EC20 Series PLC User Manual.pdf

EC20 Series PLC User Manual Version V1.1 Revision date June 26, 2006 BOM 31011166

Emerson Network Power provides customers with technical support. Users may contact the nearest Emerson local sales office or service center.

Copyright 2005 by Emerson Network Power Co., Ltd.

All rights reserved. The contents in this document are subject to change without notice.

Emerson Network Power Co., Ltd.

Address: No.1 Kefa Rd., Science & Industry Park, Nanshan District 518057, Shenzhen China

Homepage: www.emersonnetworkpower.com.cn

E-mail: [email protected]

Safety Precautions

To reduce the chance of accident, please read the safety precautions very carefully before operation. The "Caution, Notice, Warning, Danger" symbols in this manual do not represent all the safety points to be observed, and are only used as a supplement to various operation safety points. Therefore, the installation and operation personnel must be strictly trained and master the correct operations and all the safety points before actual operation.

When operating Emerson PLC products, the safety rules in the industry, the general safety points and special safety instructions specified in this manual must be strictly observed.

These notices are highlighted in the manual by a warning triangle and are marked as follows according to the level of danger:

Danger: indicates that death, severe personal injury, or substantial property damage will result if proper precautions are not taken.

Warning: indicates that death, severe personal injury, or substantial property damage could possibly result if proper precautions are not taken.

Caution: indicates that minor personal injury or property damage can result if proper precautions are not taken.

Notes for designing

The programming must include safety circuit to ensure the safe application of the PLC (Programmable Logic Controller) system upon power off or the PLC malfunction. Note the following when programming:

z The external circuit of the PLC must include the emergency braking circuit, protection circuit, mutual interlock circuit of forward/reverse rotation, and the interlock switch of position upper/lower limit for preventing equipment from damage.

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

z All the outputs may be shutdown when the CPU of the PLC detects the abnormity of the system; the failure of part PLC circuit may result in uncontrolled PLC output. A suitable external control circuit must be designed to ensure the normal operation of the equipment.

z When the PLC output unit such as the relay or the transistor is damaged, the PLC output cannot be controlled as ON or OFF state.

z The PLC is designed to be used in the electrical environment of indoor area B and C. However, to prevent the high lightning voltage from damaging the equipment through the ports of power input, signal input or control output, a SPD should be installed in the power supply system.

: According to IEC61131-2, section 8.3.1 classification declaration

Notes for installation

z Units should not be installed in areas subject to the following conditions: excessive or conductive dust, corrosive or flammable gas, moisture or rain, excessive heat, regular impact shocks or excessive vibration. Electric shock, fire hazard and mishandling may also damage the product.

z Take special care not to allow metal debris and wire lead to fall inside the vent of the PLC during the screw hole processing and wiring. Otherwise there is a danger of fire, damage or faulty operation of equipment.

z Once the installation of the new PLC is complete, remove everything on the surface of the vent, including packing goods such as protective paper. Otherwise the poor ventilation during the operation may result in fire, damage or faulty operation of equipment.

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

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

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

Notes for wiring

z Installation and wiring can be done only after the external power supplies are all disconnected. Otherwise there is a danger of electric shock or equipment damage.

z Once the installation and wiring of the PLC is complete, cleanup the spot at once. To prevent the electric shock, replace the port cover of the product before power is on.

z When wiring AC supplies, the Live cable should be connected to the L terminal and the Neutral cable should be connected to the N terminal. Otherwise the PLC will be damaged.

z Dont power +24V port of the main module by the external power supply. Otherwise the PLC will be damaged.

z Do not lay I/O signal cables of the PLC next to other power cables or strong interference circuits. z Do not make the earth port (PG) of the main module and the heavy current power system share the same

earthing.

Notes for operation and maintenance

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

z The cleaning and the fastening work can be done only after the power supply has been disconnected; otherwise there is a danger of electric shock.

z Only after the power supply has been disconnected, can the communication signal cables and the cables of the expansion module or control unit be connected or removed. Otherwise there is a danger of equipment damage or faulty operation of equipment.

z Do not disassemble the PLC. Otherwise it may destroy the inner electrical components. z Read through this manual carefully before operating the PLC. Safe and efficient operation of the product,

such as program alternation, trial operation, start and stop, is only based on correct operation and maintenance.

z Do not replace the button cell battery with power applied. If the battery replacement is indeed to be done with power applied, it shall always be carried out by adequately trained electric technical personnel wearing insulated gloves.

Notes for the product disposal

Note the following when disposing the PLC:

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

burning.

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

Follow the local environmental regulations to dispose the PLC or dispose it as industrial waste.

Contents

Chapter 1 Preface ............................................................................................................................................................ 1

Chapter 2 Product Introduction......................................................................................................................................... 2

2.1 Outline................................................................................................................................................................ 2 2.2 Maximum Configuration ..................................................................................................................................... 2 2.3 Internal Memory Capacity Of User Program ...................................................................................................... 2 2.4 Resource Configuration Of System Soft-device ................................................................................................. 2 2.5 High-speed Input/Output Function...................................................................................................................... 3 2.6 Filter Function Of Input Port ............................................................................................................................... 3 2.7 Interrupt Source.................................................................................................................................................. 3 2.8 Subroutine Call................................................................................................................................................... 3 2.9 Reinforced Debugging Function ......................................................................................................................... 3 2.10 Support Online Modification ............................................................................................................................. 3 2.11 Multiple Password Protection Function ............................................................................................................ 4 2.12 Expansion Module............................................................................................................................................ 4 2.13 RUN And STOP Control ................................................................................................................................... 4 2.14 User Program Developing And Debugging ...................................................................................................... 4 2.15 Communication And Networking ...................................................................................................................... 4

Chapter 3 Installation........................................................................................................................................................ 5

3.1 Notes For Installation ......................................................................................................................................... 5 3.2 Requirements For Installation Position............................................................................................................... 5 3.3 Installation Method ............................................................................................................................................. 5 3.4 Installation Dimensions ...................................................................................................................................... 6

Chapter 4 Product Specifications ..................................................................................................................................... 8

4.1 Model Legend..................................................................................................................................................... 8 4.2 Product Model And Configuration....................................................................................................................... 8

4.2.1 Main Module ........................................................................................................................................... 8 4.2.2 I/O Expansion Module............................................................................................................................. 8 4.2.3 Special Function Module......................................................................................................................... 9

4.3 Product Size....................................................................................................................................................... 9 4.4 Environmental Requirements ............................................................................................................................. 9 4.5 Electric Insulation Specifications ........................................................................................................................ 9 4.6 Reliability .......................................................................................................................................................... 10 4.7 Power Supply Specifications ............................................................................................................................ 10

4.7.1 Inner Power Supply Of Main Module .................................................................................................... 10 4.7.2 Use Of Each Circuit Output Power........................................................................................................ 10 4.7.3 Power Specifications Provided By Main Module To Expansion Module................................................ 11 4.7.4 Derating Design Of Power Supply Circuit ............................................................................................. 11

4.7.5 Power Consumption Of Expansion Module........................................................................................... 12 4.7.6 Power Capacity Calculation In Expansion Connection.......................................................................... 12

4.8 Programming Tool Of User Program................................................................................................................ 12

Chapter 5 Input Characteristic ........................................................................................................................................ 13

5.1 User Ports Of Main Module .............................................................................................................................. 13 5.2 Input Port Characteristic And Signal Specification ........................................................................................... 14 5.3 Inner Equivalent Circuit Of Input Port ............................................................................................................... 15 5.4 Input Connection Of High-speed Counter ........................................................................................................ 16 5.5 Interrupt Input Connection................................................................................................................................ 17 5.6 Input Signal Status Indication ........................................................................................................................... 17 5.7 Analog Potentiometer And Application ............................................................................................................. 17 5.8 Example Of Input Connection .......................................................................................................................... 17

Chapter 6 Output Characteristic ..................................................................................................................................... 19

6.1 Output Port Application .................................................................................................................................... 19 6.2 Electric Specifications Of Output Port .............................................................................................................. 19 6.3 Output Port Connection.................................................................................................................................... 20 6.4 Output Port Status Indication............................................................................................................................ 22 6.5 Example Of Output Connection........................................................................................................................ 22

Chapter 7 Expansion Module ......................................................................................................................................... 23

7.1 Model ............................................................................................................................................................... 23 7.2 Expansion Busbar Connection ......................................................................................................................... 23 7.3 Expansion Module Addressing ......................................................................................................................... 23

7.3.1 I/O Point Addressing Number Principle................................................................................................. 24 7.3.2 Special Function Module Addressing Number Principle........................................................................ 24

Chapter 8 Communication And Networking.................................................................................................................... 25

8.1 Communication Port......................................................................................................................................... 25 8.2 Programming Environment............................................................................................................................... 26 8.3 Programming Cable ......................................................................................................................................... 26

Chapter 9 Cable Specification And Wiring...................................................................................................................... 27

9.1 Connecting Power Supply Cable...................................................................................................................... 27 9.2 Connecting Ground Cable................................................................................................................................ 27 9.3 Connecting Common Port ................................................................................................................................ 28 9.4 Cable Specification........................................................................................................................................... 28

Chapter 10 First Operation And Maintenance ................................................................................................................ 29

10.1 Notes For Application ..................................................................................................................................... 29 10.2 Check Before Power On................................................................................................................................. 29 10.3 Startup............................................................................................................................................................ 29 10.4 RUN/STOP Switchover .................................................................................................................................. 29

10.4.1 How To Startup (STOP RUN) ....................................................................................................... 30

10.4.2 How To Stop (RUN STOP) ........................................................................................................... 30 10.5 Routine Maintenance ..................................................................................................................................... 30

Chapter 11 Troubleshooting ........................................................................................................................................... 32

Chapter 12 Instruction List.............................................................................................................................................. 33

Chapter 13 Special Register........................................................................................................................................... 38

13.1 Special Intermediate Register ........................................................................................................................ 38 13.2 Special Data Register..................................................................................................................................... 42

Chapter 1 Preface 1

EC20 Series PLC User Manual

Chapter 1 Preface

Thank you for using EC20 series Programmable Logic Controller (PLC) made by Emerson Network Power Co., Ltd. This book contains text, diagrams and explanations that will guide the reader in the correct installation and operation of the EC20 series PLC and should be read and understood before attempting to install or use the product.

The book describes the hardware, features and applications of the EC20 series PLC, also includes the options introduction, troubleshooting guide and instruction quick reference. For the information about how to setup an EC20 programming system and the customer programming application, please refer to ControlStar Programming Software User Manual or EC20 series PLC Programming Manual printed by Emerson Network Power Co., Ltd. For ordering the above user manuals, contact your Emerson distributor or sales office.

This manual is designed for the engineer who is studying, programming, installing, or servicing the EC20 series PLC.

Definitions of specific terms

PLC: Programmable Logic Controller

Main module: Refer to basic module or CPU module; it is the basic unit of the PLC. It includes master CPU, I/O ports and power supply.

Expansion module: Generally refer to the modules except for the main module.

I/O expansion module: The expansion module for the digital signal input/output.

Special function module: Other function expansion modules except for the I/O expansion module, such as analog signal input/output module, and busbar module.

Points: The sum of channel number of the input/output digital signal.

Digital signal: Refer to the input/output signals that only have two states: ON and OFF.

Analog signal: Continuously changed electric signal, such as 4~20mA output signal of pressure transmitter.

Unipolar signal: Generally refer to the continuously changed signal with positive polarity.

Bipolar signal: Generally refer to the continuously changed signal, which may be positive polarity or negative polarity.

High-speed pulse: Refer to the square-wave signal with higher frequency.

Counter: Refer to the counter whose counting value increases or decreases by per pulse input according to the increasing/decreasing control signal.

Two-phase counter: refer to the counter that has two-pulse input ports, one is for counting up, and the other is for counting down.

AB-phase counter: refer to the counter that has two input ports of quadrature phase pulse, and counts up or down according to the frequencies and phase differences of the two signals.

2 Chapter 2 Product Introduction


Chapter 2 Product Introduction

2.1 Outline

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

1 2 3 4

56

78

9101112

131415

Figure 2-1 Outline of EC20 main module

The name and function of the components in the figure are as follows:

1. The installation position of a button cell battery (CR2032 lithium battery) for data backup.

2. Power supply input ports

3. Signal input ports

4. Input signal status LEDs

5. 26pin busbar socket, used for connecting the expansion module

6. Output signal status LEDs

7. Fix screws, used for tightening the top/bottom cover of the PLC

8. Mounting holes, used for installing screws

9. Locking device of 35mm DIN, used for DIN rail installation mode.

10. Signal output ports

11. System operation status LEDs

12. Communication port COM1, providing RS485 and RS232 at the same time

13. Communication port COM0, RS232, Mini DIN8 socket

14. System operation control switch, with three positions: ON, TM and OFF.

15. Analog potentiometers (two)

2.2 Maximum Configuration

The main module and the I/O expansion modules can achieve the most 512 logic points (256 in/256 out maximum). And eight special function modules can be expanded at most.

2.3 Internal Memory Capacity Of User Program

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

2.4 Resource Configuration Of System Soft-device Component Name Quantity Serial No. Note

X Input relay 256 X000~X377 The soft-device numbering is octal code Y Output relay 256 Y000~Y377 The soft-device numbering is octal code M Auxiliary relay 2000 M0~M1999

LM Local relay 64 LM0~LM63

Chapter 2 Product Introduction 3


Component Name Quantity Serial No. Note SM Special auxiliary relay 256 SM0~SM255 S State relay 992 S0~ S991

T Timer 256 T0~T255 100ms precision: T0~T209 10ms precision: T210~T251 1ms precision: T252~T255

C Counter 256 C0~C255 16 bit common increasing counter: C0~C199 32 bit common decreasing counter: C200~C235 32 bit high-speed counter: C236~C255

D Data register 8000 D0~D7999 V Local data register 64 V0~V63

Z Indexed addressing register

16 Z0~Z15

SD Special data register 256 SD0~SD255

2.5 High-speed Input/Output Function High-speed port

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

X0, X1 Input High-speed pulse countSingle input: 50KHz; X0~X5 input at the same time: frequency sum is 80KHz

X2~X5 Input High-speed pulse count Single input: 10KHz Y0, Y1 (only suitable for transistor output)

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

2.6 Filter Function Of Input Port Function Description

Digital filter function X0~X17 provide digital filter function, and filter time is within 0~60mS, set by users program Hardware filter function Other X input ports

2.7 Interrupt Source

Provide eight external interrupt inputs, the interrupt edge can be set by users and is corresponding to X0~X7 ports; six high-speed counter interrupts; three inner timing interrupt sources.

2.8 Subroutine Call

At most 64 subroutines and 6-level subroutine nesting can be used. Support local variables and variable-alias, and every subroutine can provide 16 parameters to be called at most.

2.9 Reinforced Debugging Function

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

2.10 Support Online Modification

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

4 Chapter 2 Product Introduction


2.11 Multiple Password Protection Function

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

2.12 Expansion Module

The expansion module such as I/O module, analog signal input/output module, network expansion module, and position control module can be connected to the PLC main module. Every module is address allocation automatically and identification automatically.

2.13 RUN And STOP Control

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

2.14 User Program Developing And Debugging

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

2.15 Communication And Networking

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

Provide Profibus module to compose the Profibus network.

Chapter 3 Installation 5


Chapter 3 Installation

3.1 Notes For Installation

The PLC is designed to be used in the environments meeting with standard II installation ambient, and Class 2 pollution. So the unit should be installed in such environment free of dust, conductive dust, corrosive or flammable gas, excessive heat, moisture or rain; Besides, shocks and vibrations will also affect the reliability of the PLC and shorten its service life, and should therefore be avoided.

Usually, the user should mount the PLC and the associated switches, contactors to the inside wall of the electric cabinet and keep adequate natural convection. If the ambient temperature is a little high, or a heat generating equipment is nearby, then a forced convection device should be installed on the top or the side of the cabinet to prevent the overheat of the unit.

Take special care not to allow metal debris and wire lead to fall inside the vent of the PLC during the screw hole processing and wiring. Otherwise there is a danger of fire, damage or faulty operation of equipment.

Once the installation of the new PLC is complete, remove everything on the surface of the vent, including packing goods such as protective paper. Otherwise the poor ventilation during the operation may result in fire, damage or faulty operation of equipment.

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

Installation and wiring must be firm and reliable; bad contact may result in faulty operation of equipment.

3.2 Requirements For Installation Position

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

Figure 3-1 Requirements for installation position

3.3 Installation Method

Generally you can mount the PLC onto a standard rail (DIN) with 35mm width. Follow these steps:

1. Fix the DIN rail to the backboard;

2. Pull out the clip (located on the bottom of the PLC) and hook the back of the PLC onto the rail.

3. Snap the clip closed, carefully checking to ensure that the clip has fastened the PLC securely onto the rail.

4. At last, install two DIN rail stops at the two sides of the PLC to avoid slippage around.

Other EC20 series modules can be mounted using the same procedures.

6 Chapter 3 Installation


Pull out the Clip of DIN rail

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

DIN rail stopDIN rail stop

Figure 3-2 Installing a PLC onto a standard rail

Under the conditions with great impact, you should mount the PLC on a panel using the screw installation. Using four fix screws through the four 4 mounting holes on the enclosure of the PLC (while EC20-2012BR/BT has only two 4 fix screws) to fix the PLC on the back panel of the electric cabinet, as shown in the Figure 3-3.

4 mounting holes

M3 fix screw

M3 fix screw

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

3.4 Installation Dimensions

1. The dimensions for the outline and mounting holes of EC20-2012BR and EC20-2012BT are shown in the Figure 3-4:

DIN rail (35mm)

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

2. The dimensions for the outline and mounting holes of EC20-3232BR and EC20-3232BT are shown in the Figure 3-5:

Figure 3-5 Dimensions of outline and mounting holes of EC20-3232BR and EC20-3232BT

3. The dimensions for the outline and mounting holes of EC20-0808ER are shown in the Figure 3-6. And the dimensions for the outline and mounting holes of the analog signal expansion module such as EC20-4AD, EC20-4DA, EC20-4AM, and EC20-4TC are the same with that of EC20-0808ER.

Chapter 3 Installation 7


Figure 3-6 Dimensions of outline and mounting holes of EC20-0808ER and the analog signal expansion module

8 Chapter 4 Product Specifications


Chapter 4 Product Specifications

4.1 Model Legend

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

EC 2 0 - 20 12 B R D

Output mode (R: relay; T: transistors)

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

Output points

Input points

Version

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

Emerson PLC Figure 4-1 Model Legend of PLC

4.2 Product Model And Configuration

4.2.1 Main Module

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

Model Power voltage

Vac Input / output

points Input signal

voltage Output

type Input port/

common port Output port/

common port Interrupt/

pulse inputPulse output

EC20-2012BRA 90~264 20/12 DC24V Relay 20/1 12/5 Yes No EC20-2012BTA 90~264 20/12 DC24V Transistor 20/1 12/5 Yes Yes EC20-3232BRA 90~264 32/32 DC24V Relay 32/1(2) 32/6 Yes No EC20-3232BTA 90~264 32/32 DC24V Transistor 32/1(2) 32/6 Yes Yes

32/1(2) in the table: Represent only one common port in logic, but two common ports in structure, and the two are connected inside the PLC.

4.2.2 I/O Expansion Module

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

Model Power Supply Vac Input/output points Output type Inner power supply EC20-0808ERN - 8/8 Relay No EC20-0808ETN - 8/8 Transistor No EC20-1616ERA 220Vac 16/16 Relay Yes EC20-1616ETA 220Vac 16/16 Transistor Yes EC20-1600ENN - 16/00 - No EC20-0016ERN - 00/16 Relay No EC20-0016ETN - 00/16 Transistor No

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Chapter 4 Product Specifications 9


4.2.3 Special Function Module

Table 4-3 Special function module of EC20 series

Model Function EC20-4AD 4-channel analog signal input module EC20-4DA 4-channel analog signal output module EC20-4TC 4-channel thermocouple temperature input module EC20-4AM 2-channel analog signal input module, 2-channel analog signal output module

4.3 Product Size

The main modules of EC20 series PLC have the same height and width, but their lengths are related to the I/O ports. The size of each module is listed in Table 4-4.

Table 4-4 Product size

Model Length (mm) Width (mm) Height (mm) Net weight EC20-2012BR 158 90 82 680g EC20-2012BT 158 90 82 680g EC20-3232BR 227 90 82 950g EC20-3232BT 227 90 82 880g

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

4.4 Environmental Requirements

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

Environmental parameters Type Parameter Unit

Environmental conditions for operation

Environmental conditions for transport

Environmental conditions for storage

Low temperature C -5 -40 -40 Temperature

High temperature C 55 70 70 Humidity Relative humidity % 95 (30 2C) 95 (40 2C) /

Low pressure kPa 70 70 70 Clim

ate

Air pressure** High pressure kPa 106 106 106 Bit shift mm 3.5 (5-9HZ) / / Sinusoidal

vibration acceleration M/s2 10 (9-150HZ) / / acceleration spectra density

m2/s3 (dB/Oct)

/ 1.92 (5-20Hz) -3db (20-200Hz)

/

Frequency range Hz / 5-200 / Random vibration

Vibration direction / X/Y/Z / Type / Half-sine wave /

Impact acceleration m/s2 / 180 /

Mec

hani

cal s

tress

Drop Drop height m / 1 /

4.5 Electric Insulation Specifications

Table 4-6 Electric insulation specifications of EC20 series PLC

Type Value Test conditions AC input to case 5%106 AC input to DC output 5%106

Insulation resistance

DC output to case 5%106

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

AC input to case (PG port) AC input to the port between the user input and outputAC input to expansion busbar User output (relay board) to expansion busbar User input to user output (relay)

Insulation voltage

Between user output ports (relay board)

Capable of withstanding 2830Vac/50Hz AC voltage (or equivalent DC voltage) 1 minute, with leakage current 30mA, and no breakdown or flashover



Type Value Test conditions Insulation voltage

The insulation resistance and voltage of other circuits are designed according to the requirements of an extra-low voltage circuit

4.6 Reliability

Table 4-7 MTBF of EC20 series PLC

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

Relay 100,000 hours Fix on the floor , mechanical stress is almost close to zero, without temperature and humidity control300,000 hours Fix on the floor , mechanical stress is almost close to zero, with temperature and humidity control

Transistor 150,000 hours Fix on the floor , mechanical stress is almost close to zero, without temperature and humidity control

For the PLC with relay output, the life of its contactors is related to the load type and load capacity, as listed in Table 4-8.

Table 4-8 Use life of EC20 series output relay

Load capacity Action frequency Life-span of contactors 220Vac, 15VA, inductive load 1sec. ON / 1sec. OFF 3,200,000 times 220Vac, 30VA, inductive load 1sec. ON / 1sec. OFF 1,200,000 times 220Vac, 60VA, inductive load 1sec. ON / 1sec. OFF 300,000 times

4.7 Power Supply Specifications

4.7.1 Inner Power Supply Of Main Module

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

Item Unit Min. Typ. Max. Note Input voltage Vac 90 220 264 Normal start and operating range

Limiting input voltage Vac 85 - 280 Operating at 280V for 3 hours and not damaged Each circuit can power 70% rated load at 85-100Vac, and power 55% rated load at 264-280Vac

Input current A / / 1.5 90Vac input, full load output 5V/GND V 4.75 5 5.25 Output1 24V/GND V 21.6 24 26.4 Output2

Output voltage

24V/COM V 21.6 24 26.4 Output3 5V/GND mA 1000 24V/GND mA 650

Output rated current 24V/COM mA 600

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

4.7.2 Use Of Each Circuit Output Power

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

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

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

Chapter 4 Product Specifications 11


4.7.3 Power Specifications Provided By Main Module To Expansion Module

Table 4-10 Power capacity consumption and load current provided

Logic circuit power supply Auxiliary power supply output 5V/GND 24V/GND 24V/COM

Model Inner

consumption* Capacity provided*

Inner consumption

Capacity provided

Inner consumption Capacity provided

EC20-2012BR 250mA 750 mA 70 mA 580 mA EC20-2012BT 400 mA 600 mA 0 650 mA

140mA 460 mA

EC20-3232BR 480 mA 520 mA 240 mA 410 mA EC20-3232BT 650 mA 350 mA 0 650 mA

240mA 360 mA

*Explanation:

The current of Inner consumption in Table 4-10 is the average current consumed when the module inner circuit works. Users cannot change it directly.

The current of capacity provided in Table 4-10 is the part capacity of the main module that can be used for the external control module. The data listed in Table 4-10 is under the stable ambient condition with 25C. If input voltage is out of rated voltage range or the working temperature exceeds +50C, users should consider the derating design, which is mainly obtained by decreasing the value of capacity provided, to ensure the reliable operation of the PLC.

4.7.4 Derating Design Of Power Supply Circuit

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

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

Power load %

Input voltage Vac

85 Vac

100 Vac

264 Vac

280 Vac

Figure 4-2 Derating curves of power supply output capacity and power supply input voltage

2. Power output capacity derating vs. work temperature relationship

When the work temperature is higher than the upper limit of the specification, the power capacity provided (including 5V/24V/GND and 24V/COM) by the main module to the expansion module must be derating. The derating relation is shown in Figure 4-3.

Power load %

Operation ambient temperature C

-5C 50C 55C

Figure 4-3 Derating curve between power output capacity and work temperature



4.7.5 Power Consumption Of Expansion Module

Table 4-11 Power consumption of each expansion module

Max. current consumption Model

5V/GND 24V/GND 24V/COM EC20-0808ER 30mA 50mA 50mA EC20-0808ET 80mA 0 50mA

EC20-4AD 50mA 0 25mA EC20-4DA 50mA 0 120mA EC20-4AM 50mA 0 90mA EC20-4TC 50mA 0 25mA

: Refer to the power consumption when the analog output channel port connects with the output. If the current output port (0~20mA) is not used, the current can be decreased to 50mA.

4.7.6 Power Capacity Calculation In Expansion Connection

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

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

Checking computations as following: Power circuit Current provided by the main module Actual consumed current conclusion

5V/GND 750mA (802+502+50+50) = 360mA Pass 24V/GND 580mA (02+02+0+0) =0 mA Pass 24V/COM 460mA (502+252+110+25) = 285mA Pass

It is obvious that the total power consumption of above expansion module is less than the permission load of the main module, and the designing scheme is feasible.

Example 2: the main module is EC20-3232BT, at 25C ambient temperature, three EC20-0808ET, two EC20-4AD, one EC20-4DA shall be connected to, using 20mA output port and one EC20-4TC.

Checking computations as following: Power circuit Current provided by the main module Actual consumed current conclusion

5V/GND 350mA (803+502+50+50)=440mA Un-passed 24V/GND 650mA (503+02+0+0)=150mA Pass 24V/COM 360mA (503+252+120+25)=345mA Pass

The sum of the 5V/GND power consumption of the expansion module is 440mA, it is larger than 350mA which is the upper limit of 5V power supply; although the power consumption of 24V/GND and 24V/COM is less than the permitted current of the main module, the designing scheme is unfeasible.

The solution to solve the insufficient of power supply capacity is to select the expansion module with self-carried power source. It can power by itself, also its outputs of 5Vdc/GND, 24Vdc/GND, and 24Vdc/COM can power to the expansion module added later.

4.8 Programming Tool Of User Program

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

Chapter 5 Input Characteristic 13


Chapter 5 Input Characteristic

5.1 User Ports Of Main Module

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

PG COM X0 X2 X4 X6 X10 X12 X14 X16 X20 X22

L X1 X3 X5 X7 X21X11 X13 X15 X17 X23N

Wiring of EC20-2012BR and EC20-2012BT

+24V Y0 Y2 Y4 Y6 Y10 Y12Y1

Y13Y5 Y7 Y11COM COM0

COM1

COM2 Y3

COM3

COM4

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

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

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

Pin Function Note L/N 220Vac AC power input port, L is live line, N is neutral line PG Earth port Null port, used for isolation and not wiring X0~X23 User input signal ports, used together with COM can produce input signal

COM Common port, it is the negative pole of the +24Vdc auxiliary power and the common port of input as well. Two COMs connect inside the PLC

+24V The auxiliary power to user external equipment , used together with COM Y0, COM0 Control output port, group 0 Y1, COM1 Control output port, group 1 Y2, Y3, COM2 Control output port, group 2 Y4~Y7, COM3 Control output port, group 3 Y10~Y13, COM4 Control output port, group 4

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

The outline, port layout and function definition of EC20-3232BR and EC20-3232BT are the same. The port layout is shown in Figure 5-2:

14 Chapter 5 Input Characteristic


PG COM X0 X2 X4 X6 X10 X12 X14 X16 X20

L X1 X3 X5 X7 X21X11 X13 X15 X17+24VN

X24

X23 X33 X37

X22COM

X25 X27 X31

X26 X30 X32 X34 X36

X35

Wiring of EC20-3232BR and EC20-3232BT

Y0 COM2 Y5 Y7 Y11 Y13 Y15 Y17 Y21

Y6 Y12 Y22Y14 Y16 Y20COM3

Y25

Y24 Y34

Y23Y3

Y26 Y30 Y32

Y27 Y31 Y33 Y35 Y37

Y36

Y1

COM0

COM1

Y2 Y4 Y10 COM4

COM5

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

Table 5-2 Pin definition

Pin Function Note L/N 220Vac AC power input port, L is live line, N is neutral line PG Earth port Null port, used for isolation and not wiring X0~X37 User input signal ports, used together with COM can produce input signal

COM Common port, it is the negative pole of the +24Vdc auxiliary power and the common port of input as well. Two COMs connect inside the PLC.

+24V The auxiliary power to user external equipment , used together with COM. Y0, COM0 Control output port, group 0 Y1, COM1 Control output port, group 1 Y2~Y7, COM2 Control output port, group 2 Y10~Y17, COM3 Control output port, group 3 Y20~Y27, COM4 Control output port, group 4 Y30~Y37, COM5 Control output port, group 5

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

5.2 Input Port Characteristic And Signal Specification

Table 5-3 Input port characteristic and signal specification

Item High-speed input port X0~X7 General input port Signal input mode Leak mode, users only need to connect dry contact with Xn and COM ports.

Test voltage 24Vdc Input impedance 3.3k 4.3k Input ON External circuit resistance < 400

Electric parameters Electric parameters Input OFF External circuit resistance > 24k

Digital filter X0~X17 have digital filtering function, the filtering time can be set within 0~60ms Filtering function Hardware filter Except for X0~X17, other I/O ports are hardware filtering, filtering time is about 8mS.

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

Input Only has one common port: COM Common port

Output Have multi isolated common ports according to different point configuration.



5.3 Inner Equivalent Circuit Of Input Port

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

24Vdc auxiliarypower supply

Logi

c pr

oces

sing

circ

uit

Working power forinner logic circuit

24V+

24V-

24V+

COM

X0

X1

X2

Xn

Sensor

User signal wiring Inner equivalent circuit of PLC main module

24V/5V/GNG

Var

ious

sig

nal i

nput

equ

ipm

ent

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

As shown in Figure 5-3, the external signal input is a SINK input. You may need a SOURCE input in some special application, and you can change the soldering of the three jumper terminals of JP0, JP1, and jp2 on the interface board inside the PLC to reset the input mode, according to the screen-printing on the board ( represents soldering; represents disconnection). As shown in Table 5-4:

Table 5-4 Screen print illustration

JP0 JP1 JP2 Source input mode % % Drain input mode (default setting) %

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

COM

X2

24V-

X0

Xn

24V+24V+

X1

User signal wiring

24Vdc auxiliarypower supply

Working power forinner logic circuit

24V/5V/GND

Logi

c pr

oces

sing

circ

uit

Var

ious

sig

nal i

nput

equ

ipm

ent

Inner equivalent circuit of SOURCE input mode of the main module

For e

quip

men

t with

sel

f-car

ried

pow

er s

ourc

e (2

4Vdc

)

Figure 5-4 inner equivalent circuit of SOURCE input mode of the main module



Note: in the main module, all the input ports can but use the same input mode (SOURCE input mode or SINK input mode); if you have any requirement, please contact your supplier and ask for the technical support before purchasing the product. To avoid damage, youd better not change the circuit by yourself.

The inner equivalent power supply and input signal connection of the I/O expansion module are shown in Figure 5-5:

Logi

c ci

rcui

t

Provided byextension cable

To 24V+ of main module

To COM of main module

X0

X1

X2

Xn

SensorS

igna

l inp

ut e

quip

men

t

User signal wiring Internal equivalent circuit of thePLC extension module

Power supply of logiccircuit : 24V/5V/GND24V+

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

5.4 Input Connection Of High-speed Counter

Table 5-5 the counter connection method and characteristic realized by X0~X7

Counter Input point

X0 X000 X001 X002 X003 X004 X005 X006 X007Max. Fre.

(KHz)

Counter C236 Up/down 50 Counter C237 Up / down 50 Counter C238 Up / down Counter C239 Up / down Counter C240 Up / down Counter C241 Up / down Counter C242 Up/down Reset Counter C243 Up / down Up / down Counter C244 Up/down Reset Reset

Single-phase single-end count input mode

Counter C245 Up / down Up / down Reset

10

Counter C246 Up Down 50 Counter C247 Up Down Reset Counter C248 Up Down Reset Counter C249 Up Down Reset Start

Single-phase up/down count input

Counter C250 Up Down Reset Start

10

Counter C251 Phase A Phase B 30 Counter C252 Phase A Phase B Reset Counter C253 Phase A Phase B Reset Counter C254 Phase A Phase B Reset Start

Two-phase up/down count input

Counter C255 Phase A Phase B Reset Start

5

Among which:

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

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



5.5 Interrupt Input Connection

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

If the input port is used as interrupt process mode, the corresponding interrupt control identification should be enabled when programming and the corresponding interrupt routine should be programmed (for details, refer to Programming Reference Manual). When using interrupt, the digital filter function of corresponding X port will be disabled and the filter time of the corresponding port is set as zero automatically.

z When used as high-speed count input or interrupt input, the corresponding input port should use shielding wire, and the shielding wire should connect to earth line (same as PG port) to improve the interference rejection.

z Some counters require multiple X input ports to realize (for example, C242, C244, and C254 consist of 2, 3, 4 ports separately). After using this kind of counter, the used ports cannot be used as input of other counters and the common input mode.

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

5.6 Input Signal Status Indication

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

Output terminal status LEDs

Working status LEDs Input terminal status LEDs

Figure 5-6 Status LEDs of EC20 series main module

5.7 Analog Potentiometer And Application

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

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

5.8 Example Of Input Connection

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



L PG N 24V COM

AC-L

AC-N

X0 X1

+24V+5VGND

EC20-3232BT 0808ER

XmXn24V

X3X2 X5X4 XmXn

Sens

or

X7X6 X11X10 X36 X37

A B Z

+24V

VGN

D

PG

Switch powersupply

Using terminal block connects to COM

Figure 5-7 electric connection of EC20-3232BT and EC20-0808ER

Chapter 6 Output Characteristic 19


Chapter 6 Output Characteristic

6.1 Output Port Application

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

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

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

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

Table 6-1 Comparison of relay output and transistor output

Item Relay output Transistor output Output action

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

Common port

Divided into multiple groups, each group has a common port COMn, suitable for the control circuit with different potential, and all common ports are insulated one another.

Voltage 220Vac; 24Vdc, no polarity requirement 24Vdc, polarity requirement Current Accord with output electric specifications (see Table 6-2) Difference High drive voltage, high current Low drive current, high frequency, long lifespan

Application To drive the load with low action frequency such as: intermediate relay, contactor coil, and LEDs

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

6.2 Electric Specifications Of Output Port

Table 6-2 Electric specifications of output port

Item Relay output port Transistor output port Loop power supply voltage Below 250Vac, 30Vdc 5~24 Vdc

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

0.5A 24Vdc The total current of the 8 points sharing COM port is less than 2A.

Circuit insulation mechanical insulation Optical coupling insulation

Act indication Relay output contacts closed, LED on

Optical coupling is driving, LED on

Leakage current at open circuit

- Less than 0.1mA/30Vdc

Min. load 2mA/5Vdc 5mA (5~24Vdc)

20 Chapter 6 Output Characteristic


Item Relay output port Transistor output port

Resistive load 2A/1 point; 8A/4 points, using a COM 8A/8 points, using a COM

Y0, Y1: 0.3A/1 point; Others: 0.3A/1 point; 0.8A/4 point; 1.6A/8 point; Above 8 points, total current increases 0.1A at 1 point increase

Inductive load 220Vac80VA Y0, Y1: 7.2W/24Vdc Others: 12W/24Vdc

Max

. out

put c

urre

nt

Electric light load 220Vac100W Y0, Y1: 0.9W/24Vdc Others: 1.5W/24Vdc

ON response time 20ms Max OFF response time 20ms Max

Y0, Y1: 10uS ; Others: 0.5ms

Y0,Y1 max. output frequency

- Each channel : 100KHz

Output common port Y0-COM0; Y1-COM1; Y2, Y3-COM2; Y4~Y7-COM3; Every 8 ports use one common port after Y8, and all the common port are isolated one another.

Fuse protection No

6.3 Output Port Connection

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

Y0

Y2

Y3

COM0

COM1

Y1

COM2

Y4

Y5

Inner equivalent circuit of PLC

Working power of innerlogic circuit

Logi

c pr

oces

sing

circ

uit

Out

put d

rive

circ

uit

Output group o

Output group 1

Output group 2

24Vdc power

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

Figure 6-1 shows, output ports are divided into multiple groups, and each group is electrical isolated from others. Output contacts of different group can connect to the different power loop. For the inductive load in AC loop, the external circuit should be RC transient voltage absorbing circuit; for the inductive load in DC loop, it should consider to add a fly-wheel diode. As shown in Figure 6-2:

Chapter 6 Output Characteristic 21


Inductive load

24V -24V +

1N4004

Y7

Fly-wheel diode

Inductive load

24V -

Y1

Fly-wheel diode

24V +

1N4004

R=200, 2WR

AC - N

C

Y11

AC - L

C=0.022uF , 250Vav

Inductive load

Figure 6-2 Protective circuit of PLC output contact

The inner equivalent circuit of the output part of the transistor output PLC is shown in Figure 6-3.

We can see that, output ports are divided into multiple groups, and each group is electrical isolated from others. Output contacts of different group can connect to the different power loop. Transistor output can but be used in DC 24Vdc load circuit, and you should pay attention to the polarity of the power supply. When driving the inductive load, it should consider adding a fly-wheel diode.

5Vdc power

Logi

c pr

oces

sing

circ

uit

Working power of innerlogic circuit

Y0

Y2

Y3

Inner equivalent circuit of PLC

Out

put d

rive

circ

uit

COM0

COM1

Y1

COM2

Y4

Y5

Output group 0

Output group 1

Output group 2

Figure 6-3 Inner equivalent circuit of output part of transistor output PLC

22 Chapter 6 Output Characteristic


6.4 Output Port Status Indication

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

6.5 Example Of Output Connection

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

L PG N 24V COM

AC-L

AC-N

X0 X1

+24V+5VGND EC20-3232BR

0808ER

X1X024V

X3X2 X4 X7X37X36

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

AC-L

AC-N+5V+24V

AB

AB

AB

AB

AB

AB

AB

AB

AB

AB

AB

AB

AB

Various low-voltagesignal circuit

220Vac control loadcircuit

Switchpower supply

Using terminal block connectsto COM

Figure 6-4 Electrical connection example of EC20-3232BR and EC20-0808ER

Chapter 7 Expansion Module 23


Chapter 7 Expansion Module

7.1 Model

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

Table 7-1 Expansion module provided by EC20 series

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

module EC20-0808ETN Digital signal 8-channel input, 8-channel transistor output EC20-4AD 4-channel analog signal input EC20-4DA 4-channel analog signal output EC20-4AM 2-channel analog signal input, 2-channel analog signal output

Special module

EC20-4TC 4-channel electric couple temperature input

7.2 Expansion Busbar Connection

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

Removing extension port cover before connection

Main module Extension moduleExtension cable Figure 7-1 Cascade connection of expansion module

7.3 Expansion Module Addressing

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

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

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

24 Chapter 7 Expansion Module


7.3.1 I/O Point Addressing Number Principle

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

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

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

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

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

EC20-2012BR 0808ER0808ER 4AD 4AD 4DA 0808ER

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

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

4TC

7.3.2 Special Function Module Addressing Number Principle

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

Chapter 8 Communication And Networking 25


Chapter 8 Communication And Networking

8.1 Communication Port

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

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

Port Socket Signal Work mode Protocol provide Purpose Special programming protocol

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

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

COM0 Mini DIN8 RS232 Full-duplex

Free protocol User-defined protocol ModBus master station network as master station to control other equipment.

ModBus slave station Network as slave station equipment and connect to HMI to operate

COM1 EK500V RS232 and can be selected

RS232 Full-duplex RS485 half-duplex Free protocol User-defined protocol

Among of which, the communication protocol of COM0 is selected by the operation control switch (ON/TM/OFF) on the side of the port. Refer to Figure 8-1.

ON/OFF confrot andprotocol conversion

COM0 port

COM1 port

RS232 RS485 Figure 8-1 Communication port and operation switch

Used as special port of user programming, COM0 can be compulsorily converted to programming protocol through ON/TM/OFF switch. The conversion relation between PLC operating status and the protocol used by COM0 refers to Table 8-2.

Table 8-2 COM0 protocol conversion by switch

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

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

TM(ON

TM) Operation TM(OFF

TM) Stop Compulsorily converted to programming protocol .

OFF Stop If the system configuration of user program is free-portprotocol, it converts to programming protocol automatically after stop; otherwise the system configured protocol keep unchanged.

COM1 port is suitable to connect with the equipment that have communication function, such as variable speed drive, and uses Modbus protocol or RS485 port free protocol to control multiple equipment through network.

COM1 port is fixed by screws. You can use a twisted pair line to make the communication signal cable by yourself.

Note: you should not use RS232 port and RS485 port at the same time, and do not connect the cable to the ports that are not used; otherwise the communication may be interrupted.

26 Chapter 8 Communication And Networking


8.2 Programming Environment

The user program of EC20 series PLC is running on ControlStar integrated software development environment developed by Emerson Network Power Co., Ltd. The operating system should support Microsoft Windows 98, Me, NT 4.0, Windows 2000 or XP. The basic system configuration is shown in Table 8-3:

Table 8-3 Program environment basic configuration of EC20 series PLC

Item Lowest configuration Recommended configuration CPU Equivalent to Intel Pentium 233 or above Correspond to Intel Pentium 1G CPU or above Memory 64M 128M Video card 640480, 256 800%600 resolution, 65535 color mode Communication port A DB9 output RS232 serial communication port

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

Detailed information refers to ControlStar Programming Software User Manual.

8.3 Programming Cable

Emerson Network Power Co., Ltd provides a serial communication cable for download program. The model of the cable is B2053RASL1, and the two connectors at the cable ends are Mini-DIN8 and DB9. The cable is non-isolated. Users should not insert or pull out the cable with power on to avoid the equipment damage.

Also our company provides an isolated RS232 cable for PLC, which can be hot swappable.

ControlStarProgramming cable B2053RASL1

Figure 8-2 Develop environment of user program

IrfanHighlight

Chapter 9 Cable Specification And Wiring 27


Chapter 9 Cable Specification And Wiring

9.1 Connecting Power Supply Cable

Warning

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

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

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

z Do not connect or disconnect the cable with power on. Otherwise it may get an electric shock or equipment damage.

L PG N 24V COM

AC - L

AC - N

X0 X7

Switch Powersupply

COM24V PG24VXn Xm

0808ER

4AD4DA4AM4TC

+24V+5VGND

EC20-2012BR

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

9.2 Connecting Ground Cable

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

PLC

Other equipment

PLC

PLC

Best Better Worst

Other equipment

Other equipment

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

When using a PLC expansion module, you should connect the earthing line of each module with earthing object separately, as shown in Figure 9-3:

28 Chapter 9 Cable Specification And Wiring


Better Worse

PLC main module

Expansion module 1

Expansion module 2

PLC main module

Expansion module 1

Expansion module 2

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

9.3 Connecting Common Port

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

9.4 Cable Specification

When wiring PLC system, it is recommended to use the multi-strand copper wire and ready-made isolated terminals to ensure the wiring quality. The recommended cross-sectional area and the model of the wire see Table 9-1.

Table 9-1 Recommended cable model of PLC

Wire Cross-sectional area Recommended model Wiring terminal and heat-shrink tube to be connected AC power wire (L, N) 1.0~2.0mm AWG12, 18 H1.5/14 terminal, or terminal tin-plated Earthing line (PG) 2.0mm AWG12 H2.0/14 terminal, or terminal tin-plated Input signal line (X) 0.8~1.0mm AWG18, 20 Output signal line (Y) 0.8~1.0mm AWG18, 20

UT1-3 or OT1-3 cold-pressed terminal, 3 or 4 heat-shrink tube

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

Chapter 10 First Operation And Maintenance 29


Chapter 10 First Operation And Maintenance

10.1 Notes For Application

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

10.2 Check Before Power On

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

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

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

4. Make sure the wiring and the specification of the earthing line are in compliant with the requirement.

5. Make sure irrelevant objects falls inside the PLC and the heat dissipation channel is free.

6. Make sure the insulating paper on the holder of the button lithium cell is removed.

7. Make sure the communication signal cable connects correctly if the host or HMI is needed.

8. After checking the items mentioned above one by one, then power on the PLC.

10.3 Startup

1. Switch on the PLC, the POWER indicator of the PLC should be on.

2. Startup the Controlstar software, download the compiled user program to the PLC;

3. After checking the download program, switch the operation switch to RUN position, the RUN indicator should be on; if the ERR indicator is on, it indicates that the user program or the system has mistake, then remove the mistake referring to the programming reference manual.

4. Then switch on the circuit breaker of the PLC external system to carry through system debugging.

10.4 RUN/STOP Switchover

The operation statuses of the main module include RUN and STOP.

RUN

When the main module operation status is ON, user program will be executed by the system, which is a scan period including four tasks (executing the user program communicating housekeeping refreshing I/O).

STOP

When the main module operation status is STOP, the system does not execute the user program, but still execute other three tasks in a scan period (communicating housekeeping refreshing I/O).

30 Chapter 10 First Operation And Maintenance


10.4.1 How To Startup (STOP RUN)

Reset mode

Status switch is in ON position, after resetting (including power on resetting), the system starts up automatically.

Note: if the input point control mode in the system configuration is enabled, the status of the appointed input point should be ON. Otherwise the system cannot startup. The description about the input point control mode refers to the fourth pieces in the following.

Manual mode

In the STOP state, toggle the status switch from OFF or TM position to ON position, the system stars up automatically.

Communication command mode

In the STOP state, the system stars up automatically upon receiving the RUN communication command.

Input point control mode

In the STOP state, the main module starts up automatically when the system detects the status change from OFF ON of the appointed input port.

Note When selecting input point control mode, you should enable the input point control mode in the system configuration and set the status switch in ON position.

10.4.2 How To Stop (RUN STOP)

Reset mode

The status switch is in OFF position, and the system will stop automatically after resetting (including system power on reset).

Note If the input point control mode is enabled in the system configuration, the state of the input point should be OFF; otherwise the system will not stop. Manual mode

In the RUN state, after the status switch is toggled from ON or TM position to OFF position, the system stops.

Communication command mode

In the RUN state, the system stops when receiving the STOP communication command.

Instruction control mode

In the RUN state, after the STOP instruction in the user program is executed effectively, the system stops.

Stop by mistake

When the system detects the serious mistake (such as the user program error, overtime operation), the system stops executing the user program automatically.

10.5 Routine Maintenance

The routine maintenance should check the following:

z Ensure the clearance of the PLC operation environment, and avoid the impurity and the dust falling inside the PLC.

z Keep the ventilation and heat dissipation of the PLC in good condition. z All the wiring and the terminals are reliable fixed and in the normal state.

Chapter 10 First Operation And Maintenance 31


Observe the PLC BATT indicator and know the capacity state of the standby battery. When the BATT indicator flashing, it indicates that the battery capacity is insufficient and the new button lithium cell should be replaced during a month; when the BATT indicator is on, it indicates that the battery voltage is severe insufficient or battery lost, and a new button lithium cell should be replaced as soon as possible. Only trained personnel can replace the cell; the power must be disconnected; the shorter the replacement time the better; the replacement should be within one minute to avoid losing the backup data and the real time clock data.

32 Chapter 11 Troubleshooting


Chapter 11 Troubleshooting

When the PLC works abnormally, first check the wiring of the power supply line and the status of the relative switches and protective device; if PLC is power on, check whether the user ports are fastness, the position of the run control switch is right; if all the conditions are normal but the PLC still does not work, you can analyze the problem according to the PLC operation state and the I/O state LEDs in Table 11-1.

Table 11-1 Faults and actions

Phenomena Cause Actions Power off or power source voltage too low Check power source Power source switch or fuse disconnected Power source wiring abnormal

Check switch, line, and fuse state POWER LED and other LEDs all off

Power source board damaged Bad contact of power source circuit Too many expansion module connected to result in current limit

POWER LED intermittent blinking

24V/COM auxiliary power source output short circuit and result in current limit

Check: 1) the voltage between L and N terminal is within the normal range 2) whether a short circuit or overload occur between 24V and COM port

User program mistake Use ControlStar to re-compile the user program and download again ERR LED blinking

Actual run time exceeds the WDT setting time Increase the WDT setting time BATT LED blinking Cell low voltage alarm BATT LED is on Cell voltage low or no stand-by cell

Replace button cell

ON/TM/OFF is not in ON position Toggle the switch to ON position Set the run control mode as port mode, but the port is in OFF position

Close the setting control run port

The host remote control power off Make the host remote control power on RUN LED is off

Power off due to system mistake Check PLC application system

Conducting resistance of user line toobig Modify the electric parameters of the external circuit to the suitable value, shorten the wire length and do not use thin wire

Input state LED inconsistent with the input port state

Bad contact of the signal circuit Bad contact of the external wiring

Check wiring Can not shutdown the output (OFF) Relay contactors damaged Status LED inconsistent with output port state

Relay aging or LED damaged The relay port with frequently action can exchange with the idle port

Can not download / upload / monitor

Bad contact of cable wiring, the position of ON/TM/OFF switch wrong

Use the specialized communication cable of Emerson to download

Bad contact of cable wiring, or the signal characteristic mistake, such as confusing TXD with RXD

Connect signal wire correctly

Communication parameters of slave/master computer are inconsistent, such as baudrate, checking, data bit and address

Set the communication parameters consistent

Serial port can not control other equipment

Communication protocols used by slave/master computer are inconsistent

Set the communication parameters consistent

I/O expansion board or special expansion board no response

Bad contact of expansion wire Power off , check and get rid of the problem, then power on again.

In most conditions, input signal waveform has much bigger interference

Parallel connecting a 22uF50V capacitor with the counter input port (note the capacitor polarity)

Low-speed counting inaccuracy In few conditions, the cycle of detected signal

is shorter than the executive cycle of the PLC.

If the user program executing time is too long, the counter signal should connect with the high speed counting port. If the setting is constant scan, the scan time should be set reasonably.

Chapter 12 Instruction List 33


Chapter 12 Instruction List

Instruction Type Instruction Function LD Normally open contact instruction LDI Normally closed contact instruction AND Normally open contact AND instruction ANI Normally closed contact AND instruction OR Normally open contact OR instruction ORI Normally closed contact OR instruction OUT Coil output instruction SET Coil setting instruction RST Coil cleanup instruction ANB Power-flow block AND instruction ORB Power-flow block OR instruction INV Power-flow inverse instruction NOP No operation instruction MPS Output power-flow in stack instruction MRD Read output pow

EC20 Series PLC User Manual.pdf

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