User’s Manual
LG Programmable Logic Controller
K7F – PIDA
K4F – PIDA
MASTER-K
LG
Industrial Systems
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Chapter 4. BUFFER MEMORY CONFIGURATION AND FUNCTIONS
4.1 Buffer Memory Configuration ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 4-1
4.1.1 K7F-PIDA Buffer Memory ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 4-1
4.1.2 K4F-PIDA Buffer Memory ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 4-2
4.2 Functions of Buffer Memory ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 4-3
4.2.1 Specifying Loop Enable/Disable ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 4-3
(K7F-PIDA : addresses 0 and 1, K4F-PIDA : address 0)
4.2.2 Specifying Auto/Manual Processing ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 4-3
(K7F-PIDA : addresses 2 and 3, K4F-PIDA : address 1)
4.2.3 Specifying Forward/Reverse Action ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 4-4
(K7F-PIDA : addresses 4 and 5, K4F-PIDA : address 2)
4.2.4 Specifying SET Data Enable/Disable ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 4-4
(K7F-PIDA : addresses 6 and 7, K4F-PIDA : address 3)
4.2.5 Loop Run Information ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 4-5
(K7F-PIDA : addresses 8 and 9, K4F-PIDA : address 4)
4.2.6 Setting PID Control Data ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 4-5
4.2.7 Outputting Manipulated Value ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 4-6
(K7F-PIDA : addresses 202 and 203, K4F-PIDA : addresses 53 to 60)
4.2.8 Setting Error Information ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 4-6
(K7F-PIDA : addresses 203 to 265, K4F-PIDA : addresses 61 to 68)
Chapter 5. DEDICATED INSTRUCTIONS FOR SPECIAL MODULES
Read from/Write to Buffer Memory)
(
5.1 Read to Buffer Memory ...GET, GETP ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 5-1
5.2 Write to Buffer Memory ... PUT, PUTP ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 5-2
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Chapter 6. PROGRAMMING
6.1 Basic Programming ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 6-1
6.1.1 K7F-PIDA ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 6-1
6.1.2 K4F-PIDA ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 6-2
6.2 Application Programming ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 6-3
6.2.1 A Program for Controlling an Electric Furnace ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 6-3
(with Applying the A/D Conversion Module, PID Control Module and D/A Conversion Module)
6.2.2 A Program for Control Using a RTD ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 6-6
(with Applying the RTD Input Module, PID Control Module and D/A Conversion Module.)
6.2.3 A Program for Control Using a Thermocouple ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 6-8
(with Applying the TC Input Module, PID Control Module and D/A Conversion Module)
Chapter 7. TROUBLESHOOTING
7.1 Errors Indicated by RUN LED Flickering ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 7-1
7.2 Troubleshooting Procedure ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 7-1
7.2.1 RUN LED Flickering ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 7-1
7.2.2 RUN LED Off ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 7-1
7.2.3 Unreadable Processing Result of PID Control Module ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 7-2
7.2.4 Run LED of Enabled Loops Off ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 7-2
7.2.5 PID Control Module Hardware Defect ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 7-2
Chapter 8. DIMENSIONS
8.1 K7F-PIDA Dimensions ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 8-1
8.2 K4F-PIDA Dimensions ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 8-2
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SAFETY PRECAUTIONS
Be sure to read carefully the safety precautions given in data sheet and user’s manual before operating the module
and follow them.
The precautions explained here only apply to the K7F-PIDA and K4F-PIDA.
For safety precautions on the PLC system, see the MASTER-K200S/300S/1000S User’s Manuals.
A precaution is given with a hazard alert triangular symbol to call your attention, and precautions are represented as
follows according to the degree of hazard.
If not provided with proper prevention, it can cause death or fatal
WARNING
injury or considerable loss of property.
If not properly observed, it can cause a hazard situation to result
CAUTION
in severe or slight injury or a loss of property.
However, a precaution followed with
CAUTION can also result in serious conditions.
Both of two symbols indicate that an important content is mentioned, therefore, be sure to observe it.
Keep this manual handy for your quick reference in necessary.
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Installation Precautions
CAUTION
ꢀ Operate the PLC in the environment conditions given in the general specifications.
ꢀ If operated in other environment not specified in the general specifications, it can cause
an electric shock, a fire, malfunction or damage or degradation of the module
ꢀ Make sure the module fixing projections is inserted into the module fixing hole and fixed.
ꢀ Improper installation of the module can cause malfunction, disorder or falling.
Test Run and Maintenance
Precautions
CAUTION
ꢀ Do not separate the module from the printed circuit board(PCB), or do not remodel the mod-
ule.
They can cause disorder, malfunction, damage of the module or a fire.
When mounting or dismounting the module, perform them after the power has been turned
off.
ꢀ Do not perform works while the power is applied, which can cause disorder or malfunction.
Waste Disposal Precautions
CAUTION
ꢀ When disposing the module, do it as an industrial waste.
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Chapter 1. INTRODUCTION
Chapter 1. INTRODUCTION
These two modules are called K7F-PIDA and K4F-PIDA. The K7F-PIDA is used with the CPU of K1000S series, and
the K4F-PIDA is used with the CPU of K300S series. Hereafter, the two modules will be commonly called the PID control
module.
PID control means a control action that in order to keep the object at a value set beforehand (SV), it compares the SV
with a sensor-measured value (PV) and when a difference between them is detected the controller makes PV come to
be SV by adjusting output to eliminate the difference. The PID control is composed of combinations of Proportional (P),
Integral (I) and Derivative (D) actions.
When a difference between SV and PV occurs, proportional, integral, differential quantities are calculated upon that
difference and a MV(Manipulated Value) is output.
1.1 Features
The features of the PID control module are as follows.
1) One module can control various processes separately and at the same time.
2) Forward/reverse action selection is available.
3) Manually manipulated out (forced to be output by the user), not operation processing output, is available.
4) The number of modules available on one base unit is unlimited.
1 - 1
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Chapter 2. SPECIFICATIONS
Chapter 2 . SPECIFICATIONS
2.1 General Specifications
Table 2.1 shows the general specifications of MASTER-K series.
No
1
Items
Specifications
0 ~ 55
Standard
Operating ambient
temperature
ꢀ
Storage ambient
temperature
2
-25 ~ 70
ꢀ
Operating ambient
humidity
3
5 ~ 95%RH, non-condensing
Storage ambient
humidity
4
5 ~ 95%RH, non-condensing
Occasional vibration
Frequency
10 57 Hz
Acceleration
Amplitude
0.075 mm
-
Sweep count
-
f
ꢁ ꢂ
57
f 150 Hz 9.8 {1G}
ꢁ ꢁ
ꢃ
5
6
Vibration
Shocks
IEC 1131-2
IEC 1131-2
10 times in each
direction for
X, Y, Z
Continuous vibration
Acceleration
Frequency
10 57 Hz
Amplitude
0.035 mm
-
-
f
ꢁ ꢂ
57 f
ꢁ ꢁ
150 Hz 4.9 {0.5G}
ꢃ
*Maximum shock acceleration: 147
*Duration time :11 ms
{15G}
ꢃ
*Pulse wave: half sine wave pulse( 3 times in each of X, Y and Z directions )
Square wave impulse noise
Electrostatic discharge
1,500 V
ꢄ
IEC 1131-2
IEC 801-2
IEC 1131-2
IEC 801-3
Voltage :4kV(contact discharge)
27 ~ 500 MHz, 10 V/m
Radiated electromagnetic field
7
Noise immunity
Digital Digital I/Os
I/Os
( Ue
≥
(Ue 24 V)
<
Severity All power
Analog I/Os
communication
I/Os
IEC 1131-2
IEC 801-4
Level
modules
Fast transient burst noise
24 V)
Voltage
2 kV
1 kV
0.25 kV
8 Operating atmosphere
Free from corrosive gases and excessive dust
9
Altitude for use
Pollution degree
Cooling method
Up to 2,000m
2 or lower
10
11
Self-cooling
[Table 2.1 ] General specifications
REMARK
1) IEC(International Electrotechnical Commission)
: The international civilian organization which produces standards for electrical and electronics industry.
2) Pollution degree
: It indicates a standard of operating ambient pollution level.
The pollution degree 2 means the condition in which normally, only non-conductive pollution occurs.
Occasionally, however, a temporary conductivity caused by condensation shall be expected.
2 - 1
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Chapter 2. SPECIFICATIONS
2.2 Performance Specifications
Table. 2.2 shows performance specifications of the PID control module.
Specifications
K7F-PIDA
Items
K4F-PIDA
0.01 ~ 100.00
Proportional constant (P)
( When integral and derivative constants are set to
0.0 sec, proportional action is applied.)
Setting range
of PID
0.0
~
3000.0 sec
Integral constant (I)
( When integral constant is set to 0.0 sec, integral action
shall not be applied.)
constants
0.0
~
3000.0 sec
Derivative constant (D)
( When derivative constant is set to 0.0 sec, derivative
action shall not be applied.)
Setting range : SV (Set Value)
Input range : PV (Process Value)
Output range : MV (Manipulated Value)
Setting range : M_MV
0
0
0
~
~
~
16,000
16,000
16,000
0
~
16,000
(Manually Manipulated Value)
RUN : The run LED of corresponding loops ON
RUN / STOP
LED
STOP
:
The run LED of corresponding loops OFF
Normal
Error
:
RUN LED ON
NORMAL/ERROR
:
RUN LED flickering
Number of PID control loops
Control action
32 loops
8 loops
Forward/Reverse action control is available.
0.1 sec
Control cycle
Measured value derivative type
(Pre-derivative type)
Processing type
Internal current consumption
Weight
0.3 A
370 g
0.2 A
190 g
[Table. 2.2 Performance Specifications]
2 - 2
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Chapter 2. SPECIFICATIONS
2.3 Names of Parts and Functions
The following gives names of parts :
K7F-PIDA
K4F-PIDA
No.
Descriptions
Loop Run LED
x
It shows the PID control module run status.
! ON : The corresponding loop is running.
! OFF : The corresponding loop is running.
! Flickering : Error status. Error Value is displayed.
RUN LED
x
It shows the PID module Operating status.
! ON: Normal
! Flickering : Error
2 - 3
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Chapter 2. SPECIFICATIONS
2.4 PID Control Action
2.4.1 Processing type
1) Velocity type
Velocity type is a processing that in PID processing, the present Manipulated Value(MV) is obtained by
adding the calculated variation of MV (∆MV) to the previous MV
MV
=
MV
+
∆ MV
n
n-1
n
MV
:
Present Manipulated Value
Previous Manipulated Value
Variation of the Previous Manipulated Value
n
MV
:
n-1
∆ MV
:
n
2) Measured Value Derivative Type (Pre-derivative)
Measured value derivative processing, in PID processing, uses the process value(PV) for the derivative term.
Generally, PID processing, when a deviation occurs, operates toward the direction in which the deviation will
be reduced.
The deviation occurs due to alteration of set value(SV) or outside disturbances. Therefore, if the deviation is
used in the derivative processing, the output of the derivative term changes rapidly when the deviation occur
due to alteration of set value (SV). So, to prevent raid changes like that, this processing uses the process
value(PV) for the derivative term.
MV
=
MV + K x (En−En-1)
+
K x S/K x En
n
n-1
p
p
I
+
K x K /Sx (2PV −PV −PV )
p
d
n
n-1
n-2
MV
:
Present Manipulated Value
Previous Manipulated Value
n
MV
:
n-1
:
:
:
:
:
:
:
:
:
:
Variation of the Previous Manipulated Value
Present Deviation
Previous Deviation
Proportional Constant
Integral Constant
Derivative Constant
Control Cycle (100ms)
Present Process Quantity (Present Value)
One-step previous Process Quantity (Present Value)
Two-step previous Process Quantity (Present Value)
∆ MV
n
En
En-1
K
p
K
i
K
d
S
PV
n
PV
n-1
PV
n-2
2 - 4
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Chapter 2. SPECIFICATIONS
2.4.2 Control Action
1) Proportional Action (P Action)
(1) P action means a control action that obtains a MV which is proportional to the deviation (E: the difference
between SV and PV).
(2) The expression which denotes the change relationship of E to MV in P action is shown as follows:
MV = Kpx E
where Kp is a proportional constant and means gain.
(3) When deviation occurs, the MV by P action is shown in Fig. 2.1.
[Fig. 2.1] MV with the proportional action
(4) As shown in Fig. 2.1, the larger the proportional constant Kp the larger the MV, that is, the stronger the P
action when the deviation(E) is same . Also, the smaller the Kp the smaller the MV after P action.
(5) If the Kp is too large, PV reaches SV swiftly but can make bad effects like oscillations shown in Fig. 2.2
and cause damage in control stability.
(6) If the Kp is too small, oscillations do not occur but the velocity with which PV reaches SV slows down and
offset can happen as shown in Fig. 2.3.
(7) Manipulated Value varies within 0 to 16,000.
2 - 5
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Chapter 2. SPECIFICATIONS
[Fig. 2.2] When the proportional constant Kp is large.
[Fig. 2.3] When the proportional constant Kp is small.
2 - 6
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Chapter 2. SPECIFICATIONS
2) Integral Action (I Aaction)
(1) When a deviation(E) occurs between SV and PV, Integral action continuously adds the deviation to or
subtracts it from the MV in accordance time in order to eliminate the deviation
When a deviation is small it is not expected that the MV will be changed by P action but I action will
eliminate it.
Therefore, the offset which occurs in P action can be eliminated by I action.
(2) The period of the time from when the deviation has occurred in I action to when the MV of I action become
that of P action is called Integration time and represented as Ki.
(3) Integral action when a given deviation has occurred is shown as the following Fig. 2.4.
MV
MV of P action
[Fig. 2.4] Integral action at a constant deviation
(4) Expression of Integral Action is as follows:
As shown in the expression, Integral action can be made stronger or weaker by adjusting integration time
(Ki) in I action.
That is, the more the integration time (the longer the integration time) as shown in Fig. 2.5, the lesser the
quantity added to or subtracted from the MV and the longer the time needed for the PV to reach the SV.
As shown in Fig. 2.6, when the integration time given is short the PV will approach the SV in short time
since the quantity added or subtracted become increased. But, If the integration time is too short then
oscillations occurs, therefore, the proper P.I value is requested.
(5) Integral action is used in either PI action in which P action combines with I action or PID action in which P
and D actions combine with I action.
2 - 7
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Chapter 2. SPECIFICATIONS
[Fig. 2.5] When a long integration time is given.
[Fig. 2.5] When a short integration time is given.
2 - 8
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Chapter 2. SPECIFICATIONS
3) Derivative Action (D Action)
(1) When a deviation occurs due to alteration of SV or external disturbances, D action restrains the changes of
the deviation by producing MV which is proportioned with the change velocity (a velocity whose deviation
changes at every constant interval) in order to eliminate the deviation.
!D action gives quick response to control action and has an effect to reduce swiftly the deviation by
applying a large control action (in the direction that the deviation will be eliminated) at the earlier time
that the deviation occurs.
!D action can prevent the large changes of control object due to external conditions.
(2) The period of time from when the deviation has occurred to when the MV of D action become the MV of P
action is called derivative time and represented as Kd.
(3) The D action when a given deviation occurred is shown as Fig. 2.7.
[Fig. 2.7] Derivative action at a constant deviation
(4) The expression of D action is represented as follows:
!In this expression, an output proportional with the variation rate of deviation is added to P action quantity.
!If the derivative time is increased then P action is strengthened.
!D action is applied when a change of deviation occurs and the deviation at normal state become 0. D
action, therefore, do not reduce offset.
(5) D action is used in either PD action in which P action combines with D action or PID action in which P and I
actions combine with D action.
2 - 9
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Chapter 2. SPECIFICATIONS
4) PID Action
(1) PID action controls the control object with the manipulation quantity produced by (P+I+D) action.
(2) PID action when a given deviation has occurred is shown as the following Fig. 2.8.
[Fig. 2.8] PID action at a constant deviation
5) PID Processing Expression
PID expressions are of measured value derivative type.
Expressions
Parameters names
: Present Manipulated Value
: One-step-previous
Manipulated Value
: Present deviation
: Previous deviation
: Proportional constant
: Integral constant
: Derivative constant
: Control cycle (100 ms)
: Process value
: One-step-previous
Process Value
MVn
MVn-1
En
En-1
Kp
Ki
Kd
En = SV − PV
n
MV
=
MV + K x (En−En-1)
n
n-1
p
+K x S/K x En
p
I
S
PVn
PVn-1
+K x K /Sx (2PV −PV −PV )
p
d
n
n-1
n-2
PVn-2
: Two-step-previous
Process value
2 - 10
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Chapter 2. SPECIFICATIONS
6) Forward/Reverse Actions
(1) PID control has two kinds of action, forward action and reverse action.
a) Forward action makes PV reach SV by outputting MV when PV is less than SV.
b) Reverse action makes PV reach SV by outputting MV when PV is more than SV.
(2) A diagram in which forward and reverse actions are drawn using MV, PV and SV is shown as Fig. 2.9.
[Fig. 2.9] Forward and reverse action with MV, PV and SV
(3) Fig 2.10 shows examples of process control by forward and reverse actions, respectively.
[Fig. 2.9] Examples of process control by forward and reverse actions
2 - 11
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Chapter 3. INSTALLATION
Chapter 3. INSTALLATION
3.1 Installation Ambience
This module has high reliability regardless of its installation ambience. But be sure to check the following for
system in higher reliability and stability.
1) Ambience Requirements
Avoid installing this module in locations, which are subjected or exposed to:
- Water leakage and dust a large amount of dust, powder and other conductive power, oil mist, salt, of
organic solvent exists.
- Mechanical vibrations of impacts are transmitted directly to the module body.
- Direct sunlight.
- Dew condensation due to sudden temperature change.
- High or low temperatures (outside the range of 0-55ꢀ)
2) Installing and Wiring
- During wiring or other work, do not allow any wire scraps to enter into the PLC
- Install it on locations that are convenient for operation.
- Make sure that it is not located near high voltage equipment on the same panel.
- Make sure that the distance from the walls of duct and external equipment be 50 mm or more.
- Be sure to be grounded to locations that have good noise immunity.
3.2 Handling Precautions
From unpacking to installing the PID control module, be sure to check the following:
1) Do not drop it off, and make sure that strong impacts should not be applied.
2) Do not dismount printed circuit boards from the case. It can cause malfunctions.
3) During wiring, be sure to check any foreign matter like wire scraps should not enter into the upper side of
the PLC, and in the event that foreign matter entered into it, always eliminate it.
4) Be sure to disconnect electrical power before mounting or dismounting the module.
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Chapter 4. BUFFER MEMORY CONFIGURATION AND FUNCTIONS
Chapter 4. BUFFER MEMORY CONFIGURATION AND FUNCTIONS
The PID control module has the PLC CPU and the buffer memories for communications.
4.1 Buffer memory Configuration
The followings describe buffer memory configuration.
4.1.1
K7F-PIDA Buffer Memory
Default
Setting
Read /
Write
Address
(Decimal)
Function
Loop enable/disable
Descriptions
0
Specification area
(loop 0 to 15)
Bit On(1): Enabled
Bit Off(0): Disabled
Disabled
R/W
Loop enable/disable
Specification area
(loop 16 to 31)
Auto/Manual operation
Specification area
(loop 0 to 15)
Auto/Manual operation
Specification area
(loop 16 to 31))
Forward/Reverse action
Specification area
(loop 0 to 15)
Forward/Reverse action
Specification area
(loop 16 to 31)
Set data enable/disable
Specification area
(loop 0 to 15)
1
2
3
4
5
6
Bit On(1): Auto
Bit Off(0): Manual
Auto
R/W
Bit On(1): Reverse
Bit Off(0): Forward
Forward
R/W
Bit On(1) : Set each content of address
0, 1, 4, 5, 10 to 41, and 74 to 201
to a new setting.
Bit Off(0) : The previous values of
address 0, 1, 4, 5, 10 to 41, and
74 to 201 remains without
change.
No Setting
Values
R/W
Set data enable/disable
Specification area
(loop 16 to 31)
7
Loop run information
(loop 0 to 15)
Loop run information
(loop 16 to 31)
8
9
Bit On(1) : Run
Bit Off(0) : Stop
Read
Only
10 to 41
42 to 73
SV of each loop
PV of each loop
M-MV of each loop
P of each loop
I of each loop
D of each loop
Setting range
Input range
:
:
:
:
:
:
:
0 to 16000
0 to 16000
0 to 16000
0 to 10000
0 to 30000
0 to 30000
0 to 16000
“0”
“0”
“0”
“500”
“1000”
“0”
R/W
R/W
R/W
R/W
R/W
R/W
Read
74 to 105
106 to 137
138 to 169
170 to 201
202 to 233
Setting range
Setting range
Setting range
Setting range
Output range
MV of each loop
Bit 0 On(1) : out-of-range SV
Bit 1 On(1) : out-of-range PV
Bit 2 On(1) : out-of-range M_MV
Bit 3 On(1) : out-of-range P
Bit 4 On(1) : out-of-range I
Bit 5 On(1) : out-of-range D
Read
Only
234 to 265
Error information of each loop
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Chapter 4. BUFFER MEMORY CONFIGURATION AND FUNCTIONS
4.1.2
K4F-PIDA Buffer Memory
Default
Setting
Read /
Write
Address
Function
Descriptions
Bit On(1): Enabled
Bit Off(0): Disabled
Bit On(1): Auto
Bit Off(0): Manual
Bit On(1): Reverse
Bit Off(0): Forward
(Decimal)
Loop enable/disable
Specification area
Auto/Manual operation
Specification area
Forward/Reverse action
Specification area
0
1
Disabled
R/W
R/W
R/W
Auto
2
Forward
Bit On(1) : Set each content of address
0, 2, 5 to 12, and 21 to 52 to a
new setting.
Bit Off(0) : The previous values of
address 0, 2, 5 to 12, and 21 to
52 remains without change.
SET data enable/disable
Specification area
No Setting
Values
3
R/W
Bit On(1) : Run
Bit Off(0) : Stop
Read
Only
R/W
R/W
R/W
R/W
R/W
R/W
Read
4
Loop run information
5 to 12
13 to 20
21 to 28
29 to 36
37 to 44
45 to 52
53 to 60
SV of each loop
PV of each loop
M_MV of each loop
P of each loop
I of each loop
Setting range
Input range
:
:
:
:
:
:
:
0 to 16000
0 to 16000
0 to 16000
0 to 10000
0 to 30000
0 to 30000
0 to 16000
“0”
“0”
“0”
“500”
“1000”
“0”
Setting range
Setting range
Setting range
Setting range
Output range
D of each loop
MV of each loop
Bit 0 On(1) : out-of-range SV
Bit 1 On(1) : out-of-range PV
Bit 2 On(1) : out-of-range M_MV
Bit 3 On(1) : out-of-range P
Bit 4 On(1) : out-of-range I
Bit 5 On(1) : out-of-range D
Read
Only
61 to 68
Error information of each loop
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Chapter 4. BUFFER MEMORY CONFIGURATION AND FUNCTIONS
4.2 Functions of Buffer Memory
Each address in the buffer memory occupies one word and it is represented with 16 bits.
In the 16 bits which compose an address, every bit can be set to either “1” when it should be turned On or “0”
when Off in order to implement the function of each bit.
4.2.1 Specifying Loop Enable/Disable
(K7F-PIDA : Addresses 0, 1, K4F-PIDA : Address 0)
1) Loop enable/disable specification is possible on every channel.
2) Disabled loops will not be used in processing.
3) The followings show the bit corresponding to each loop.
K7F-PIDA
K4F-PIDA
4.2.2 Specifying Auto/Manual Processing (K7F-PIDA : Addresses 2, 3, K4F-PIDA : Address 1)
1) Turn the corresponding bit Off(0) if a loop runs with auto processing. Turn the corresponding bit On if a
loop runs with M_MV set before by the user.
2) Default is auto processing.
3) The followings show the bit corresponding to each loop.
K7F-PIDA
K4F-PIDA
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Chapter 4. BUFFER MEMORY CONFIGURATION AND FUNCTIONS
4.2.3 Specifying Forward/Reverse Action
(K7F-PIDA : Addresses 4, 5, K4F-PIDA : Address 2)
1) Turns the corresponding bit Off(0) for forward action processing and On (1) for reverse action
processing.
2) Default is forward action.
3) The following show the bit corresponding to each loop.
K7F-PIDA
K4F-PIDA
4.2.4 Specifying SET Data Enable/Disable
(K7F-PIDA : Addresses 6, 7, K4F-PIDA : Address 3)
1) If a bit, corresponding to each loop, in Set Data specification area is turned On(1), then the PID
processing is executed with new user-defined data due to loop enable/disable specification,
forward/reverse action specification, setting SV, setting M_MV, and change of P.I.D constants.
2) If the bit corresponding to each loop is not turned On(1), then the PID processing is executed not
with the new user-defined data but with the previous Setting range.
3) The followings show the bit corresponding to each loop.
K7F-PIDA
K4F-PIDA
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Chapter 4. BUFFER MEMORY CONFIGURATION AND FUNCTIONS
8.2.5
Loop Run Information
(K7F-PIDA : Addresses 8, 9, K4F-PIDA : Address 4)
1) This area stores information on run status of each loop.
K7F-PIDA
K4F-PIDA
8.2.6
etting PID Control Data
1) The addresses for PID control data and their setting range are given as follows.
Address (10 decimal)
Item
Setting range
Default
K7F-PIDA
10~41
K4F-PIDA
5~12
SV
42~73
13~20
21~28
29~36
37~44
45~52
PV
M_MV
P constant (Kp)
I constant (Ki)
D constant (Kd)
0 ~ 16000
“0”
74~105
106~137
138~169
170~201
1 ~ 10000
0 ~ 30000
0 ~ 30000
“500”
“1000”
“0”
2) If PID control data is outside the range, the execution continues with the setting range of the
previous processing.
3) If PID control data is outside its setting range, error information appear on the setting error
information area.
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Chapter 4. BUFFER MEMORY CONFIGURATION AND FUNCTIONS
4.2.7 Outputting Manipulated Value (K7F-PIDA : Addresses 202 to 233, K4F-PIDA : Addresses 53 to 60)
1) This area stores the MV of each loop.
2) The MV output range is 0 to 16000.
4.2.8 Setting Error Information (K7F-PIDA : Addresses 234 to 265, K4F-PIDA : Addresses 61 to 68)
1) When setting the control data for each loop, if any setting exceeds its range the error
information is indicated on this area.
2) Bit 0 to 5 are used to indicate error information for each loop. The following shows the error information
indicated by each bit when it turns On(1).
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Chapter 5. DEDICATED INSTRUCTIONS FOR SPECIAL MODULES
ꢀ
Chapter 5. DEDICATED INSTRUCTIONS FOR SPECIAL MODULES
(Read from /Write to Buffer memory)
The PID module is available only for local and occupies 16 I/O points.
⋅ ⋅ ⋅
5.1 Read from Buffer Memory
GET, GETP
<Format>
execution condition
for GET
GET n1 n2
D
n3
Format
n1
Descriptions
The slot No. where a special module is mounted
Available Data Type
Integer
Head address of the special module buffer memories from which
the data will be read.
n2
Integer
D
n3
Head address of the device to store the data read.
Number of data to be read .
M,P,K,J,T,C,D,#D
Integer
<The difference between GET and GETP>
GET: Always executed if the execution condition turns on.(
GETP : Executed if the execution condition is triggered.
)
)
(
Example 1) In this example, the PID control module is mounted on the slot 3 in the base unit and the data of
buffer memory addresses 202 and 203 will be read to the CPU module addresses D202 and D203.
PID control module
(address) CPU module D area
D200
buffer memory
(address)
D200
D201
D201
D202
D203
D204
D202
D203
D204
MV of loop 0
MV of loop 1
MV of loop 0
MV of loop 1
<GETP> execution condition for GETP
GET 00003 00202 D0202 00002
<GET>
execution condition
for GET
D
M0000
execution condition
for GETP
<GETP>
M0000
GETP 00003 00202 D0202 00002
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Chapter 5. DEDICATED INSTRUCTIONS FOR SPECIAL MODULES
⋅ ⋅ ⋅
5.2 Write to Buffer Memory
PUT, PUTP
<Format>
execution condition
for PUT
PUT n1 n2
S
n3
Format
n1
Descriptions
The slot No. where a special module is mounted.
Available Data Type
Integer
Head address of the special module buffer memories to which the
data will be written..
n2
Integer
Head address of the device where the data to be written has been
stored, or an integer
Number of data to be written.
D
M,P,K,L,T,C,D,#D
Integer
n3
<The difference between PUT and PUTP>
PUT: always executed if the execution condition turns on. (
PUTP : executed if the execution condition is triggered.
)
)
(
Example 1) In this example, the PID control module is mounted on the slot 6 in the base unit and the data of
CPU module addresses D0 and D1 will be written to the buffer memory addresses D202 and D203.
(address) CPU module D area
PID control module
buffer memory
(address)
0
D0
D1
D2
D3
D2
Data 0
Data 1
Specify the enabled loop
Specify the enabled loop
1
2
3
4
<PUT>
PUT 00006 00000 D0000 00002
execution condition
for PUT
D
M0000
execution condition
for PUTP
<PUTP>
M0000
PUTP 00006 00202 D0000 00002
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Chapter 6. PROGRAMMING
Chapter 6. PROGRAMMING
6.1 Basic Programming
▲ The following describes the method to set the running conditions in the buffer memories of the PID control
module.
▲ The PID control module is already mounted on the slot 0.
▲ The PID control module occupies 16 I/O points.
6.1.1 K7F-PIDA
SET data are processed with
triggering P21 whenever the
contents in the buffer memories
(addresses: 1,1,4,5,10~ 41 and
74 ~ 202) are changed.
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Chapter 6. PROGRAMMING
6.1.2 K4F-PIDA
SET data are processed with
triggering P21 whenever the
contents in the buffer memories
(addresses: 1,1,4,5,10~ 41 and
74 ~ 202) are changed.
processing
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Chapter 6. PROGRAMMING
6.2 Application Programming
6.2.1 A Program for Controlling an Electric Furnace
(with Applying the A/D Conversion Module, PID Control Module and D/A Conversion Module)
1) System Configuration
K7S-
122S
K7S-
30AS
K7X-
310S
K7X-
310S
K7F-
AD4A
K7F-
PIDA
K7F-
DI4A
K7S-
132S
K7Y-
201S
Ch. 0
Loop 0
Ch. 0
1)
Initial Settings
(1) PID control module
A) Specifying used loop : loop 0
B) Specifying forward/reverse action : forward action
C) Setting SV: 12800
D) Specifying auto/manual processing : auto processing
(2) A/D conversion module
A) Specifying used channel: channel 0
B) Specifying output data type: -192 to 16191
C) Setting filter constant: 50
(3) D/A conversion module
A) Specifying used channel: channel 0
B) Specifying input data type: -192 to 16191
C) Output when no channel is used or the CPU module is in the stop state : The median value of the output range is
output.
2) Descriptions of the Program
(1) A temperature 0 to 200°C from the temperature sensor is converted into an analog signal 4 to 20 mA and then
the signal is input to the channel 0 of the A/D conversion module channel and converted into a digital value 9600
to 16000.
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Chapter 6. PROGRAMMING
(2) In the PID control module, 100°C (where the signal converter output is 12 mA, 12800 as a digital value.) is set as
SV. With regards to P.I.D constants, the manipulated value in the BCD digital switch is set as the proportional
constant when P0020 turns on, as the integral constant when POO21 turns on, and as the Derivative constant
when P0022 turns on.
(3) MV, the result from PID processing is output at the channel 0 of the D/A conversion module.
(4) If P0023 turns on, initial setting of the A/D conversion module, PID control module and D/A conversion module is
executed.
3) Modules and their Signal Processing
Sensor measuring temperature range
:
0 ~ 200 °C
Signal converter current output range : DC 4 ~ 20 mA
A/D conversion module input current range : DC –20 ~ 20 mA
A/D conversion module digital output range : 9600 ~ 16000
PID control module PV(process value) input range : 9600 ~ 16000
PID control module processed MV range : 0 ~ 16000
D/A conversion module digital input range : 0 ~ 16000
D/A conversion module analog output range : DC 4 ~ 20 mA
Electric furnace temperature range by heater : 0 ~ 200°C
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Chapter 6. PROGRAMMING
5) Program
D/A conversion
Module initialization
switch
Making the PV of PID
control module be set to
the A/D conversion value
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Chapter 6. PROGRAMMING
10.2.2 A Program for Control Using a RTD
(with Applying the RTD Input Module, PID Control Module and D/A Conversion Module)
1) System Configuration
K7S-
122S
K7S-
132S
K7Y-
301S
K7P-
30AS
K7X-
310S
K7X-
210S
K7F-
RD3A
K7F-
PIDA
K7F-
AD4A
Ch. 0 Loop 0 Ch. 0
Power conversion device
RTD
2) Initial Settings
(1) PID control module
A) Specifying used loop : loop 0
B) Specifying forward/reverse action: forward action
C) Specifying the Set Value: 8000
D) Specifying auto/manual processing : auto processing
(2) RTD input module
A) Specifying used channel: channel 0
B) Specifying RTD sensor type: Pt100
(3) D/A conversion module
A) Setting the voltage input range to –5 to 5 DCV (offset: DC 1V, gain: DC 3V)
B) Specifying used channel : channel 0
C) Specifying input data type : 0 to 16000
3) Descriptions of the Program
(1) The channel 0 of the RTD input module detects a temperature of the electric furnace through Pt100 and receives it as
a digital value.
(2) The Set Value of PID control module loop 0 is set to 8000(where the temperature is 100°C). With regards to P.I.D
constants, the manipulated value in the BCD digital switch is set to the proportional constant when P0022 turns on, to
the integral constant when P0023 turns on, and to the Derivative constant when P0023 turns on. As the change of
MV, the manipulated value in the BCD digital switch is set to a new MV.
(3) MV, the result from PID processing is output at the channel 0 of the D/A conversion module.
(4) If P0021 turns on, PV is displayed on the BCD digital LED.
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Chapter 6. PROGRAMMING
4) Program
RTD
RTD
RTD input module
Reading the BCD digital
Switch value and then
using it as P or I or D value
Making the PV of PID
Control module be set to
the detected temperature
value
RTD
RTD
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Chapter 6. PROGRAMMING
6.2.3 A Program for Control Using a Thermocouple
(with Applying the TC Input Module, PID Control Module and D/A Conversion Module)
1) System Configuration
K7S-
122S
K7S-
30AS
K7X-
210S
K7F-
TC4A
K7F-
PIDA
K7F-
DI4A
K7Y-
201S
K7Y-
201S
K7S-
132S
Ch. 0
Ch. 0
Loop 0
Power conversion device
TC (K type)
SV( 200.0°C)
2) Initial Settings
(1) TC input module
A) Specifying used channel : channel 0
B) Specifying TC type: K type
(2) PID control module
A) Specifying used loop : loop 0
B) Specifying forward/reverse action: forward action
C) Specifying auto/manual processing : auto processing
D) Setting SV: 200°C (4571 as digital value)
E) Setting M_MV (Used when errors occur) : 4500
F) Setting P : 3000
G) Setting I : 100
H) Setting D : 100
I) Auto processing is changed to manual processing when errors occur.
(3) D/A conversion module
A) Specifying used channel: channel 0
B) Specifying input data type: -192 ~ 16191
C) The output when no channel is used or the CPU module is in the stop state : The median value of the output
range.
3) Descriptions of the Program
1) The temperature of the electric furnace is converted into a digital value through the channel 0 of the TC input module,
and the digital value stored at address 18 is used as PV of the PID control module.
2) The MV of the PID control module is used as input digital data of the channel 0 of the D/A conversion module.
3) If an error occurs by the K type TC or the compensation wire which are connected to the TC input module (In the
channel 0, it is indicated at address 19.), then the PID control module changes auto processing into manual processing.
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Chapter 6. PROGRAMMING
4) Program
Specifying TC of channel to K type
TC input module
initialization
Specifying TC input module SET data enable
Reading the temperature-
to-digital conversion value
and Error detection
Reading the digital conversion value of the TC input module to D0 and error information to D1.
If an error occurs at the channel 0 of the TC input module, M10 turns on.
Using manual processing
when an error occurs in the
TC input module
If the channel 0 of the TC input module runs normally, auto processing is specified in the PID
control module.
If an error occurs at the channel of the TC input module, manual processing is specified in the
PID control module..
Writing the digital conversion value of the TC input module as the PV of loop 0.
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Chapter 7. TROUBLESHOOTING
Chapter 7. TROUBLESHOOTING
The followings explain errors that could occur during operating the PID control module and their troubleshooting.
7.1 Errors Indicated by RUN LED Flickering
Errors indicated by PID control module RUN LED flickering are given below.
RUN LED Status
Flickering
(cycle: 0.1 sec)
Error Type
Loop RUN LED status
WDT Error
Loop “0” RUN LED ON
Flickering
(cycle: 0.2 sec)
System Error
Buffer Memory Error
All Loops RUN LED OFF
Loop “1” RUN LED ON
7.2 Troubleshooting Procedure
7.2.1 RUN LED Flickering
RUN LED flickering
ꢀ ꢀ
Is the PID control module is correctly mounted on the base unit?
Mount correctly the PID control module.
The PID control module hardware defect. If the loop run LED
is turned ON, write down their error numbers and see Section
7.2.5.
7.2.2 RUN LED Off
RUN LED off
Is the PID control module is correctly mounted on the base unit?
See Section 7.2.5.
Mount correctly the PID control module.
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Chapter 7. TROUBLESHOOTING
4.2.3 Unreadable Processing Result of PID control module
Is RUN LED turned OFF?
See Section 7.2.2.
See Section 7.2.1.
Is RUN LED flickering?
Are the numbers of the loops used in the processing
correctly specified?
Specify correctly the loop numbers.
See Section 7.2.5.
4.2.4 Run LED of enabled Loops Off
Is RUN LED turned OFF?
See Section 7.2.2.
See Section 7.2.1.
Is RUN LED flickering?
Are the loops that should be executed correctly specified?
See Section 7.2.5.
Check the numbers of the loops which
are actually being executed and specify
them correctly
4.2.5 PID Control Module Hardware Defect
PID control module hardware defect.
Contact the nearest agency or service
stationꢁ
ꢀ ꢀ ꢀ ꢀ ꢀ ꢀ
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Chapter 8. DIMENSIONS
Chapter 8. DIMENSIONS
8.1 K7F-PIDA Dimensions.
K7F-PIDA
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Chapter 8. DIMENSIONS
8.2 K4F-PIDA Dimensions
K4F-PIDA
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