse...
Page 96 Chapter 7 Usage of Various Functions 9) Programming example (1) Parameter setting • Channel : Ch0 • Counter format : Ring counter ( 0 ~ 100,000) • Counter mode : 2-phase multiplication mode - P0 : A-phase pulse input, P1 : B-phase pulse input •...
Page 97 Chapter 7 Usage of Various Functions (2) Programming • When M0 turns on, HSC starts its operation • If current value is not less than 50,000, F170 turns on. • Current value is saved in D0(double word). Remark The contact point which is designated as HSC input can’t be used for pulse catch or external interrupt. Duplicated designation may cause faults.
Page 98: Pulse Catch Function
Chapter 7 Usage of Various Functions 7.1.2. Pulse Catch Function In the main unit, 4(economic type) or 8(standard type) points of pulse catch input contact points are internalized. Through using this contact point, short pulse signal short can be taken which can not be executed by general digital input. 1) Usage When narrow width of pulse signal is input, a trouble occurs which can not be detected by general digital input, so the operation does not perform as user's intention.
Page 99 Chapter 7 Usage of Various Functions Remark 1) Pulse catch input contact points operate as general digital input if they are not designated as pulse catch input. 2) Do not designate HSC input points as pulse catch input. 7-15...
Page 100: Input Filter Function
Chapter 7 Usage of Various Functions 7.1.3 Input Filter Function External input of MASTER-K120S selects input on/off delay time from the range of 0-1000ms of KGLWIN. Credibility secured system may be established by adjustment of input correction no. through using environment. 1) Usage Input signal status affects to the credibility of system in where noise occurs frequently or pulse width of input signal affects as a crucial factor.
Page 101: External Interrupt Function
Chapter 7 Usage of Various Functions 7.1.4 External Interrupt Function MASTER-K120S Series can perform max 4(economic) or 8(standard) points of external contact interrupt by using input of main unit without special interrupt module. 1) Usage This function is useful to execute a high speed execution regardless of scan time. 2) Minimum processing time.
Page 102 Chapter 7 Usage of Various Functions 5) Usage (1) Click twice the parameter on the project window of KGLWIN. (2) Designate contact point, no. of priority and movement condition of the task program which is moved by interrupt inputting. Time driven Interrupt execution periodic set xecuting interrupt input e...
Page 103: Pid Control Function(Standard Type Only)
Chapter 7 Usage of Various Functions 7.1.5 PID control function(Standard type only) 1) Introduction This chapter will provide information about the built-in PID (Proportional Integral Derivative) function of MASTER-K120S main unit. The MASTER-K120S series does not have separated PID module like MASTER-K300S and MASTER- K1000S series, and the PID function is integrated into the main unit.
Page 104 Chapter 7 Usage of Various Functions 2) Specification (1) Control operation (a) Proportional operation (P operation) ① P action means a control action that obtain a manipulate value which is proportional to the deviation (E : the difference between SV and PV) ②...
Page 105 Chapter 7 Usage of Various Functions (b) Integral operation (I operation) ① With integral operation, the manipulate value (MV) is increased or decreased continuously in accordance time in order to eliminate the deviation between the SV and PV. When the deviation is very small, the proportional operation can not produce a proper manipulate value and an offset remains between PV and SV.
Page 106 Chapter 7 Usage of Various Functions Fig. 2.5 The system response when a long integration time given Fig. 7.4 The system response when a long integration time given Fig. 2.6 The system response when a short integration time given Fig. 7.5 The system response when a short integration time given (c) Derivative operation (D action) ①...
Page 107 Chapter 7 Usage of Various Functions ⑤ The D action when a constant deviation occurred is shown as Fig. 7.6 Fig. 7.6 Derivative action with a constant deviation ⑥ The expression of D action is as following; × ⑦ Derivative action is used only in PID action in which P and I actions combine with D action. (d) PID action ①...
Page 108 Chapter 7 Usage of Various Functions (e) Integral windup All devices to be controlled, actuator, has limitation of operation. The motor has speed limit, the valve can not flow over the maximum value. When the control system has wide PV range, the PV can be over the maximum output value of actuator.
Page 109 Chapter 7 Usage of Various Functions (2) Realization of PID control on the PLC In this chapter, it will described that how to get the digitized formula of the P, I, and D terms. (a) P control The digitized formula of P control is as following; −...
Page 110 Chapter 7 Usage of Various Functions (4) parameter setting and explanation (a) PID8 instruction parameter setting and explanation. ① Scan time Scan time is the period of reading data (sampling), and also 10 times scaled up. The range of sampling time is 0.1 ~ 10 seconds, and actual input range is 0 ~ 100.
Page 111 Chapter 7 Usage of Various Functions ⑥ Proportional gain The MASTER-K120S can handle only integer, not the floating point type. Therefore, to enhance the accuracy of PID operation, the PID8 instruction is designed to input the P_GAIN data as the 100 times scaled up. For example, if the designated P_GAIN is 98, actual input data of P_GAIN should be 9800.
Page 112 Chapter 7 Usage of Various Functions ⑩ SV Ramp If a large amount of SV changes during PID operation, The deviation(E) changes rapidly. Then manipulation value(MV) is changed rapidly also. This can cause damage on load or actuator. To prevent this situation, SV can be changed step by step by parameter setting.
Page 113 Chapter 7 Usage of Various Functions (b) PID8AT instruction parameter setting and explanation. ① Scan time S_TIME is the period of reading data (sampling), and 10 times scaled up for more precious operation. The range of sampling time is 0.1 ~ 10 seconds, and actual input range is 0 ~ 100. ②...
Page 114 Chapter 7 Usage of Various Functions ⓐ Relay response method. • PID parameters are obtained by On/Off operation during 1 cycle of PV variation. • PID parameters are obtained by amplitude and period of oscillation • The On/Off operation will be occur at the SV value. Period Amplitude ⓑ...
Page 115 Chapter 7 Usage of Various Functions 5) instruction (1) PID8 PID8 PID Control Flag Available device No. of Instruction Error Zero Carry Steps integer (F110) (F111) (F112) ○ ○ ○ ○ Designation Flag set Registration No. at parameter(0~7) Error flag turns on when designating area is over Error and the instruction isn’t executed.
Page 116 Chapter 7 Usage of Various Functions (2) PID8AT PID8AT PID Auto Tuning Flag Available device No. of Instruction Error Zero Carry steps integer (F110) (F111) (F112) ○ ○ ○ ○ Designation Flag set Registration No. at parameter(0~7) Error Error flag turns on when designating area is over (F110) and the instruction isn’t executed.
Page 117 Chapter 7 Usage of Various Functions 6) Program Example (1) System configuration G7F- G7F-DA2I MASTER-K120S RD2A RS-232C (PV : temperature) KGL-WIN V3.5 above (MV: 4~20mA) Electric Oven Heater (2) In case of using PID function only When PWM set is selected, Scan time parameter When PWM is designated, this window is activated and is disabled and this value is ignored PID function operates by PWM period...
Page 118 Chapter 7 Usage of Various Functions PID operation explanation (without A/T function) • Measure current temperature (-200~600°C) by RTD module then digital conversion value(0 ~ 4000) is stored to D4780 • PID8 instruction will calculate manipulate value (MV : 0 ~ 4000) based on PID parameter settings (P_GAIN, I_TIME, D_TIME, etc.) and PV from RTD module.
Page 119 Chapter 7 Usage of Various Functions Program Explanation • When the input condition M0 turns on, PID operation executes at no.0 parameter. • PID execution status registrate D0000 and the output value of control result registrate D0001 • If SV Ramp is designated, current SV is registrate D0005 •...
Page 120 Chapter 7 Usage of Various Functions operation parameters • Scan time : S_TIME=5 (sampling time = 0.5 seconds) • Auto / Manual operation setting : Auto • Output limit : Max. = 4000, Min = 0 • High frequency noise removal ratio : 10 •...
Page 121 Chapter 7 Usage of Various Functions Program Explanation • When the input condition M2 turns on, PID auto tuning operation executes at no.0 parameter. • When auto tuning finished, PID operation executes with calculated P,I,D parameter. • PID execution status registrate D0000 and the output value of control result registrate D0001 •...
Page 122 Chapter 7 Usage of Various Functions 6) Error code list (1) PID8AT Description Error Code Corrective action H0100 Scan time setting range error Set scan time to available setting range H0200 PV setting range error Set PV setting to available setting range Set SV to available setting range SV H0300 SV setting range error...
Page 123: Special Module
Chapter 7 Usage of Various Functions 7. 2 Special module The special module and allocated data registers are as followings. Item Data Analog RTD input Combination module Conversion D/A Conversion module Expansion timer module Register module G7F-ADHA G7F-ADHB G7F-AD2A G7F-DA2I G7F-DA2V G7F-AT2A G7F-RD2A...
Page 124: A/D·d/A Combination Module
Chapter 7 Usage of Various Functions 7.2.1 A/D·D/A Combination module 1) Performance specification The performance specification of the analog mixture module are following. Specifications Item G7F-ADHA G7F-ADHB Voltage DC 0∼10V (input resistance more than 1 ㏁) DC 0∼20 ㎃ (input resistance 250Ω) Input range Current DC 4∼20 ㎃...
Page 125 Chapter 7 Usage of Various Functions 2) Names of parts and functions Explain about names of parts and functions (1) G7F-ADHA Contents. RUN LED ① Indicate the operating status the G7F-ADHA Analog input terminal Voltage Input Current input CH0 (INPUT) CH0 (INPUT) I0 COM0 I0 COM0...
Page 126 Chapter 7 Usage of Various Functions (2) G7F-ADHB Contents. RUN LED ① Indicate the operating status the G7F-ADHB Analog input terminal Voltage Input Current input CH0 (INPUT) I0 COM0 ④ I0 COM0 ② ① When current input is used, short the V and I terminal. Dip switch of analog input OUTPUT Input Select...
Page 127 Chapter 7 Usage of Various Functions 3) Parameter setting (1) Scaling function This function convert automatically range when the inout/output range is not matched. In case that input/output is current , this function is useful that external equapment’ range is not matched each other. (MASTER-K120S series converts range automatically as following : 0 ~ 20mA ⇔...
Page 128 Chapter 7 Usage of Various Functions 4) Wiring (1) Caution for wiring • Make sure that external input signal of the mixture module of AC and analog I/O is not affected by induction noise or occurs from the AC through using another cable. •...
Page 129 Chapter 7 Usage of Various Functions 5) I/O converstion characteristics (1) Analog input characteristics a) Voltage input 4000 2004 2003 2002 2001 2000 2000 Analog input voltage Input Voltage A/D conversion characteristics (voltage input) In voltage input, digital amount 0 is output by 0V input and 4,000 is output by 10V input. Therefore input 2.5mV equals to digital amount 1, but value less than 2.5mV can’t be converted.
Page 130 Chapter 7 Usage of Various Functions (2) Analog output characteristics Voltage output 2.5 ㎷ 5.0025 2000 2001 2002 200 Digital input 0V 0 2000 4000 Digital input value D/A conversion characteristic (voltage output) Input of digital amount 0 outputs analog amount 0V, 4000 does 10V.Digital input 1 equals to 2.5mV of analog amount. Current output 20 ㎃...
Page 131 Chapter 7 Usage of Various Functions 6) Program example (1) Distinction program of A/D conversion value a) Program explanation - When digital value of channel 0 is less than 2000, P090 is on. - when digital value of channel 0 is more than 3000, P091 is on. - When digital value of channel 0 is more or same than 2000 or lesser than 3000, P092 is on.
Page 132 Chapter 7 Usage of Various Functions (2) Program which controls speed of inverter by analog output voltage of 5 steps a) Program explanation -.When P80 becomes On, 2000 (5V) is output. -. When P81 becomes On, 2400 (6V) is output. -.When P82 becomes On, 2800 (7V) is output.
Page 133: A/D Conversion Module
Chapter 7 Usage of Various Functions 7.2.2 A/D Conversion module 1) Performance specifications The performance specifications of the analog input module are following. Item Specifications Voltage 0∼10VDC ( input resistance 1 ㏁ ) DC 4∼20 ㎃ ( input resistance 250Ω ) Current Analog DC 0∼20 ㎃...
Page 134 Chapter 7 Usage of Various Functions 2) Names of parts and functions The Names of parts and functions of the analog input module are following. Contents RUN LED ① Indicate the operating status the G7F-AD2A Analog input terminal Voltage input Current input ④...
Page 135 Chapter 7 Usage of Various Functions 3) Parameter setting (1) Scaling function The scaling function is the same that of A/D, D/A combination module. 4) Wiring (1) Caution for wiring • Make sure that external input signal of the mixture module of AC and analog I/O is not affected by induction noise or occurs from the AC through using another cable.
Page 136 Chapter 7 Usage of Various Functions 5) Analog/Digital conversion characteristics (1) Analog input characteristics a) Voltage input 4000 2004 2003 2002 2001 2000 2000 Voltage Input Analog Input Voltage A/D Conversion Characteristics (Voltage Input) In voltage input, digital amount 0 is output by 0V input and 4,000 is output by 10V input. Therefore input 2.5mV equals to digital amount 1, but value less than 2.5mV can’t be converted.
Page 137 Chapter 7 Usage of Various Functions 6) Program example (1) Distinction program of A/D conversion value(Analog input range: DC4∼20 ㎃, 0~10VDC) (a) Program explanation • When digital value of channel 0 is the same or more than 2000 and the same or less than 3000, P090 is on. •...
Page 138 Chapter 7 Usage of Various Functions (c) Program 7-54...
Page 139: D/A Conversion Module
Chapter 7 Usage of Various Functions 7.2.3 D/A Conversion module 1) Performance specifications The performance specifications of the analog output module are following. Specifications Item G7F-DA2I G7F-DA2V DC 0∼20 ㎃( Load resistance 510Ω) Output Range DC 4∼20 ㎃( Load resistance 510Ω) DC 0 ~ 10V(Lod resistance 2 ㏀∼1 ㏁) Classified by parameter Digital Output...
Page 140 Chapter 7 Usage of Various Functions 2) Names of parts and functions The Names of parts and functions of the analog input module are following. ③ ③ ① ① 24V 24G Inpu G7F-DA2I PROGRAMMABLE ⑤ G7F-DA2V ⑤ LOGIC PROGRAMMABLE CONTROLLER LOGIC CONTROLLER CH1 CH2 CH3...
Page 141 Chapter 7 Usage of Various Functions 3) Parameter setting 1) Specify the kind of special module 2) Set Output type of each channel 7-57...
Page 142 Chapter 7 Usage of Various Functions 5) Scaling function The scaling function is the same that of A/D, D/A combination module. 6) Wiring (1) Caution for wiring • Make sure that external input signal of the mixture module of AC and analog I/O is not affected by induction noise or occurs from the AC through using another cable.
Page 143 Chapter 7 Usage of Various Functions 7) Digital/Analog conversion characteristics (1) G7F-DA2I a) 0~20mA output 20 ㎃ 10 ㎃ 5 ㎂ 10.005 ㎃ 10.000 2000 2001 2002 2003 2004 2005 0 ㎃ Digital input 0V 0 2000 4000 Digital input D/A conversion characteristics(Current output) Digital amount 0 outputs analog amount 0mA, 4000 does 20mA.Digital input 1 equals to 5 ㎂...
Page 144 Chapter 7 Usage of Various Functions 8) Program example (1) Program which controls speed of inverter by analog output voltage of 5 steps(0 ~ 20mA output) a) Program explanation • When P80 becomes On, 2000 (10mA) is output. • When P81 becomes On, 2400 (12mA) is output. •...
Page 145 Chapter 7 Usage of Various Functions 7.2.4 Analog timer 1) Performance specification The performance specification of the analog timer module are following. Item Specification Number of channels Output value range 8 Bit (Digital output range: 0 ∼ 200) Setting type Setting by variable resistance Accuracy of timer ±2.0% (Accuracy about max.
Page 146 Chapter 7 Usage of Various Functions 3) Program example (1) Program explanation Program which controls on-delay time of output contact point within 0 to 20 sec. By analog timer module. (2) System configuration Main Unit Analog timer module (3) Program A/T conversion data is moved D000 always 7-62...
Page 147: Rtd Input Module
Chapter 7 Usage of Various Functions 7.2.5 RTD input module(Standard type only) 1) Performance specification The performance specification of the RTD input module are following. Item Specification Pt 100 (JIS C1640-1989, DIN 43760-1980) Connectable RTD JPt100 (KS C1603-1991, JIS C1604-1981) Pt 100 : -200 ~ 600℃...
Page 148 Chapter 7 Usage of Various Functions 3) Parameter setting 4) Digital conversion value register Detected Digital conversion Data register Remark Temperature value value D4980 D4780 D4880 D4981 D4781 Special module D4982 D4782 D4881 D4983 D4783 D4984 D4784 D4882 D4985 D4785 Special module D4986 D4786...
Page 149 Chapter 7 Usage of Various Functions 6) Temperature conversion characteristics The RTD input module, as shown below, linearlizes the non-linear characteristic resistance input of the RTD 7) Digital conversion value The RTD input module, as shown below, outputs digital converted value of detected temperature value.(Range 0 ~ 4000) Digital conversion value 4000 Detected temp.
Page 150 Chapter 7 Usage of Various Functions 8) Burn-out detection function The RTD input module has the function of burn-out detection on the Pt100, JPt100 or cable. • As shown below, if disconnection occurs in the RTD or cable then a voltage outside the measurable range voltage is inputted by the internal burn-out detection circuit and burn-out detection error code is generated.
Page 151 Chapter 7 Usage of Various Functions 9) Wiring (1) Caution for wiring • Make sure that external input signal of the mixture module of AC and analog I/O is not affected by induction noise or occurs from the AC through using another cable. •...
Page 152 Chapter 7 Usage of Various Functions 10) Program example (1) A program for output of detected temperature value as a BCD value a) Program explanation The present A/D conversion value of the detected temperature value which is detected from the temperature-measuring resistor Pt 100 is displayed on the BCD digital display by use of channel 0 of the temperature-measuring resistor input module.
Page 153: Positioning Function(Drt /Dttype Only)
Chapter 7 Usage of Various Functions 7.3 Positioning Function(DRT/DT type only) The DRT/DT type of MASTER-K120S series support 2 axes of positioning function. The purpose of positioning function is to transfer the moving objects by setting speed from the current position and stop them on the setting position correctly. And it also control the position of high precision by positioning pulse string signal as it is connected to various servo running devices or stepping motor control running devices.
Page 154 Chapter 7 Usage of Various Functions 2) Output Specification(P40, P41) Signal Name Rated load voltage Load voltage range Max. load current Max. voltage drop during On DC 10.2∼26.4V 100 ㎃ DC 0.3V DC 12/24V ≤ Positioning Forward direction Reverse direction CW/Pulse CCW/Directio 3) Names of wiring terminal...
Page 155 Chapter 7 Usage of Various Functions 4) Internal circuit and wiring example P - Power supply(DC 12/24V) P40 – pulse output(Ch0) COM0 – Output common 0 P41 – pulse output(Ch1) Internal COM1 – Output common 1 circuit P42 – Direction pulse(Ch0) P43 –...
Page 156: Positioning Function
Chapter 7 Usage of Various Functions 7.3.2 Positioning function 1) Positioning function Positioning Control includes position control, speed control. (1) Position control Positioning control from start address (present stopped position) to goal address (transfer amount) for the assigned axis A) Control by Absolute method (Absolute coordinate) ⓐ...
Page 157 Chapter 7 Usage of Various Functions (2) Speed Control (Uniform Speed Operation) • This controls the speed by the setting speed until deceleration stop command(POSCTR) is entered after execution by POSVEL command.. • The speed can be changed by the speed override instruction(POSSOR) •...
Page 158 Chapter 7 Usage of Various Functions 2) Operation pattern • Operation pattern describes various configuration for how to operate the positioning data using several operation step no and how to determine the speed of position data. • Operation mode types are as follows Operation mode Remark One operation step is executed with one start command...
Page 159 Chapter 7 Usage of Various Functions 3) Operation Mode End Operation A) With one time start command(rising edge of POSIST command), the positioning to the goal position is executed and the positioning shall be completed at the same time as the dwell time proceeds. B) This operation mode can be used as last positioning data of pattern operation.
Page 160 Chapter 7 Usage of Various Functions Operation (2) Keep A) With one time Start command(POSIST), the positioning to the goal position of operation step is executed and the positioning shall be completed at the same time as dwell time proceeds and without additional start command, the positioning of operation step for (current operation step no.
Page 161 Chapter 7 Usage of Various Functions Continuous Operation A) With one time Start command, the positioning for operation step set by continuous operation mode is executed to the goal position without stop and the positioning shall be completed at the same time as dwell time proceeds. B) If you want to operate with the position and speed of next step before the operation step that is active currently reaches the goal position, the operation by Next Move continuous operation command is available.
Page 162 Chapter 7 Usage of Various Functions 4) Operation Method Operation (1) Repeat A) With one time start command, the positioning to the goal position is executed and the positioning shall be completed at the same time as the dwell time proceeds. B) The operation type of Repeat operation mode is same as that of Single operation but the different thing is to determine next operation by operation step no.
Page 163 Chapter 7 Usage of Various Functions 5) Positioning start (1) Direct start(POSDST) • This is used to operate directly by setting the axis, goal position address, operation speed without parameter setting. • Refer to the ‘7.3.4 Instruction’ for details. (2) Indirect start(POSIST) •...
Page 164 Chapter 7 Usage of Various Functions 7) Return to Origin(POSORG : Rising edge ↑) • Return to Origin (homing) is carried out to confirm the origin of the machine when applying the power. • In case of Return to Origin, it is required to set Return to Origin parameter for each axis. •...
Page 165 Chapter 7 Usage of Various Functions Origin Detection after Deceleration when Approximate origin turns on This is the method using the approximate origin and origin signal and the action by origin return command is as follows. (A) It accelerates to the setting origin return direction and acts by origin return high speed. (B) In this case, if approximate origin as external input is entered, it decelerates and acts by origin return low speed.
Page 166 Chapter 7 Usage of Various Functions JOG Operation (POSJOG : Level input) (1) JOG operation • Carries out the positioning control by Jog command(POSJOG). • Carries out the monitoring when the positioning acts by JOG command and the position address is changed. •...
Page 167 Chapter 7 Usage of Various Functions 10) External Input Stroke High/Low Limit • External input stroke limit includes External input high limit signal and External input low limit signal. • This is used to stop the positioning function promptly before reaching Stroke limit/Stroke End of the Driver by installing the stroke limit inside Stroke limit/Stroke end of the Driver.
Page 168 Chapter 7 Usage of Various Functions • Timing diagram 1) Unused the M Code Output Continues Positioning Indirect start Completed Flag Current step M-th step N-th step 2) Use the M Code Continues Positioning Indirect start Completed Flag Current step M-th step N-th step M1911...
Page 169: Positioning Parameter And Operation Data
Chapter 7 Usage of Various Functions 7.3.3 Positioning parameter and operation data 1) Positioning parameter • Positioning parameter setting • Parameter should be assigned for each axis Basic parameter (1) Basic parameter (A) Acceleration/Deceleration time • This is applied at the starting/ending point of positioning operation, return to origin high speed, and JOG high speed operation •...
Page 170 Chapter 7 Usage of Various Functions Backlash Compensation Amount • The tolerance that the machine does not work by the wear when the rotation direction changes in case that a gear, screw etc is combined to run at the motor axle, is called as ‘Backlash”. Therefore, when you change the rotation direction, it is required to add the backlash compensation amount to the positioning amount for output.
Page 171 Chapter 7 Usage of Various Functions (2) Origin return parameter (A) Origin return method • For the details, please refer to ‘7) Return to Origin’ in chapter 7.3.2 (B) DOG, origin signal Ch 0 Ch 1 P0005 P0007 Origin P0004 P0006 (C) Origin return speed •...
Page 172 Chapter 7 Usage of Various Functions (3) JOG speed (A) JOG High Speed • JOG high speed operation has operation pattern as acceleration, constant speed, deceleration section. Therefore, acceleration section and deceleration section is controlled by JOG acceleration/deceleration time. • JOG high speed setting range : 5 ∼ 100,000(unit: 1pps) (notices when setting the high speed : Bias speed ≤...
Page 173 Chapter 7 Usage of Various Functions (2) Coordinate • The coordinate of position data includes Absolute and Incremental (A) Absolute Coordinate (Control by Absolute method) ① This carries out the positioning control from the current position to the goal position (the goal position assigned by positioning data).
Page 174 Chapter 7 Usage of Various Functions 6) Speed • Operation speed can be assigned for each operation step No. • Setting range of operation speed : 5 ~ 100,000( Setting unit: 1pps ) • The change of speed value is available when assigned by D area (7) Dwell Time •...
Page 175: Instructions
Chapter 7 Usage of Various Functions 7.3.4 Instructions 1) Positioning Indirect start(POSIST) POSIST Positioning Indirect Start Flag Available device No. of Instruction Error Zero Carry steps integer (F110) (F111) (F112) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○...
Page 176 Chapter 7 Usage of Various Functions 2) JOG Operation(POSJOG) POSIST Positioning Indirect Start Flag Available device No. of Instruction Error Zero Carry steps integer (F110) (F111) (F112) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○...
Page 177 Chapter 7 Usage of Various Functions 3) Positioning Control Instruction(POSCTR) POSCTR Positioning control instruction Flag Available device No. of Instruction Error Zero Carry steps integer (F110) (F111) (F112) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○...
Page 178 Chapter 7 Usage of Various Functions 4) Current position preset (POSPRS) POSPRS Current position preset Flag Available device No. of Instruction Error Zero Carry steps integer (F110) (F111) (F112) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○...
Page 179 Chapter 7 Usage of Various Functions 5) PWM output (PWM) PWM(Pulse Width Modulation) output Flag Available device No. of Instruction Error Zero Carry steps integer (F110) (F111) (F112) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○...
Page 180 Chapter 7 Usage of Various Functions 6) Speed control operation (POSVEL) POSVEL Speed control operation Flag Available device No. of Instruction Error Zero Carry steps integer (F110) (F111) (F112) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○...
Page 181 Chapter 7 Usage of Various Functions 7) Speed override (POSSOR) POSSOR Speed override instruction Flag Available device No. of Instruction Error Zero Carry steps integer (F110) (F111) (F112) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ Flag set Designation Ch.
Page 182 Chapter 7 Usage of Various Functions 8) Positioning direct start(POSDST) POSDST Positioning direct start Flag Available device No. of Instruction Error Zero Carry steps integer (F110) (F111) (F112) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 9/11/13 ○ ○...
Page 183 Chapter 7 Usage of Various Functions 9) Return to origin(POSORG) POSORG Return to origin Flag Available device No. of Instruction Error Zero Carry steps integer (F110) (F111) (F112) ○ ○ ○ ○ 플래그 Set 영역설정 Ch. for origin return(0~1) Error flag turns on when designating area is over Error Operation direction(0:Forward, 1:Reverse) and the instruction isn’t executed...
Page 184: Flag List And Error Code
Chapter 7 Usage of Various Functions 7.3.5 Flag list and Error codes 1) Flag list Device Function Description F0280 Operating flag Operation status of Ch0 (0: stop, 1:Busy) F0281 Error status Error status of Ch0 (0: normal, 1: error) F0282 End of positioning Indicates end of operation for Ch0 (0: operating, 1: End) *1Scan On F0283...
Page 185 Chapter 7 Usage of Various Functions Device Function Description F0310 Position control Position control operation of Ch1 F0311 Speed control Speed control operation of Ch1 F0312 Return to origin Return to origin operation of Ch1 F0313 JOG low speed JOG low speed operation of Ch1 F0314 JOG high speed JOG high speed operation of Ch1...
Page 186 Chapter 7 Usage of Various Functions 2) Error code Error Condition Corrective action Operation code Acceleration time of basic parameter is out of range Stop Set Acceleration time within 0~10,000 range Deceleration time of basic parameter is out of range Stop Set Deceleration time within 0~10,000 range Speed limit of basic parameter is out of range...
Page 187 Chapter 7 Usage of Various Functions Error Condition Corrective action Operation code Check if positioning is in the decelerating section when POSSOR signal POSSOR command can’t be executed during decelerating Operating occur. POSORG command can’t be executed during operation Operating Check if positioning operation is executing when POSORG signal occur.
Page 188: Wiring With Servo And Stepping Motor
Chapter 7 Usage of Various Functions 7.3.6 Wiring with servo and stepping motor driver (Open Collector) 1) Wiring with stepping motor driver(DC 5V) Max : 2m K7M-DRT**U Stepping Motor Driver Signal name Pulse Common COM0 COM1 Direction CCW- Common COM2 COM2 CCW+ DC5V Input +24V...
Page 189 Chapter 7 Usage of Various Functions 3) Wiring with servo motor driver(MR-J2/J2S-□A) HC-MF HA-FF Series motor MR-J2S- A TE11 Power 3Phase 200VAC CTE2 electronic brake 24VDC CN1A OPP of Servo ON signal detector Max: 2m Cutoff by alarm signal K7M-DRT**U Signal Pulse Common...
Page 190 Chapter 7 Usage of Various Functions 4) Wiring with Servo motor driver(FDA-5000 AC Servo Driver) K7M-DRT**U Max 2m FDA-5000 Signal name PFIN Pulse PPFIN Common 1.5K,1/2W COM0 COM1 PRIN Direction P24V PPRIN Common COM2 COM2 1.5K,1/2W Input +24V PZO+ Origin PZO- INPOS 0 SPEED...
Page 191: Chapter 8. Communication Function
Chapter 8 Communication Functions Chapter 8. Communication Functions 8.1 Dedicated Protocol Communication 8.1.1 Introduction MASTER-K120S’s built-in Cnet communication uses only MASTER-K120S main unit for a dedicated communication. That is, it doesn’t need a separate Cnet I/F module to facilitate the user-intended communication system by utilizing reading or writing of any area in CPU, and monitoring function.
Page 192: System Configuration Method
Chapter 8 Communication Functions 8.1.2 System configuration method According to the method of connection, the system using MASTER-K120S built-in communication can be composed. 1) Connecting system configuration (link between MASTER-K’s) (1) 1:1 connection with general PC a) Communication program made by C or BASIC computer language on the user’s computer, or utility program like FAM or CIMON can be used.
Page 193 Chapter 8 Communication Functions (2) 1:1 connection with a monitoring device like PMU PMU(LGIS) MASTER-K120S main unit RS-485 interface RS-232C interface MASTER-K120S main unit Pin assignment and direction Pin No. Pin no. Signal RXD1 TXD1 RXD2 TXD2 Female Type Connection method and signal direction MASTER-K120S main unit 485+ 485+...
Page 194 Chapter 8 Communication Functions (3) 1:1 connection with other MASTER-K120S MASTER-K120S main unit MASTER-K120S main unit RS-232C interface RS-485 interface MASTER-K120S MASTER-K120S main unit main unit Pin assignment and direction Pin no. Pin no. Signal RXD1 TXD1 RXD2 TXD2 Male Type MASTER-K120S main unit Connection method and signal direction MASTER-K120S main unit 485+...
Page 195: Frame Structure
Chapter 8 Communication Functions 8.1.3 Frame Structure 1) Base Format (1) Request frame(external communication device → MASTER-K120S main unit), (Max. 256 Bytes) Header Station Tail Frame check Command Command type Structurized data area (ENQ) number (EOT) (BCC) (2) ACK Response frame (MASTER-K120S main unit → external communication device, when receiving data normally) (max.
Page 196 Chapter 8 Communication Functions Remark 1) The numerical data of all frames are ASCII codes equal to hexadecimal value, if there’s no clear statement. The terms in hexadecimal are as follows. • Station No. • When the main command is R(r) or W (w) and the command type is numerical (means a data type) •...
Page 197: Lists Of Commands
Chapter 8 Communication Functions 8.1.4 List of commands Classification Command Treatment Main command Command type Items Code ASCII code Code ASCII code Reads data from device of Bit, Byte, Word type. Individual r(R) 5353 Reading (H52) device Reads device Word in block unit. r(R) 5342 Continuous...
Page 198: Data Type
Chapter 8 Communication Functions 8.1.5 Data type It’s possible to read and write device in built-in communication. When device is used, be aware of data type. 1) Data type of variable • Available types of device Device Name Explanation Read/Write Bit/Byte/Word Assignment Input/Output relay Available...
Page 199: Execution Of Commands
Chapter 8 Communication Functions 8.1.6 Execution of commands 1) Individual reading of device(R(r)SS) (1) Introduction This is a function that reads PLC device specified in accord with memory data type. Separate device memory can be read up to 16 at a time. (2) PC request format Station Command...
Page 200 Chapter 8 Communication Functions (3) Response format (ACK response) Station Command Number of Number Frame Format name Header Command data Tail ..type blocks of data check Ex. of frame R(r) HA9F3 ASCII value H3230 H52(72) H5353 H3031 H3032 H41394633 1 block(max.
Page 201 Chapter 8 Communication Functions (4) Response format (NAK response) Error code Format name Header Station No. Command Command type Tail Frame check (Hex 2 Byte) Ex. of frame R(r) H1132 ASCII value H3230 H52(72) H5353 H31313332 Item Explanation When command is lowercase(r), only one lower byte of the value resulted by adding 1 Byte each to ASCII values from NAK to ETX is converted into ASCII and added to BCC.
Page 202 Chapter 8 Communication Functions ③ For NAK response after execution of command(PC ← MASTER-K120S main Unit) Format name Header Station No. Command Command type Error code Tail Frame check Ex. of frame Error code (2 bytes) ASCII value H3031 H5353 Error code (4 bytes) 2) Continuous reading(R(r)SB) of device (1) Introduction...
Page 203 Chapter 8 Communication Functions (3) MASTER-K120S Main unit response format (MASTER-K120S of ACK response) Command Number of Number of Frame Format name Header Station No. Command data Tail type blocks data check R(r) H1122 Ex. of frame H3130 H52(72) H5342 H3031 H3134 H31313232...
Page 204 Chapter 8 Communication Functions (4) Response format (NAK response) Error code Format name Header Station No. Command Command type Tail Frame check (Hex 2 Byte) H1132 Ex. of frame H3130 H5342 H31313332 ASCII value Item Explanation When command is lowercase(r), only one lower byte of the value resulted by adding 1 Byte each to ASCII values from NAK to ETX is converted into ASCII and added to BCC, and sent.
Page 205 Chapter 8 Communication Functions 3) Individual writing of device(W(w)SS) (1) Introduction This is a function that writes the PLC device memory directly specified in accord with memory data type. (2) PC request format Frame Command Number of Device Tail Format name Header Station No.
Page 206 Chapter 8 Communication Functions (3) Response format (ACK response) Tail Frame check Format name Header Station No. Command Command type Frame (Example) W(w) ASCII value H3230 H57(77) H5353 Item Explanation When command is lowercase(r), only one lower byte of the value resulted by adding 1 Byte each to ASCII values from ACK to ETX is converted into ASCII and added to BCC, and sent.
Page 207 Chapter 8 Communication Functions (5) Example This example supposes that "HFF" is written in M230 of station No. 1 and BCC value is checked. ① Computer request format (PC → MASTER-K120S main unit) Frame Command Number of Tail Format name Header Station No.
Page 208 Chapter 8 Communication Functions 4) Continuous writing of device(W(w)SB) (1) Introduction This is a function that directly specifies PLC device memory and continuously writes data from specified address as much as specified length. (2) Request format Number of data Frame Format Station Comman...
Page 209 Chapter 8 Communication Functions (3) Response Format (ACK response) Tail Frame check Format name Header Station No. Command Command type Frame (Example) W(w) ASCII value H3130 H57(77) H5342 Item Explanation When command is lowercase(r), only one lower byte of the value resulted by adding 1 Byte each to ASCII values from ACK to ETX is converted into ASCII and added to BCC, and sent.
Page 210 Chapter 8 Communication Functions (5) Example This example supposes that 2 byte H’AA15 is written in D000 of station No. 1 and BCC value is checked. ① Computer request Format (PC → MASTER-K120S main unit) Frame Station Command Device Number of Data Tail Format name...
Page 211 Chapter 8 Communication Functions 5) Monitor register(X##) (1) Introduction Monitor register can separately register up to 10 in combination with actual variable reading command, and carries out the registered one through monitor command after registration. (2) PC request Format Frame Registration No.
Page 212 Chapter 8 Communication Functions (3) Response Format (ACK response) Registration No. Tail Frame check Format name Header Station No. Command Frame (Example) X(x) ASCII value H3130 H58(78) H3039 Item Explanation When command is lowercase(r), only one lower byte of the value resulted by adding 1 Byte each to ASCII values from ACK to ETX is converted into ASCII and added to BCC, and sent.
Page 213 Chapter 8 Communication Functions (5) Example This example supposes that device M000 of station NO. 1 is monitor registered. ① Computer request Format (PC → MASTER-K120S main unit) Registration Format Registration Tail Frame check Format name Header Station No. Command Number of Device length Device name blocks...
Page 214 Chapter 8 Communication Functions 6) Monitor execution(Y##) (1) Introduction This is a function that carries out the reading of the variable registered by monitor register. This also specifies a registered number and carries out reading of the variable registered by the number. (2) PC request Format Registration No.
Page 215 Chapter 8 Communication Functions (4) Response Format (NAK response) Registration Error code Tail Frame check Format name Header Station No. Command (Hex 2Byte) Frame (Example) Y(y) H1132 ASCII value H3130 H59(79) H3039 H31313332 Item Explanation When command is lowercase(y), only one lower byte of the value resulted by adding 1 Byte each to ASCII values from NAK to ETX is converted into ASCII and added to BCC, and sent.
Page 216 Chapter 8 Communication Functions 7) Reading PLC Status(RST) (1) Introduction This is a function that reads flag list including operating status of PLC and error information. (2) PC request Format Tail Frame check Format name Header Station No. Command Command type Frame (Example) R(r) ASCII value...
Page 217 Chapter 8 Communication Functions (4) Response Format ( NAK response) Error code Tail Frame check Format name Header Station No. Command Command type (Hex 2 Byte) Frame (Example) R(r) H1132 ASCII value 3041 5272 5354 31313332 * When command is one of lower case(r), only one lower byte of the value resulted by adding 1 Byte each to ASCII values from NAK to ETX is converted into ASCII and added to BCC, and sent.
Page 218: 1:1, 1:N Built-In Communication Between Master-K120S's
Chapter 8 Communication Functions 8.1.7 1:1, 1:n Built-in communication between MASTER-K120S's 1) Introduction 1:1 built-in communication between MASTER-K120S's is that which constitutes a built-in communication system with the method of 1(master) : 1(slave). Setting Base parameter and communication parameter in KGLWIN can easily constitute this system.
Page 219 Chapter 8 Communication Functions 2) Parameter setting (1) Communication Parameter Setting • Open a new project file from KGLWIN - MASTER-K120S must be selected as PLC type. • After selecting communication parameter from KGLWIN and clicking twice, this window comes up. (a) When uses Ch.0 : Built-in RS-232C or External Cnet I/F module (b) When uses Ch.1 : Built-in RS-485 8-29...
Page 220 Chapter 8 Communication Functions • Set according to the following table Item Contents Station No. Sets one of station from 0 to 31. Baud rate Sets one of 1200, 2400, 4800, 9600, 19200, 38400, 57600 bps Data bit Sets one of 7 or 8 Bits Parity bit Sets one of none, Even, Odd Stop bit...
Page 221 Chapter 8 Communication Functions • Click the ‘List’ button to open the registration list window. • Total 64 data blocks can be assigned. But it's not possible to set a register number. • Sending and receiving data size can be set up to 60 Words. •...
Page 222 Chapter 8 Communication Functions 3) Flag related with operating status (1) Sending/receiving error count for each station (total 32 stations) Error code is saved following area according to station Remarks Station Device Station Device D4400 16,17 D4408 D4401 18,19 D4409 D4401 20,21 D4410...
Page 223 Chapter 8 Communication Functions • Error bit Error status of slave PLC Reserved Operation mode of slave PLC 1 : Error b4 : STOP 0 : Normal b5 : RUN b6 : PAUSE b7 : DEBUG (4) Status flag of the master PLC Status Information of master PLC is saved in D4448 D4448 - - - - - - - - - - -...
Page 224 Chapter 8 Communication Functions 4) Example MASTER-K120S main unit MASTER-K120S main unit (Slave : Station No. 31) (Master : Station No. 0) G7E-DR10A 1:1 built-in communication between MASTER-K120S • Device M000 is increased by program per 1 second. • Writing M000 to output area P004 of slave •...
Page 225 Chapter 8 Communication Functions ④ Set parameters as the following table. Protocol Communication Method and mode Comm- Station no. Baud rate Data bit Parity bit Stop bit Communication channel Timeout Dedicated unication RS232C null modem or Enable 19200 None 500ms Master RS422/485 ⑤...
Page 226 Chapter 8 Communication Functions ⑧ The registration list ‘0’ registered in the registration list can be confirmed through a window like the following. ⑨ Double click the No. 1 for receive parameter setting and Set parameters like the following table and click ‘OK’ button. Station No.
Page 227 Chapter 8 Communication Functions (2) Program (2) Parameter setting for slave station. ① Set parameters as the following table. Protocol Communication Method and mode Commu- Station no. Baud rate Data bit Parity bit Stop bit Communication channel Timeout Dedicated nication RS232C null modem or Enable 19200...
Page 228 Chapter 8 Communication Functions 8.1.8 Error code Error code Error type Error condition and causes Treatment H0001 PLC system error Interface with PLC is impossible. Off/On the power Check if other letters than capitals/small letters, Errors occurred when exchanging ASCII H0011 Data error numbers, and (‘%’,’_’,’.’) in device and data, correct...
Page 229: User Defined Protocol Communication
Chapter 8 Communication Functions 8.2 User Defined Protocol Communication 8.2.1 Introduction User Defined Protocol Communication allows users who do communication between MASTER-K120S main unit and other kind of device to define the other company’s protocol at MASTER-K PLC. There’re a number of kinds of protocols made by many companies, that it’s difficult to have all protocols in it.
Page 230 Chapter 8 Communication Functions 2) Setting frame (1) Click “List” button to activate the following window. (2) Select one of 1∼15 in frame list to open the following window. ① Frame specification • Header - Used in [Header] type. - Possible characters, as headers are 1 alphabet letter, 1 numeric number, or control characters as below. Available Control Code NUL(H00) SOH(H01)
Page 231 Chapter 8 Communication Functions Example 1) [NUL] , [ENQ] , [1] , [A] : Possible Example 2) NUL, ENQ , [12] , [ABC] : impossible - It is allowed to be only 3 consecutive characters. Example 3) [ENQ][STX][NUL] : Possible Example 4) [A][NUL][ENQ][STX] : impossible •...
Page 232 Chapter 8 Communication Functions Item Contents It is a radio button to select the input type of commands. There’re 2 kinds as hex or ASCII value. Ex1) ASCII : 1 0 R S B 0 6 % M W 1 0 0 Ex2) Hex : 31 30 52 53 42 30 36 25 57 44 31 30 30 If ARRAY is set, it asks whether it would convert data to ASCII to send (at send frame), or convert to hexadecimal to receive(at receive frame).
Page 233 Chapter 8 Communication Functions • BCC setting: set BCC when it is needed. Item Contents ASCII adds 2 bytes BCC value in ASCII type to frame. Hex adds 1 byte BCC value in Hex type to Data Type frame. For the detailed setting BCC, refer to 8.1.6 “Execution of Commands”. It is that sum all the data from 2 data to the data before the data marked as [BCC] and input the Default...
Page 234 Chapter 8 Communication Functions • Frame size - ASCII communication : max. 128 bytes - Hex communication : max. 256 bytes • Link relay (L) - It’s a flag to indicate whether a user defined frame is received in the order set by the user. - If the received frame is matched with the declared frame in frame list number 3, L003 starts blinking (0 →...
Page 235 Chapter 8 Communication Functions The last transmitting frame The kinds of The value of sum check BCC Type setting Input segment ASCII Type Hex Type ASCII Input 31 + 32 +33 +34 +04 = CE 05 31 32 33 34 04 43 41 05 31 32 33 34 04 CE Hex Input 12 + 34 +04 = 4A...
Page 236 Chapter 8 Communication Functions ④ Complement setting : Complement calculation as below example> 1’s and 2’s Complements of D3 it 7 bit 0 = h D3(sum check value) it 7 bit 0 1’ complement = h 2C(the last sum check value) it 7 bit 0 2’...
Page 237: Instruction
Chapter 8 Communication Functions 8.2.3 Instruction 1) User defined communication instruction(SNDCOM) SNDCOM User defined communication instruction Available Device Flag No. of Instruction steps Error Zero Carry integer (F110) (F111) (F112) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○...
Page 238: Example Of Usage
Chapter 8 Communication Functions 3) Error code Code Error type explanation Slave Device Busy It’s sending or waiting to receive Parameter Error Communication parameter setting error, Link enable setting error Frame Type Error Frame does not setting or frame does not ‘sending’ 8.2.4 Example of Usage This example is supposed that there’s a communication between MASTER-K120S’s by the user-defined protocol.
Page 239 Chapter 8 Communication Functions ③ Double click the number ‘0’ ④ Designate the header, segment, send/receive , tail as below and then click the BCC Setting 8-49...
Page 240 Chapter 8 Communication Functions ⑤ Designate BCC Setting as below and Click the OK button, then you can see the frame list window which is designated 8-50...
Page 241 Chapter 8 Communication Functions ⑥ Double click the number 1 frame ⑦ BCC Setting method is same frame 0. ⑧ After the frame setting and BCC setting completes, click the OK button. ⑨ You can see the frame list window which is designated as below. 8-51...
Page 242 Chapter 8 Communication Functions ⑧ Program • When the data is received at frame no. 1, link relay L001 turns on during 1 scan. At that moment, M000 increases and the value of M000 moves output relay P004. • The new value of M000 is sending again every 1 second period (F092 is 1second period flag) •...
Page 243 Chapter 8 Communication Functions ③ Double click the frame list number ‘0’ ④ Click the BCC Setting after set the header , segment , tail as below. 8-53...
Page 244 Chapter 8 Communication Functions ⑤ Click the OK button after BCC setting as below. Then you can see the frame list which is designated. 8-54...
Page 245 Chapter 8 Communication Functions ⑥ Set the frame number ‘1’ as below and click the BCC Setting ⑦ BCC Setting method is same as master station. 8-55...
Page 246 Chapter 8 Communication Functions ⑧ After the frame setting and BCC setting completes, click the OK button. ⑨ You can see the frame list window which is designated as below ⑩ Program • When the data is received at frame no. 0, link relay L000 turns on during 1 scan. At that moment P004 increases and the value of P004 moves M000.
Page 247: Modbus Protocol Communication
Chapter 8 Communication Functions 8.3 Modbus Protocol Communication 8.3.1 Introduction MASTER-K120S built-in communication supports Modbus, the Modicon product’s communication protocol. It supports ASCII mode, using ASCII data and RTU mode using Hex data. Function code used in Modbus is supported by instruction and especially function code 01, 02, 03, 04, 05, 06, 15 and 16.
Page 248 Chapter 8 Communication Functions 3) Address area (1) Setting range is available from 1 to 247, but MASTER-K120S supports from 0 to 31. (2) Address 0 is used for broadcast address. Broadcast address is all slave device recognize and respond to like the self- address, which can't be supported by MASTER-K120S.
Page 249 Chapter 8 Communication Functions 7) Function code types and memory mapping Modicon PLC Code Function code name Remark Data address Read Coil Status 0XXXX(bit-output) Read bits Read Input Status 1XXXX(bit-input) Read bits Read Holding Registers 4XXXX(word-output) Read words Read Input Registers 3XXXX(word-input) Read words Force Single Coil...
Page 250 Chapter 8 Communication Functions 10) Map of wiring MASTER- K120S Quantum (9PIN) Connecting no. and direction main unit Pin no. Pin no. Signal Male Type • Use RS-485 connector when using channel 2. 8.3.3 Parameters Setting 1) Setting communication parameter (1) Open a new project file at KGLWIN.
Page 251 Chapter 8 Communication Functions (3) Set the contents as follows. Item Setting contents Set a number between 0 to 31 (Don’t assign no. 0 as broadcasting station lest it may be a cause Station No. for mistaken operation) Baud Rate Set one from 1200, 2400, 4800, 9600, 19200, 38400, or 57600 bps.
Page 252: Instruction And Examples
Chapter 8 Communication Functions 8.3.4 Instruction and example 1) MODBUS communication instruction(MODCOM) MODCOM MODBUS communication Available device Flag No. of Instruction Error Zero Carry steps i n teger (F110) (F111) (F112) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○...
Page 253 Chapter 8 Communication Functions • S3 format is as below. bit 15 bit 8 bit 1 bit 0 Error bit NDR bit Error code • NDR : when the communication ends normally, this bit turns on during 1 scan. • Error bit : when communication error occurs, this bit turns on during 1 scan. At that time error code stores bit 8 ~ bit 15. •...
Page 254 Chapter 8 Communication Functions 2) Example program 1 It’s supposed that MASTER-K120S main unit is the master and it reads Coil Status of the station no. 17, a Modicon product. The master reads status of the Coil 00020 ~ 00056 of the slave station no. 17. The Coil of the slave station is supposed to be as follows and the data that are read is saved in D1000 Coil Status...
Page 255 Chapter 8 Communication Functions 3) Example program 2 It’s supposed that MASTER-K120S main unit is the master and it reads Coil Status of the station no. 17, a Modicon product. The master reads status of the input contact 10197 ~ 10218 of the slave station no. 17. The input contact of the slave station is supposed to be as follows and the data that are read is saved in M015.
Page 256 Chapter 8 Communication Functions 4) Example program 3 The master writes data D1000 ~ D1003 to contact 40000 of the slave station no. 10. ① ② ③ ④ ① : It designates slave station and function code ( No. of station : h0A(10) , function code : h10 ) ②...
Page 257: No Protocol Communication
Chapter 8 Communication Functions 8.4 No Protocol Communication 8.4.1 Introduction No protocol communication is useful when communication between MASTER-K120S main unit and other kind of devices with user defined protocol is impossible. User defined protocol is very convenient when there are enough interval between frames or a kind of frame is less than 16.
Page 258: Parameter Setting
Chapter 8 Communication Functions • Receiving format can be designated as below. Upper byte(hex) Lower byte(hex) H00(Receiving by Length of frame) H03 (Receives when length of frame data is 3) H01(Receiving by last byte) H03 (Receives when last frame data is 03(ETX)) - When designated as length of frame : Stores received data to devices when number of received byte is equal to designated lower byte value of receiving format.(setting range : 1~255) - When designated last byte : Stores received data to devices when receives designated ending byte.
Page 259: Instructions
Chapter 8 Communication Functions 8.4.3 Instructions 1) No protocol receive(DRCV) DRCV No protocol receive Available Device Flag No. of Instruction Error Zero Carry step Integer (F110) (F111) (F112) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○...
Page 260 Chapter 8 Communication Functions 1) No protocol send(DSND) DSND No protocol send Available Device Flag No. of Instruction Error Zero Carry step Integer (F110) (F111) (F112) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○...
Page 261: Examples
Chapter 8 Communication Functions 8.4.4 Examples Assume that a electrical weighing machine sends data which has unfixed size continuously. MASTER-K120S can communicates with it using no protocol. MASTER-K120S Main unit Electrical weighing machine For no protocol communication, one of following ending condition is designated. One is size of received data and the other is whether it has some pre-defined data.
Page 262 Chapter 8 Communication Functions 1) Communication Parameter Setting • Open a new project file from KGLWIN - K120S must be selected as PLC type. • After selecting communication parameter from KGLWIN and clicking twice, this window comes up. • Designate baud rate, data bit, parity bit, stop bit, and protocol. 2) Program •...
Page 263: Remote Connection And Communication I/F Module
Chapter 8 Communication Functions 8.5 Remote connection and communication I/F module 8.5.1 Remote connection MASTER-K120S series can connect to other PLC by built-in Cnet interface or communication I/F modules. 1) Remote connection by built-in Cnet I/F Remote connection by built-in Cnet I/F is available by dedicated communication protocol only. If KGLWIN and Master station is connected physically, it can connect to each slave station using remote connection function.
Page 264 Chapter 8 Communication Functions • Open a new project file from KGLWIN • After selecting menu-project-option, click ‘connection option’ • Click ‘Remote 1’ in depth of connection -. Type : Select GLOFA Cnet. -. Base : Select ‘0’. -. Clot : set to 0 when uses channel 0, and ‘1’ when uses channel 1 -.
Page 265 Chapter 8 Communication Functions • Dedicated modem and dial-up modem are both available and Set connection option of KGLWIN as below. 3) Remote connection by Fnet I/F module G7L-FUEA G7L-FUEA • Remote connection by Fnet interface is available by setting connection option of KGLWIN as below 8-75...
Page 266: Communication I/F Module
Chapter 8 Communication Functions 8.5.2 Communication I/F module MASTER-K120S series supports various kinds of communication I/F module. In this time, Built-In Cnet in main unit must be set to ‘Off’ as below and only one communication module can be extended BUILT_IN CNET Must be off ROM MODE...
Page 267 Chapter 8 Communication Functions Master Slave Slave Slave Wiring Example : RS-485 I/F 3) Usage of G7L-FUEA/RUEA G7L-FUEA and G7L-RUEA are Field Bus Interface module of LGIS and they support High speed link communication service by parameter setting. But communication by command(Read, Write) are not available Station number setting switch •...
Page 268 Chapter 8 Communication Functions • Clicking List button then this window comes up. • Designate self-station No. and set link items after double clicking entry list • For the details, refer to User’s manual of Fnet I/F module 4) Usage of G7L-PBEA/DBEA G7L-PBEA support profibus slave function only and G7L-DBEAsupports DeviceNet slave interface function only.
Page 269: Chapter 9. Installation And Wiring
Chapter 9 Installation and Wiring Chapter 9. Installation and wiring 9.1 Installation 9.1.1 Installation Environment This unit has high reliability regardless of its installation environment, but be sure to check the following for system reliability. 1) Environment requirements Avoid installing this unit in locations which are subjected or exposed to: (1) Water leakage and dust.
Page 270 Chapter 9 Installation and Wiring ) Power consumption block diagram of PLC systems Main Unit 5VDC line Expansion power module Input supply special output part input part Output part Input part part CPU part module (transistor) (Transistor) AC power Output Current. Input Current Output Current.
Page 271: Handling Instructions
Chapter 9 Installation and Wiring (6) Power consumption of the special module • W X 5 + I X 24 (W) (7) The sum of the above values is the power consumption of the entire PLC system. • W = W (8) Check the temperature rise within the control panel with calculation of that total power consumption(W).
Page 272 Chapter 9 Installation and Wiring (6) Wiring • Wiring I/O wires with high voltage cable or power supply line can cause malfunction or disorder. • Be sure that any wire does not pass across during input LED(I/O status will not be clearly identified). •...
Page 273 Chapter 9 Installation and Wiring (4) Mount the wire duct as it is needed. If the clearances are less than those in Fig below, follow the instructions shown below • If the wire duct is mounted on the upper part of the PLC, make the wiring duct clearance 50 ㎜ or less for good ventilation.
Page 274: Connection Of Expansion Module
Chapter 9 Installation and Wiring 9.1.3 Connection of expansion module The following explains the Connection of expansion modules to the main unit. (1) Open the connector cover of the main unit. (2) Insert the connector of the expansion module to the connector of the base unit. ④...
Page 275: Wiring
Chapter 9 Installation and Wiring 9.2 Wiring The followings explains the wiring instructions for use of the system. 9.2.1 Power Supply Wiring (1) When voltage fluctuations are larger than the specified value, connect a constant-voltage transformer (2) Use a power supply which generates minimal noise across wire and across PLC and ground. (When excessive noise is generated, connect an insulating transformer) AC100-240V MASTER-K120S...
Page 276: Input And Output Devices Wiring
Chapter 9 Installation and Wiring (7) As a measure against very large surge(e.g. due to lightening),connect a surge absorber as shown below. Surge absorber for lightening (8) Use a insulating transformer or noise filter for protection against noise. (9) Twist every input power supply wires as closely as possible. Do not allow the transformer or noise filter across the duct. Remark Ground the surge absorber(E1) and the PLC(E2) separately from each other.
Page 277: Grounding
Chapter 9 Installation and Wiring 9.2.3 Grounding (1) This PLC has sufficient protection against noise, so it can be used without grounding except for special much noise. However, when grounding it should be done conforming to below items (2) Ground the PLC as independently as possible. Class 3 grounding should be used (grounding resistance 80Ωor less). (3) When independent grounding is impossible, use the joint grounding method as shown in the figure below (B).
Page 278: Chapter 10 Maintenance
Chapter 10 Maintenance Chapter 10 Maintenance Be sure to perform daily and periodic maintenance and inspection in order to maintain the PLC in the best conditions. 10.1 Maintenance and Inspection The I/O module mainly consist of semiconductor devices and its service life is semi-permanent. However, periodic inspection is requested for ambient environment may cause damage to the devices.
Page 279: Periodic Inspection
Chapter 10 Maintenance 10.3 Periodic Inspection Check the following items once or twice every six months, and perform the needed corrective actions. Check Items Checking Methods Judgment Corrective Actions Ambient 0 ~ 55 °C temperature -. Measure with thermometer and Adjust to general standard Ambient hygrometer...
Page 280: Chapter 11 Troubleshooting
Chapter 11 Troubleshooting Chapter 11 Troubleshooting The following explains contents, diagnosis and corrective actions for various errors that can occur during system operation. 11.1 Basic Procedures of Troubleshooting System reliability not only depends on reliable equipment but also on short downtimes in the event of faults. The short discovery and corrective action is needed for speedy operation of system.
Page 281: Troubleshooting Flowchart Used When The Power Led Turns Off
Chapter 11 Troubleshooting 11.2.1 Troubleshooting flowchart used when the POWER LED turns OFF. The following flowchart explains corrective action procedure used when the power is supplied or the power led turns off during operation. Power LED is turned OFF Supply the power. Is the power supply operating? Does the power led turn on? See the power supply be within...
Page 282: Troubleshooting Flowchart Used When The Error Led Is Flickering
Chapter 11 Troubleshooting 11.2.2 Troubleshooting flowchart used when the ERR LED is flickering The following flowchart explains corrective action procedure use when the power is supplied starts or the ERR LED is flickering during operation. ERR LED goes flickering. Check the error code, with connected KGLWIN.
Page 283: Troubleshooting Flowchart Used When The Run Led Turns Off
Chapter 11 Troubleshooting 11.2.3 Troubleshooting flowchart used when the RUN LED turns off. The following flowchart explains corrective action procedure to treat the lights-out of RUN LED when the power is supplied, operation starts or operation is in the process. RUN LED is off.
Page 284 Chapter 11 Troubleshooting 11.2.4 Troubleshooting flowchart used when the I/O part doesn’t operate normally. The following flowchart explains corrective action procedure used when the I/O module doesn’t operate normally. When the I/O module doesn’t work normally. Is the indicator LED of the P40 on? Measure the voltage of power Replace the connector of the...
Page 285 Chapter 11 Troubleshooting Continue Are the indicator LED of the switch 1 and 2 on? Check the status of the switch 1and 2 Check the status of the switch 1and 2 Is the terminal screw tighten Is input wiring correct? Is input wiring correct? securely? Is the condition...
Page 286 Chapter 11 Troubleshooting 11.2.5 Troubleshooting flowchart used when a program cannot be written to the CPU part The following flowchart shows the corrective action procedure used when a program cannot be written to the PLC module. Program cannot be written to the PC CPU Switch to the remote STOP mode and execute the program write.
Page 287: Troubleshooting Questionnaire
Chapter 11 Troubleshooting 11.3 Troubleshooting Questionnaire When problems have been met during operation of the MASTER-K120S series, please write down this Questionnaires and contact the service center via telephone or facsimile. For errors relating to special or communication modules, use the questionnaire included in the User’s manual of the unit. 1.
Page 288: Troubleshooting Examples
Chapter 11 Troubleshooting 11.4 Troubleshooting Examples Possible troubles with various circuits and their corrective actions are explained. 11.4.1 Input circuit troubles and corrective actions The followings describe possible troubles with input circuits, as well as corrective actions. Cause Condition Corrective Actions Leakage current of external device Connect an appropriate register and capacity, (Such as a drive by non-contact switch)
Page 289: Output Circuit Troubles And Corrective Actions
Chapter 11 Troubleshooting 11.4.2 Output circuit troubles and corrective actions The following describes possible troubles with input circuits, as well as their corrective actions. Condition Cause Corrective Action Connect registers of tens to hundreds KΩ across the When the output is Load is half-wave rectified inside (in some cases, it is true off, excessive of a solenoid)
Page 290 Chapter 11 Troubleshooting Output circuit troubles and corrective actions (continued). Condition Cause Corrective actions The load off Over current at off state [The large solenoid current Insert a small L/R magnetic contact and drive the load response time fluidic load (L/R is large) such as is directly driven with using the same contact.
Page 291: Error Code List
Chapter 11 Troubleshooting 11.5 Error code list Error Message CPU state Message Cause Corrective Actions Code Internal system Fault of some area of operating ROM, 0001h Stop System Error Contact the service center. error or H/W defect 0002h OS ROM error Stop OS ROM Error Internal system ROM is defected...
Page 292 Chapter 11 Troubleshooting (continued) Error Error CPU state Message Cause Corrective Actions Code FMM 3 Parameter 0026h Stop FMM 3 PARA Error FMM 3 Parameter Error Correct the parameter. Error • A digit of other than 0 to 9 has met during BCD conversion.
Page 293: Appendix 1 System Definitions
Appendix 1 System Definitions Appendix 1. System Definitions 1) Option (1) Connect Option You should set the communication port (COM1∼4) to communicate with PLC. • Select the Project-Option-Connection Option in menu. • Default Connection is RS-232C interface. • For the detail information about Connection Option, refer to KGLWIN Manual. App1-1...
Page 294 Appendix 1 System Definitions (2) Editor option • Monitor display type - Select the desired type in the monitor display type(4 types). • Source File Directory : - You can set directories for the files to be created in KGLWIN. - In Source Directory, KGLWIN saves source program files of program, parameter etc.
Page 295 Appendix 1 System Definitions (3) Page setup You can select print option when the project print out .(margin, cover, footer) App1-3...
Page 296 Appendix 1 System Definitions 2) Basic Parameters The basic parameters are necessary for operation of the PLC. Set the ‘Latch area’, ‘Timer boundary’’ , ‘Watchdog timer’, ‘PLC operation mode’, ‘Input setting’, ‘Pulse catch’ (1) Latch area setting Set the retain area on the inner device. (2) Timer boundary setting Set the 100ms/10ms/1ms timer boundary.
Page 297: Appendix 2 Flag Lists
Appendix 2 Flag List Appendix 2. Flag List 1) Special relay (F) This flag is useful to edit user program. Relay Function Description F0000 RUN mode Turns on when the CPU in the RUN mode. F0001 Program mode Turns on when the CPU in the Program mode F0002 Pause mode Turns on when the CPU in the Pause mode...
Page 298 Appendix 2 Flag List (Continued) Relay Function Description When the reserved I/O module (set by the parameter) differs F0040 to F005F I/O error from the real loaded I/O module or a I/O module has been mounted or dismounted, the corresponding bit turns on. F0060 to F006F Storing error code Stores the system error code, (See Section 2.9)
Page 299 Appendix 2 Flag List (Continued) Relay Function Description F190 to F193 Borrow flag for HSC Turn on when borrow is occurred on the HSC current value F200 to F20F Unit ID F0210 to F021F HSC error code Stores error of HSC Ch0 F0220 to F022F HSC error code Stores error of HSC Ch1...
Page 300 Appendix 2 Flag List 3) Data relay (D) When communication function is used, its status are stored in D register, and they can be monitored. And If correspond communication function is unused, these flags can be used as general data register. (1) When FNET module is connected Relay Keyword...
Page 301 Appendix 2 Flag List (2) When communication mode is dedicated master mode (Channel 0) Relay Function Relay Function D4400 Communication Error Code of station 0 and1 D4432 Mode and Error of Slave station 0 and 1 D4401 Communication Error Code of station 2 and 3 D4433 Mode and Error of Slave station 2 and 3 D4401...
Page 302 Appendix 2 Flag List (3) When communication mode is dedicated master mode (Channel 1) Relay Function Relay Function D4300 Communication Error Code of station 0 and1 D4332 Mode and Error of Slave station 0 and 1 D4301 Communication Error Code of station 2 and 3 D4333 Mode and Error of Slave station 2 and 3 D4301...
Page 303 Appendix 2 Flag List (4) D register for Forced I/O setting Forced I/O designation register Forced I/O data register P000 D4700 D4800 P001 D4701 D4801 P002 D4702 D4802 P003 D4703 D4803 P004 D4704 D4804 P005 D4705 D4805 P006 D4706 D4806 P007 D4707 D4807...
Page 304 Appendix 2 Flag List (5) System error history(when RTC module is attached) Relay Description D4900 Error pointer D4901 Year, Month D4902 Day, Time D4903 Minute, Second D4904 Error code (6) Clock data Relay Description D4990 Year, Month D4991 Day, Time D4992 Minute, Second D4993...
Page 305: Appendix 3 Dimensions
Appendix 3 External Dimensions Appendix 3 External Dimensions (unit: mm) 1) Main unit Model K7M-DR10/14UE K7M-DR20/30UE 95 105 115 K7M-DR(T)20/30U K7M-DR(T)40U K7M-DR(T)60U 2) Extension module (1) Standard type 95 105 115 App3-1...
Page 306 Appendix 3 External Dimensions (2) Slim type(G7E-DC08A,G7E-RY08A,G7F-ADHB,G7F-DA2V,G7F-RD2A) App3-2...

LG MASTER-K 120S Series User Manual

Chapter 1. General

Chapter 2. System Configuration

Chapter 3 General Specifications

Chapter 4. Names of Parts

Chapter 5. Power Supply / CPU

Chapter 6 . Input and Output Modules

Chapter 7. Usage of Various Functions

Chapter 8. Communication Function

Chapter 9. Installation and Wiring

Chapter 10 Maintenance

Chapter 11 Troubleshooting

Appendix 1 System Definitions

Appendix 2 Flag Lists

Appendix 3 Dimensions

Quick Links

Troubleshooting

Related Manuals for LG MASTER-K 120S Series

Summary of Contents for LG MASTER-K 120S Series

Table of Contents