Toshiba T3 User Manual

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Page 1

TOSHIBA

UM-TS03***-E002

PROGRAMMABLE CONTROLLER

PROSEC T3

USER’S MANUAL

- HARDWARE -

Contents

Toshiba Corporation

Page 2

Important Information

Misuse of this equipment can result in property damage or human injury. Because controlled system applications vary widely, you should satisfy yourself as to the acceptability of this equipment for your intended purpose. In no event will Toshiba Corporation be responsible or liable for either indirect or consequential damage or injury that may result from the use of this equipment.

No patent liability is assumed by Toshiba Corporation with respect to use of information, illustrations, circuits, equipment or examples of application in this publication.

Toshiba Corporation reserves the right to make changes and improvements to this publication and/or related products at any time without notice. No obligation shall be

incurred other than as noted in this publication.

This publication is copyrighted and contains proprietary material. No part of this book

may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means — electrical, mechanical, photocopying, recording, or otherwise — without

obtaining prior written permission from Toshiba Corporation.

PROSEC and TOSLINE are registered trademarks of TOSHIBA Corporation.

Publication number: UM-TS03***-E002

1st edition Aug. 1992, 3rd edition Sept. 1997

Page 3

Safety Precautions

This manual is prepared for users of Toshiba’s Programmable Controller PROSEC T3. Read this manual thoroughly before using the T3. Also, keep this manual and related manuals so that you can read them anytime while the T3 is in operation.

General Information

1. The T3 has been designed and manufactured for use in an industrial environment. However, the T3 is not intended to be used for systems which may endanger human life. Consult Toshiba if you intend to use the T3 for a special application, such as transportation machines, medical apparatus, aviation and space systems, nuclear controls, submarine systems, etc.

2. The T3 has been manufactured under strict quality control. However, to keep safety of overall automated system, fail-safe systems should be considered outside the T3.

3. In installation, wiring, operation and maintenance of the T3, it is assumed that the users have general knowledge of industrial electric control systems. If this product is handled or operated improperly, electrical shock, fire or damage to this product could result.

4. This manual has been written for users who are familiar with Programmable Controllers and industrial control equipment. Contact Toshiba if you have any questions about this

manual.

5. Sample programs and circuits described in this manual are provided for explaining the operations and applications oi the T3. You should test completely if you use them as a

part of your application system.

Hazard Classifications

In the following pages, the following two hazard classifications are used to explain the safety precautions.

As. WARNING indicates a potentially hazardous situation which, if not avoided, could

result in death or serious injury.

A\ PAl mON Indicates a potentially hazardous situation which, if not avoided, may

^ result in minor or moderate injury. It may also be used to alert

against unsafe practices.

Even a precaution is classified as CAUTION, it may cause serious results depending on

the situation. Observe all the safety precautions described on this manual.

User’s manual - Hardware

Page 4

Safety Precautions

Installation:

1. Excess temperature, humidity, vibration, shocks, or dusty and corrosive gas environment can cause electrical shock, fire or malfunction. Install and use the T3 in

the environment described in this manual.

2. Improper installation directions or insufficient installation can cause fire or the units to drop, install the T3 in accordance with the instructions described in this manual.

3. Turn off power before installing or removing any units, modules or terminal blocks. Failure to do so can cause electrical shock or damage to the T3 and related equipment.

4. Entering wire scraps or other foreign debris into to the T3 and related equipment can cause fire or malfunction. Pay attention to prevent entering them into the T3 and related equipment during installation and wiring.

Safety Precautions

A CAUTION

Wiring:

1. Turn off power before wiring to minimize the risk of electrical shock.

2. Exposed conductive parts of wire can cause electrical shock. Use crimp-style

3. Operation without grounding may cause electrical shock or malfunction. Connect the

4. Applying excess power voltage to the T3 can cause explosion or fire. Apply power of

5. Improper wiring can cause fire, electrical shock or malfunction. Observe local

II PROSEC T3

A CAUTION

terminals with insulating sheath or insulating tape to cover the conductive parts. Also close the terminal covers securely on the terminal blocks when wiring has been completed.

ground terminal on the T3 to the system ground.

the specified ratings described in this manual.

regulations on wiring and grounding.

Page 5

Safety Precautions

Operation:

A WARNING

1. Configure emergency stop and safety interlocking circuits outside the T3. Otherwise, malfunction of the T3 can cause injury or serious accidents.

A CAUTION

2. Operate the T3 and the related modules with closing the terminal covers. Keep hands away from terminals while power on, to avoid the risk of electrical shock.

3. When you attempt to perform force outputs, RUN/HALT controls, etc. during operation, carefully check for safety.

4. Turn on power to the T3 before turning on power to the loads. Failure to do so may cause unexpected behavior of the loads.

5. Set operation mode switches of the T3 and I/O modules. Improper switch settings may cause malfunction of the T3 and related equipment.

6. Do not use any modules of the T3 for the purpose other than specified. This can cause electrical shock or injury.

7. Configure the external circuit so that the external power required for output modules and power to the loads are switched on/off simultaneously. Also, turn off power to the loads before turning off power to the T3.

8. Install fuses appropriate to the load current in the external circuits for the relay output modules. Failure to do so can cause fire in case of load over-current.

9. Check for proper connections on wires, connectors and modules. Insufficient contact can cause malfunction or damage to the T3 and related equipment.

10. Turn off power immediately if the T3 is emitting smoke or odor. Operation under such condition can cause fire or electrical shock. Also unauthorized repairing will cause fire or serious accidents. Do not attempt to

repair. Contact Toshiba for repairing.

User’s manual - Hardware ¡11

Page 6

Safety Precautions

Maintenance:

A CAUTION

1. Do not charge, disassemble, dispose in a fire nor short-circuit the batteries. It can cause explosion or fire. Observe local regulations for disposal of them.

2. Turn off power before removing or replacing units, terminal blocks or wires. Failure to do so can cause electrical shock or damage to the T3 and related equipment.

3. Replace a blown fuse with a specified one. Failure to do so can cause fire or damage to the T3.

4. Perform daily checks, periodical checks and cleaning to maintain the system in normal condition and to prevent unnecessary troubles.

5. Check by referring ‘Troubleshooting” section of this manual, when operating

improperly. Contact Toshiba for repairing if the T3 or related equipment is failed. Toshiba will not guarantee proper operation nor safety for unauthorized repairing.

6. The contact reliability of the relays used in the relay output module will reduce if the

switching exceeds the specified life. Replace the module if exceeded.

7. Replace the battery every 2 years to maintain the T3’s program and data normally.

8. Do not modify the T3 and related equipment in hardware nor software. This can cause fire, electrical shock or injury.

9. Pay special attention for safety if you attempt to measure circuit voltage at the T3’s terminal.

10. Turn off power before replacing modules. Failure to do so can cause electrical shock or damage to the T3 and related equipment. If you attempt to replace an I/O module while power on (by using on-line I/O replacement function), carefully check for safety.

IV PROSEC T3

Page 7

Safety Label

The safety label as shown on the right is

attached to the power terminal of the T3.

Safety Precautions

A CAUTION

Remove the mount paper before wiring.

Peel off the label from the mount paper and stick It near the power terminals where it can be readily seen.

Contact Toshiba if the label is damaged.

Do not touch terminals

Hazardous voltage can ^lock, bum or cause death. Do not touch termirials while power on. Read related manual thoroughly for safety. Stick this seal on unit or near unit

Take off this sheet before wiring.

while power on.

User’s manual - Hardware V

Page 8

VI PROSEC ТЗ

Page 9

Before reading this manuai

FOR SAFETY To use the T3 safely, read this section carefully before use.

1. Only use the T3 after first carefully reading this Manual and related guides.

2. Do not use in any of the following environments, as they will cause malfunctions:-

(1 ) Where the ambient temperature of the T3 (the temperature

inside the panel) is 0"C or below or 55“C or above

(2) Where the ambient humidity of the T3 (the humidity inside the

panel) is 20% or less or 90% or more

(3) Where condensation may form due to severe changes of

temperature (4) Where there are vibration or violent shocks (5) Where there are corrosive gases or flammable gases (6) Where there is dust,salinity or iron content (7) Where there is direct sunlight

3. Pay attention to the following at the T3 installation site:-

(1 ) For safety in maintenance and operation, keep a distance of

at least 200mm from high-voltage equipment (high-voltage

lines) and power equipment (power lines), or separate by a shield such as a steel plate.

(2) Keep the expansion cables separate from other povv'er

sources when wiring. In particular, separate by at least 200mm from high-power lines.

(3) Provide an air space of at least 70mm around the units for

ventilation.

(4) install the units vertically.

4. The T3 power supply module is a dedicated module for the T3. Do not use it on its own for other purposes.

5. For the wiring to the module, use crimp-style terminals fitted with reverse power sheaths. When it is not possible to use crimp-style

terminals fitted with sheaths, cover with insulating tape and ensure that the conducting parts are<iot exposed.

User's manual - Hardware

Page 10

Before reading this manual

^ This is the warning mark for dangerous locations. It is attached

to the equipment in positions where there is a risk of electric shock and in positions where there is a risk of damage to the equipment through wrong wiring.

Take the following precautions where there is a A mark>

(1) Hazardous voltage can shock or cause severe injury if you

(2) For safety, always switch off power when wiring and during

(3) Wire the power input terminals correctly and do not apply

touch the power input terminals while power on. Do not touch the power input terminals.

maintenance and inspections.

voltages in excess of the specified voltage limits, since this will cause the equipment damege.

2 PROSEC T3

Page 11

Before reading this manual

The purpose of this

manual

This manual explains the hardware of the programmable controller

PROSEC T3. The explanation covers the configuration,

specification, installation, wiring, maintenance and service.

Scope of this manual This manual covers the following basic parts of the T3 system.

T3 main body: CPU module

Power supply module Rack Expansion interface module

Basic Dl/0 : 32 points DC input module (12-24 Vdc)

64 points DC input module (24 Vdc) 32 points AC input module (100-120 Vac, 200-240 Vac)

16 points DC output module (12-24 Vdc) 32 points DC output module (12-24 Vdc) 64 points DC output module (5-24 Vdc)

16 points AC output module (100-240 Vac) 32 points AC output module (100-240 Vac) 32 points relay output module (240 Vac/24 Vdc)

16 points isolated relay output module (240 Vac/24 Vdc)

User's manual - Hardware

Page 12

Before reading this manuai

Related manuals The following related manuals are available for the T3.

T3 User's Manual - Hardware

This manual covers the T3‘s main body and basic I/O - their specifications, handling, maintenance and services.

T3 User's Manual - Functions

This document explains the functions of the T3 and how to use them. The necessary information to create user program is covered in this volume.

T-series Instruction Set

This manuai provides the detailed specifications of instructions for Toshiba's T-series Programmable Controllers.

T-PDS Basic Operation Manuai

This manual explains how to install the T-series program development system (T-PDS) into your personal computer and

provides basic programming operations.

T-PDS Command Reference Manual

This manual explains each command of the T-series program

development system (T-PDS) in detail.

T-series Computer Link Function

This manual explains the specification and handling method of the

T-series Programmable Controller's Computer Link function.

4 PROSEC T3

Page 13

Before reading this manuai

Note and caution

symbols

Terminology

Users of this manual should pay special attention to information preceded by the following symbols.

NOTE Calls the reader's attention to information considered

important for full understandings of programming procedures and/or operation of the equipment.

CAUTION Calls the reader's attention to conditions or practices that

could damage the equipment or render It temporarily inoperative.

AWG American Wire Gage ASCI! American Standard Code for Information Interchange CPU Central Processing Unit

EEPROM Electrically Erasable Programmable Read Only Memory IF Interface

I/O Input/Output LED Light-Emitting Diode ms millisecond

NEMA National Electrical Manufacturers' Association

PLC Programmable Controller

PS Power supply

RAM Random Access Memory

ROM Read Only Memory

jj. s microsecond

Vac ac voltage

Vdc dc voltage

User's manual - Hardware

Page 14

1. System Configuration.............................................................................. 9

1.1 T3 hardware configuration....................................................................... 9

1.2 Unit configuration ..................................................................................11

1.3 Power supply module

1.4 CPU module...........................................................................................15

1.5 Rack....................................................................................................... 19

1.6 Expansion interface module ..................................................................20

1.7 Expansion cable.....................................................................................21

1.8 List of I/O modules .................................................................................22

1.9 Examining the power supply capacity

2. Specification............................................................................................26

2.1 General specifications

2.2 External dimensions...............................................................................27

2.3 I/O module specifications

3. Precautions for I/O Modules...................................................................48

3.1 Precautions for DC input modules .........................................................48

3.2 Precautions for AC input modules

3.3 Precautions for DC output modules........................................................53

3.4 Precautions for AC output modules .......................................................55

3.5 Precautions for relay output modules ................................................... 56

............................................................................

....................................................

..........................................................................

......................................................................

........................................................

4. Installation and Wiring ...........................................................................57

4.1 Installation environment

4.2 Installing units ....................................................................................... 58

4.3 Mounting modules..................................................................................59

4.4 Connecting expansion units

4.5 Grounding...............................................................................................62

4.6 Wiring of the power supply

4.7 I/O wiring............................................................................................... 67

5. Maintenance and Checking....................................................................69

5.1 Daily checking items ............................................................................. 69

5.2 Periodical checking items ..................................................................... 70

5.3 Maintenance parts

5.4 Replacing battery ................................................................................. 71

5.5 Replacing fuses..................................................................................... 72

5.6 IC memory card handling

........................................................................

..................................................................

.....................................................................

...............................................................................

.....................................................................

6 PROSEC T3

Page 15

6. Troubleshooting..........................................................75

6.1 Troubleshooting procedure.....................................................................75

6.2 Checking the power supply

6.3 Checking the CPU..................................................................................77

6.4 Checking program.................................................................................. 77

6.5 Checking input........................................................................................78

6.6 Checking output......................................................................................79

6.7 Troubles due to external factors

6.8 I/O module replacement during operation .............................................81

6.9 List of self-diagnostic items

....................................................................

.............................................................

....................................................................

User s manual - Hardware 7

Page 16

1. System Configuration

8 PROSEC T3

Page 17

1. System Configuration

1.1

T3 hardware The T3 consists of the rack (s), the power supply modules (s), the

configuration CPU module, the expansion interface module (s), the expansion

cables (s) and I/O modules (s).

User's manual • Hardware

Page 18

1. System Configuration

The modules which configure the T3 system are listed below, (except I/O modules)

Power supply module

CPU module

Rack

Type Description

PS361

PS332

Type

PU315 RAM

2 PU325

Type

BU31A BU315

BU35B

3 4

BU356

Power supply voltage : 100-120 Vac/200-240 Vac,

common for basic and expansion units

Power supply voltage: 24 Vdc, common for basic and expansion units

RAM+EEPROM

For basic unit

For expansbn unit

Description

Description 10 slots for I/O modules 5 slots for I/O modules 11 slots for I/O modules 6 slots for I/O modules

Expansion interface module

Type

IF311

IF351

IF312

4 IF352

IF353

For basic

unit

Fcx expansion unit

For basic unit

For middle expan^n unit

For end expansion unit

Description

Standard type, 2m maximum between the units, total 6 m maximum

Long-distance type,

total 40 m maximum

Expansion cable

Type

CS3R5 0.5m

2 CS301 Im

CS302

3 4

CL3R5 0.5m CL301

5 6 CU05 5m Long-distance type, 7 CL310

CL320

CL340

10m 20m 40m

Description

Standard type, both-end connector (50-pin)

both^nd connector (68-pin)

PROSECT3

Page 19

1.2

Unit configuration

1. System Configuration

(1) Minimum configuration of the T3

c 1 1 1 1 1 i I 1 1 1

/ / / / / / / / /

0 0 0 0 0 0 0 0 0 0

Basic unit (10 t/0 rack) 320 points (32-point I/O)

Basic unit (5 I/O rack) 160 points (32-point I/O)

The minimum configuration of the T3 is one basic unit. In this

case, no expansion interface module is needed.

(2) Maximum configuration of the T3

Number of l/Q points (when 32point I/O modules are used)

320 points (10 I/O rack) 160 points (5 t/O rad()

672 points (11 I/O rack)

/ : / :

352 points (6 t/O rack)

1 (

1 I

1 (

1024 points (11 I/O rack) 544 points (6 I/O rack)

c 1 ! 1 1 1

p 1

p / / / / /

p 1

c¡1

u 0

0 0 0 0

Expansion unit No.1

1 1 1 1 1 1 1

/ /

/ / /

0 0 0 0 0

Expansion unit No.2

Basic unit

11(1 (1(1

1 1 1 : 1 ; 1 : 1 /;/:/:/;/

0 : 0 : 0 ; 0 ; 0

till (III ( ( ( 1

( 1

J 1 J 1

; 1 : 1 ; 1 ;

; / : : 0 :

1 1

( 1 ( (

1 1 1 1 1 1

0:0:

Expansion un t No.3

p s F

□

i/1/1

0 0

/1/

1376 points (11 I/O rack) 736 points (6 I/O tack)

Up to three expansion units can be connected to the basic unit. There is no limitation in combining different size of racks. The expansion interface module is needed for each unit,

(indicated as "IF" in the figure) The expansion interface module is dedicated for basic or expansion units

User's manual - Hardware

Page 20

1. System Configuration

If the Standard type expansion is used, all expansion interface modules must be the standard type. In this case, the maximum length of the expansion cable is 2m between units, 6m total.

If the long-distance type expansion is used, all expansion interface modules must be the long-distance type. In this case, the maximum length of the expansion cable is total 40m.

If the standard type expansion is used, the necessity of the power supply modules on the expansion units is determined depending on the internal current consumption. (See 1.9 Examining the power supply capacity)

The power supply mode plug of the expansion interface module

must be set according to the power supply module mounting

status.

If the long-distance type expansion is used, all expansion units should have the power supply modules.

The dedicated expansion cables are available for the standard expansion and for the long-distance expansion, respectively.

12 PROSEC T3

Page 21

1.3

Power supply module

1. System Configuration

The following table shows that two types of power supply modules

are available, depending on the power supply voltage. These modules can be used for both the basic unit and the expansion unit. The power supply module is mounted in the extreme left of the rack.

However, the expansion rack that is connected to the standard expansion IF may not need the power supply module. For details, see 1.9 Examining the power supply capaci^.

Type

PS361

PS332

Rated voltage

100-120 Vac/200-240 Vac (selectable)

24 Vdc

POWER LED

Fuse

Tenninal block eject screw

(on top at bottom)

Run signal output terminals

Frequency

50/60 Hz

Voltage switch terminals (100 to 120 Vac... ^ort\

1200 to 240 Vac... open)

Power su|:^ly input terminais

Line filter ground terminal Frame ground terminal

Module fixing screw

User's manual - Hardware

Page 22

1. System Configuration

POWER LED (green):

This LED is lit when the internal 5 Vdc power supply is normal.

Fuse:

For PS361 ...250 Vac-3A (with one spare fuse) For PS332...250 Vac-6A (with one spare fuse)

Run signal output terminals

Built-in NO contact which closes when T3 is in RUN mode. Contact output...240 Vac/24 Vdc-2A (max.) (can also be used on the expansion unit)

Voltage switch terminals:

These terminals are shorted or opened, depending on the power supply voltage (with a short-circuit bar).

100 to 120 Vac...short

200 to 240 Vac...open

Power supply input terminals :

These terminals are used to connect the power supply line.

Line filter ground terminal (LG):

This terminal is a neutral point for the primary line filter of the power supply, (grounding terminal)

Frame ground terminal (FG):

This terminal is connected to the frame of the T3. (grounding terminal) The terminal is connected, via a capacitor, to the signal ground (SG) of the internal circuit.

CAUTION (1) Correctly set the voltage switch terminals, otherwise

▼AT

the module will be damaged.

(2) For details, see 2.1 General Specifications, for the

external power supply conditions.

(3) The screw size for the terminal is M3.5. For details

of the wiring, see 4.5, Grounding, and 4.6, Wiring of the Power Supply.

14 PROSEC T3

Page 23

1. System Configuration

1.4

CPU module As shown in the table below, the CPU module is available in two

types.

Type Specification

PU315

PU325

PU315/PU325

RAM (battery backup), 32K steps for user program, ladder diagram, SFC

EEPROM+RAM (battery backup), 32K steps for user program, ladder diagram, SFC

Status display LED (RUN, FAULT. I/O, BATT)

RAM/ROM switch

Operation mode switch (HALT/RUN/P-RUN)

Battery cover

RS232C port for the programmer

(D-Sub 9-pin female connector)

RS485 port for the computer iink (D-Sub 15-pin female connector)

1C memory card slot

IC memory card ejection button

Module fixing screw

User's manual - Hardware

Page 24

1. System Configuration

Status display LED:

Lit User program is executing (in the RUN mode)

RUN

(green)

Blink Not lit Execution is stopped (in the HALT mode or in the ERROR mode)

Execution is stopped (in the HOLD mode)

FAULT

(red)

I/O

(red)

ВАТТ

(green)

Blink Not lit Ut Blink Hardware initialization error Not lit Ut Normal battery voltage Not lit Battery voltage becomes low

RAM/ROM switch

Position at

power ON

RAM

ROM

Typed

CPU

PU315 PU325

PU315

PU325

CPU/program error Hardware initialization error Normal

I/O error

Normal

Operation of the CPU

(program transfer at power ON)

Program transfer is not executed.

When an tC memory card which stores user program is

inserted, contents d the 1C memory card is transferred to RAM. (When the operation mode switch is in P-RUN, the program transfer is not executed.)

When an 1C memory card is not inserted or when the 1C

memory card does not contain a user program, program

transfer is not executed. When an 1C memory card that stores user program has

been inserted, contents of the 1C memory card is transferred to RAM. (When the operation mode switch is in P-RUN, the program transfer is not executed.)

When an 1C memory card is not inserted, or when the 1C memory card inserted does not contain a user program, the contents of the EEPROM will be transferred to RAM. (When the operation mode switch is in P-RUN, the program transfer is not executed)

16 PROSEC T3

By using the RAM/ROM switch and the operation mode switch together, the user can select a initial operation mode when power is applied. For details,-see the next page.

Page 25

1. System Configuration

Operation mode switch :

Position of

the switch

User program execution is hatted (HALT mode).

HALT

RUN

P-RUN

Changing the operation mode by the programmer is invalid.

Normally programming is done in this state.

When the operation mode switch is changed to RUN, the user program execution is started (the RUN mode). Changing the operation mode from the programmer is possible.

When the operation mode switch is changed to P-RUN,

user program execution is started (the RUN mode).

Changing the operation mode from the programmer is possible. The user program and leading 4K words of data registers (D) are write-protected.

The table below shows the initial operation modes after power ON

depending on the Operation mode switch and RAM/ROM switch status.

Function

RAM/ROM switch

RAM

ROM

Mode switch

HALT HALT

RUN HALT

P-RUN HALT

HALT

RUN

P-RUN RUN

Mode after power on

HALT

RUN

Remarks

The CPU module is started in the HALT mode and then waits for the RUN command from the programmer, or for a change-over of ttie operation

mode switch (->HALT->RUN).

The user program is transferred in accordance with the conditions

mentioned in the table on the preceding

page. The program transfer is not executed.

The CPU module is started based on the contents of RAM.

NOTE (1) When power is turned on while the RAM/ROM switch

BAM, user program execution will not be started.

Regardless of the type of CPU module, therefore, the RAM/ROM switch should be set to ROM for normal operation.

(2) When the Operation mode switch is changed to RUN

while theRAM/ROM switch is in ROM, the program transfer is executed, according to the conditions mentioned in the table on the preceding page, before the CPU module starts operation.

(3) For details on operation modes, see "T3 User's

Manual-Functions" in a separate volume.

User's manual - Hardware 17

Page 26

1. System Configuration

Battery cover:

A batteiy has been installed inside this cover at the factory shipment. The battery keeps the RAM contents (user program and user data) and supports the clock-calendar operation during power OFF.(See 5.4 Replacing battery)

RS232C port for the programmer :

The T-series programmer (T-PDS or HP911) is connected to the T3 through this port. Dedicated connection cables are available.

RS485 port for the computer link:

The CPU module has the computer link function as standard.

By using this function, T3 can communicate with a host computer or an intelligent equipment through RS485 interface. For details of the computer link function, see separate "T-series Computer Link

Funciton Operation Manual".

IC memory card slot:

Optional !C memory card (type : ME914) is inserted into this slot.

By installing the IC memory card, user program back-up/switchover

or user data expansion become available. Refer to 5.6 IC memory

card handling.

18 PROSEC T3

Page 27

1.5

Rack

1. System Configuration

As described in the table below, in total four racks are available : two racks are for the basic unit, and two racks, for the expansion

unit.

Type

BU31A

BU315

BU35B

BU356 PS X1,IF X1,I /0X6

Use

For basic unit

For

expansion

unit

Number of modules mountable

PSX1, IFX1, CPUX1,1/0X10

PS XI.IF XI.C PUX I, 1/0X5

PS XI.IF XI, 1/0X11

) "PS" and "IF" in the above table indicate the power supply

module and the expansion interface module respectively.

I II I I I

BU315

BU356

• The connector on the extreme-left slot of the rack is dedicated to the power supply module, and the connector next to the right slot is dedicated to the expansion interface module. The third connector from the extreme left slot of the basic unit rack

(BU31A, BU315) is dedicated to the CPU module.

CAUTION Place a cap on each of the connectors where no module

is mounted so that no foreign material will enter.

User's manual - Hardware

Page 28

1. System Configuration

1.6

Expansion interface

module

If the expansion units are used, the expansion interface modules

must be mounted in each of the basic unit and the expansion units. There are basically two types of expansion interface modules-the standard type and the long-distance type. What type to use will depend on the cable distance. The dedicated expansion interface module must be mounted on each of the basic unit and the expansion units.

Type

IF311

IF351

IF312

IF352

IF353

Use

For basic unit

For etqjansion unit

For basic unit

For middle

expansion unit

For end

expansion unit

IF311

(standard type, tor basic unit)

iF311

OUT iS.

Standard type

2m maximum between two units, 6m maximum in total cable length

Long-distance type 40m maximum in total cable length

(standard type, for expansion unit)

Expansion connector (IN)

Connected to tiie preceding unit

Expansion connector (OUT) Connected to the next unit.

Remark

IF351

1F351

OUT

20 PROSEC T3

Page 29

1. System Configuration

Since there is no compatibility between the standard type and the long-distance type, these two types cannot be mixed in one T3 configuration.

The standard type expansion cable and the long-distance type

expansion cable are not compatible with each other. (See

Section 1.7 Expansion Cable.)

If the standard type is used, whether a power supply module is necessary for the expansion unit will depend on the internal 5

Vdc current consumption. (See Section 1.9 Examining the

power supply capacity.) For the IF351, change the power supply mode plug as shown in

the figure below (depending on whether a power supply module

has been mounted on its own unit).

IF351

1.7

Expansion cable

to 1-2 shorted (witii a power supply).

For the long-distance type, a power supply module is needed for each of the expansion units. In the long-distance type, the IF312 is for basic unit, the IF352 is for middle expansion units and the IF353 is for the end expansion unit.

The following types of expansion cables are available.

Type

CS3R5

CS301

CS302 2m

CL3R5 0.5m

GL301 1m

CL305

CL310

CL320 20m

CL340 40m

Cable length Remarks

0.5m

10m

Standard type With both-end connectors (50-pin)

Long-distance type

With both-end connectors (68-pin)

Front

User’s manual - Hardware

Page 30

1. System Configuration

1.8

List of I/O Modules

This manual explains the basic I/O modules in the list below and

how to use them.

Type

DI334

DI334H

D1335

DI335H

IN354

IN364

D0333

D0334

D0335

AC363

AC364

R0364

R0363S

input

output

Relay

output

Specification

32 points (8 pts common), 12 to 24 Vdc,

10 mA/point

32 points (8 pts common), 12 to 24 Vdc, 10 mA/point, high-speed response

64 points (8 pts common), 24 Vdc,

5 mA/point 64 points (8 pts common), 24 Vdc,

5 mA/point, high-speed response 32 points (8 pts common), 100 to 120 Vac,

10 mA/point 32 points (8 pts common), 200 to 240 Vac,

10 mA/point 16 points (8 pts common), 12 to 24 Vdc,

2 A/point, 5 A/common

32 points (16 pts common), 12 to 24 Vac,

0.5 A/point, 5 A/common

64 points (8 pts common), 5 to 24 Vdc, 100 mA/point

16 points (8 pts common), 100 to 240 Vac,

2 Appoint, 5 A/common

32 points (16 pts common), 100 to 240 Vac,

0.5 A/point, 3.2 A/common, 5 A/module 32 points (8 pts common), 240 Vac/24 Vdc,

2 A/point, 5 A/common

16 points (isolated contact), 240 Vac/24 Vdc,

2 A/point

22 PROSEC T3

For details on the specification of I/O modules, see 2.3, I/O

module specifications.

Carefully read the Cautions described In Section 3 for applying I/O modules.

The I/O module can be mounted in any I/O slot functionally.

However, to improve noise-immunity for the entire system, it is recommended to separate the low voltage 1/Os and the power I/Os. (See 4.7, I/O Wiring.)

Page 31

1.9

Examining the power

supply capacity

1. System Configuration

The maximum output current (5 Vdc) of the power supply module

(PS361/PS332) is 7 A. (5.1V at factory setting)

In the standard type expansion configuration, if the power supply module of the previous unit can supply 5 Vdc to the following units, no power supply module for the following expansion units is necessary.

In this case, however, there may be a voltage drop of the 5 Vdc power caused by the resistance of the expansion cable. The minimum limit voltage is 4.75 Vdc. It should also be considered.

Basic unit

Internal S Vdc current consumption ^PU+IF+l/0 {A)=lo[A]

Exfsansion cable resistance

= Ro [Q]

Internal 5 Vdc current consumption ==IF+l/0 (BHi[A]

Expansion cable resistance

= Ri [Q]

internal 5 Vdc current consumption =IF+l/0 (C)=l2[A]

Expansion cable resistance

= R2 [Q]

Internal 5 Vdc current consumption =IF+l/0 (D)=l3lA]

Concerning the above figures, the following conditions (1) and (2)

must be satisfied so that the expansion units N0.1 through 3 can be

mounted in the slots using no power supply of their own.

(1) lo+li+l2+l3<7A

(2) 5.1-RoX(li+l2+l3)-RiX{h+l3)-R2Xl3> 4.75V

If either of the above conditions is not satisfied, a power supply

module is needed for the expansion unit.

If a power supply module is mounted on the expansion unit, the

power supply module will supply 5 Vdc to the own unit and to the following expansion units, disconnecting 5 Vdc line from the previous unit (OV line is common).

User's manual - Hardware

Page 32

1. System Configuration

For example, if the user is going to mount a power supply module on the expansion unit No.2, check that the following conditions are satisfied.

(1) lo+li<7A

(2) 5.1-RoXh > 4.75V

(3) l2+l3 < 7A

(4) 5.1-R2Xl3>4.75V Additional power supply modules may be mounted on the units

even though the power supply capacity has enough margin.

NOTE (1) Correctly set the power supply mode plug of the

\~ZiX7 expansion interface module (IF351) according to a

Conditions for the power supply capacity of the basic unit

Conditions for the power supply capacity of expansion unit No.2

power supply module to be mounted on the unit. If the setting is wrong, the T3 will not work normally. (For details, see 1.6 Expansion interface module.)

(2) For the long-distance expansion interface module,

each of the units must be equipped with a power supply module.

The table below shows the resistance values (typical value) of

expansion cables.

Cable

length

0.5m

Part No.

CS3R5

CS301

CS302

Resistance

value

38m Q

66m Q

112mQ

Remarks

Standard type With both-end connectors

(50-pin)

24 PROSEC T3

Page 33

1. System Configuration

The table below lists the internal 5 Vdc current consumption (max.)

of the module for calculating allowable power capacity.

Internal 5-

Type

Expansion

interface

CPU

input

output

Relay

output

Special

I/O

Data link

Name

Standard expansion interface (for basic unit)

Standard expansion interface (for expansion unit)

Long-distance expansion interface (for basic unit)

Long-distance expansion interface (for middle expansion unit)

Long-distance expansion interface (for end expansion unit)

CPU (RAM) CPU (EEPROM+RAM) 32-point DC input 32-point DC input

(high-speed response) 64-point DC input 64-point DC input

(high-speed response) 32-point AC input (100 to 120 Vac) 32-point AC input (200 to 240 Vac) 16-point DC ou^ut (12 to 24 Vdc) 32-point DC output (12 to 24 Vdc) 64-point DC output (5 to 24 Vdc) 16-point AC output (100 to 240 Vac) 32-point AC ou^ut (100 to 240 Vac) 32-point relay output

10-point relay output (Isolated)

Analog Input (8 channels) Analog output

(4 channels)

Pulse input (2 channels) DC input (8 pts) with status change

detection ASCII interface

TOSL1NE-S20

TOSLINE-F10 (master)

Voltage Current DA374 180 mA

Coaxial Optic Coaxial/optic

Part No.

IF311 20 mA

IF351 20 mA

IF312 800 mA

IF352 700 mA

IF353 700 mA

PU315 2.5 A PU325 2.5 A

DI334 100 mA

DI334H 100 mA

DI335 170 mA

DI335H

IN354

IN364 120 mA D0333 D0334 210 mA D0335 AC363

AC364 800 mA

R0364 170 mA

R0363S 100 mA

AD368 DA364

P1312 800 mA CD332 300 mA AS311

SN321 800 mA

SN322 800 mA

SN323 800 mA

MS311

volt current

ccxisumption

170 mA 120 mA

320 mA

400 mA 530 mA

460 mA

180 mA

1 A

Note) The current consumption of the T3 CPU modules (2.5 A max.) is

the value when the handy programmer (HP911) is connected. When the HP911 is not connected, it is 1.5 A max.

User's manual - Hardware

Page 34

2. Specification

2.1

General Specifications

Item Specification

Rated

voltage

Voltage tolerance

Rated

frequency

CL 3

Frequency

<i)

tolerance

Retentive power Interruption

Power

consumption

Inrush

current

Insulation resistance

Withstand voltage

Operating temperature

Storage temperature

Ambient

humidity

(1) 100 to 120 Vac/200 to 240 Vac (2) 24 Vdc (1) 85 to 132 Vac/170 to 264 Vac (2) 20.4 to 28.8 Vdc

(1)50/60 Hz

(1)47 to 63 Hz

10 ms or less

(1) 80 VA or less (2) 50 W or less (1) 10 A/100 Vac, 20 A/200 Vac (2) 6 A

10 MQ or more (500 Vdc)

1500 Vac for 1 minute

0 to 5Sr

-20 to 75*C

20 to 90% RH

Remarks

Switchable

Max. load conditions of one

PS module

Between power terminals and FG

Between power

terminals and FG

No condensation

26 PROSEC T3

Atmosphere No corrosive gases

Dust

Vibration

immunity

Shock

immunity

Noise

immunity

Grounding

Structure

Cooling

10 mg/m3 or less

16.7 Hz, 3 mmp-p, 30 seconds

98 m/s2, 3 times, in X, Y, Z directions

1500 Vp-p, 1 M s (noise simulator method) NEMA ICS3-304

100Q or less

Control panel built-in t^

Natural cooling

Approx. 7.6 kg

Weight

Approx. 4.7 kg

No power

Power supply noise

Basic unit with 10 I/O modules

Basic unit with five I/O modules

Page 35

2.2

External Dimensions

2. Specification

Basic unit (10 I/O slots)

4-^6

Expansion unit (11 I/O slots)

4-^6

Basic unit (5 I/O slots)

4-^6

Expansion unit (6 I/O slots)

4^^6

User's manual - Hardware

units: mm

Page 36

2. Specification

I/O module

specifications

32-point DC input

2.3

Type

32-point AC input

Type

Category Number of input points insulating method Rated input voltage Range of input voltage Frequency

Rated input current input impedance

Opera tion voltage

Min. ON voltage

Max, OFF voltage

OFF - ON

Delay

ON — OFF Input signal display External connection No. of commons

No. of input points per common

Derating condition Internal current

consumption insulation resistance

Withstand voltage Weight

Internal circuit

IN354

AC input 32 points, 2-word input (X 2 W) Photo-coupler 100 to 120 Vac 85 to 132 Vac 50/60Hz(47to63Hz)

10mA(at100Vac,50Hz)

10 KQ (50Hz), 8 KQ (60Hz)

70 Vac 25 Vac

15 ms or less 15 ms or less

LED display for all points, lit at ON, internal logic side 38-pin removable terminal block, M3.5 4 (insulated between commons)

8 points per common

None

5 Vdc, 120 mA or less

10 M Q or more (500 Vdc)

1500 Vac, 1 minute (between commons, between

internal and external droiits)

480g

200 to 240 Vac 170 to 264 Vac

10 mA (at 200 Vac, 50Hz)

22 kD (50 Hz),

18 kQ (60 Hz)

140 Vac

50 Vac

IN364

32 PROSEC T3

Page 41

2. Specification

32-point AC input

(cont'd)

Terminal connections

Input power

supply

too to 120 Vdc

200 to 240 Vdc

User's manual - Hardware 33

Page 42

2. Specification

16-point DC output

Type

Category Output type

No. of output points Insulating method Rated input voltage Range of load voltage Max. load current Voltage drop at ON Leakage current at OFF

Delay

Output signal display Module status display External connection

No. of commons No. of output points

per common Common polarity Derating condition

Internal current

consumption Insulation resistance

W№stand voltage Built-in fuse

Surge suppressor Weight Internal circuit

OFF - ON ON — OFF

D0333

Transistor output

Current sinking 16 points, 1-word input (Y 1 W) Photo-coupler 12 to 24 Vdc

10to30Vdc 2 A/point, 5 A/common

1.5 V or less (at 24 Vdc)

0.1 mA or less (at 24 Vdc) 1 ms or less

1 ms or less LED display for all points, lit at ON, internal logic side

Fusing/extemal abnormal power supply LED (FL, FH), lit at abnormal state

20-pin removable terminal block, M3.5 2 (insulated between commons)

8 points per common

negative (-) polarity

See NOTE on the next page

5 Vdc, 320 mA or less

10 MQ (500 Vdc)

1500 Vac, 1 minute (between commons, between

internal and external drcuits) 6 A/commonX2

Diode 41 Og

_______________

34 PROSEC T3

Page 43

2. Specification

16-point DC output

(cont'd)

Terminal connections

—□□—

_ 1

_ . 1

. 1

_ . 1

-........1

--------1

___

--------I

___

]

------

___

-----

___

-----

____

-------1

___

-----

___

------

___

-----

___

-----

___

1 1

1. ..

t 1

1 1

1 i

1 1

_ll

_____

2 3 4 5 6 7

I ■

A B C D

F HP HC

13 14 15 16 17 18

_||_

Load pow№ SLpply: 12to24Vdc

NOTE The maximum load current has the following restrictions,

depending on the ambient temperature.

Load currant

GO Ambient temperature

rC)

User's manual - Hardware

Page 44

2. Specification

32-point DC output

Type

Category Output type No. of output points Insulating method Rated load voltage Range of load voltage Max. load current Voltage drop at ON

Leakage current at OFF

Delay

Output signal display Module status display External connection

No. of commons No. of output points

per common Common polarity Derating condition Internal current

consumption

Insulation resistance Withstand voltage Built-in fuse

Surge suppressor Weight

Internal circuit

OFF - ON ON - OFF

D0334

Transistor output Current sinking 32 points, 2-word output (Y 2 W) Photo-coupler 12 to 24Vdc 10 to 30Vdc

0.5 A/point, 5 A/common

1.5 V or less

0.1 mA or less (at 24 Vdc) 1 ms or less 1 ms or less

L£D display for all points, lit at ON, internal logic side Fusing/extemai abnormal power supply LED

(FL. FH), lit at abnormal state

38-pin removable terminal block, M3.5 2 (insulated between commons)

16 points per common negative (-) polarity

See NOTE on the ne)d page

5 Vdc, 210 mA or less

10 MQ (500 Vdc) 1500 Vac, 1 minute (between commons, between

internal and external circuits) 6 A/common X2 Diode 530g

_________

36 PROSEC T3

Page 45

2. Specification

32-point DC output

(cont'd)

Terminal connections

Load power supply :

Hi-

12to24Vdc

NOTE Maximum load current has the following restrictions,

depending on the ambient temperature.

Load current

0.5 A/point 5 A/common

10 20 30 40 50 60 Ambient temperature

0.4 A/point 4 A/common

CC)

User's manual - Hardware 37

Page 46

2. Specification

64-point DC output

Type

16-point AC output

Type

Category No. of output points

Insulating rpethod Rated load voltage Range of load voltage Max. load current

Voltage drop at ON

Leakage current at OFF Min. load current

Max. innjsh current

Delay

Output signal display Module status di^lay External connection No. of commons

No. of output points per common

Derating condition Internal current

consumption insulation resistance

Withstand voltage Built-in fuse

Surge suppressor Weight

Internal circuit

OFF — ON ON OFF

AC363

Triac output

16 points, 1-word output (Y 1 W)

Photo-coupler

100 to 240 Vac (50/60 Hz) 24 to 264 Vac (47 to 63 Hz) 2 A/points, 5 A/common

1.5 V or less

1.0 mA or less (at 100 Vac, 50 Hz)

2.4 mA or less (at 200 Vac, 60 Hz)

100 mA (24 Vac), 50 mA (100 to 240 Vac)

20 A/20 ms (point), 40 A/20 ms (common)

1 ms or less

1 ms+1/2cycle or less LED di^lay for all points, iit at ON, interna) logic side Fusing display LED (FL, FH), lit at fusing 20-pln removable terminal block, M3.5 2 (insulated between commons)

8 points per common See NOTE on die next page

5 Vdc, 530 mA or less

lOMQor less (500 Vdc)

1500 Vac, 1 minute (between commons between

interna) and external circuits) 6 A/common X2

CR snubber circuit, varistor

500g

40 PROSEC T3

Page 49

16-poìnt AC output

(cont'd)

2. Specification

NOTE Maximum load current has the following restrictions,

depending on the ambient temperature.

Load current

40 50 60 Ambient temperature

(t)

User's manual - Hardware

Page 50

2. Specification

32-point AC output

Type

Category No. of output points Insulating method Rated load voltage Range of load voltage Max. load current Voltage drop at ON

Leakage current at OFF Min. load current

Max. inrush current

Delay

Output signal display Module status display External connection No. of commons

No. of output points per common

Derating condition Internal current

consumption Insulation resistance

Withstand voltage Built-in fuse

Surge suppressor Weight

Internal circuit

OFF —ON ON — OFF

AC364

Triac output 32 points, 2-word output (Y 2 W) Photo-coupler 100 to 240 Vac (50/60 Hz) 24 to 264 Vac (47 to 63 Hz)

0.5 A/point, 3.2 A/common, 5 A/modute

1.5 V or less

0.8 mA or less (at 100 Vac, 50 Hz)

1.6 mA or less (at 200 Vac, 50 Hz) 100 mA (24 Vac), 50 mA (100 to 240 Vac)

20 A/20 ms (points and common)

1 ms or less 1 ms+1^cycle or less LED display for all points, lit at ON, internal logic side Fusing display LED (FL, FH), lit at fusing 38-pin removable terminal block, M3.5 2 (insulated between commons)

16 points per common None 5 Vdc, 800 mA or less 10 MQ or less (500 Vdc)

1500 Vac, 1 minute (between commons, between internal and external circuits)

6 A/commonX2 CR snu№er circuit 540g

42 PROSEC T3

Page 51

2. Specification

32-point AC output

(cont'd)

Terminal connections

Load power supply 100to240Vdc

NOTE Minimum 24 Vac can be used as the load voltage.

However, if ioad voltage becomes 85 Vac or less, the

fusing detection circuit may work, in this case, aithough

AC output operation has no problem, the fusing display LED (FL, FH) will light.

User's manual - Hardware 43

Page 52

2. Specification

32-point relay output

Type

Category

Output

No. of output points Insulating method Rated toad voltage Range of load voltage Max. load current Contact ON resistance Leakage current at OFF Min. load current

Delay

Output signal display Module status display External connection

No. of commons

No. of output points per common

Internal current

consumption

External power for relay

Mechanical life

Electrical contact life

insulation resistance Withstand voltage Built-in fuse

Weight

Internal drcuit

OFF ON ON — OFF

Rated voltage Rated current

Voltage range

R0364

Electromechanical relay output NO-contact 32 points, 2-word output (Y 2 W)

Photo-coupler

240 Vac/24 Vdc

Up to 264 Vac/125 Vdc

2 A/point (resistive load), 5 A/common

50 mQ or less (initial value) None 5 Vdc, 10 mA (50 mW or more) 10 ms or less 10 ms or less LED display for all points, lit at ON, internal logic side

^normal external power suF^ly display LED (F),

tit at abnormal state 38-pin removable terminal block, M3.5

4 (insulated between commons) 8 points per common

5 Vdc, 170 mA or less

24 Vdc 300 mA (24 Vdc, at all points ON)

21.6 to 26.4 Vdc 20 million times or more See the next page

10 MQ or more (500 Vdc)

1500 Vac, 1 minute (between commons, between

internal and external circuits) None 51 Og

_____

44 PROSEC T3

OCOM

Page 53

2. Specification

32-point relay output

(cont'd)

Terminal connections

Load poMer supply 240Vai/24Vdc

Hi- 24Vdc for relay

driving

SwitcNng life

(10,000 bTnes)

NOTE The following figures indicate life curves of the output

relay. The data are based on 1800 switching times/hour. For more frequently operation, the life of the output relay will become shorter.

AC load

Switchirig life

(10,000 times)

DC load

Switching Cunent

User's manual - Hardware 45

Page 54

2. Specification

16-point isolated relay

output

Type Category Output type No. of output points Insulating method Rated load voltage Range of load voltage Max. load current Contact ON resistance

Leakage current at OFF Min. load current

Delay

Output signal display Module status display External connection

Common connection

Internal current

consumption

External power

for relay

Mechanical life Electrical contact life Insulation resistance

Withstand voltage Built-in fuse

Weight

Internal circuit

OFF - ON ON OFF

Rated voltage Rated current Voltage range

R0363S

Electromechanical relay output NO-contact

16 points, 1-word output (Y 1 W) Photo-coupler 240Vac/24Vdc Up to 264 Vac/125 Vdc 2 A/point

50 mQ or less (initial value)

None

5 Vdc, 10 mA (50 mW or more)

10 ms or less

LED di^lay for all points, lit at ON, internal logic side ^normal external power supply display LED (F),

lit at abnormal state

38-pin removable terminal block, M3.5

16-point isolated contact

5 Vdc, 100 mA or less

24 Vdc

145 mA (24 Vdc, at all points ON)

21.6 Vdc to 26.4 Vdc

20 million times or more

See the next page

10 MQ or more (500 Vdc)

1500 Vac, 1 minute (between the points, between

internal and external circuits)

None

450g

46 PROSEC T3

Page 55

2. Specification

16-point isolated

relay output

(cont'd)

Terminal connections

Load power suppty 240Vac/24VdC

-J|_ 24Vdc for retay ' driving

Switching life

(10,000 tiines)

NOTE The following figures indicates life curves of the output

relay. The data are based on 1800 switching times/hour. For more frequently operation, the life of the output relay

will become shorter.

AC load

Switching life

(10,000 times)

DC load

0,2 0.3 0.5 0.7

1.5 2 Current

Swit^ng

User's manual - Hardware

Page 56

3. Precautions for I/O Modules

3.1

Precautions for DC

Input modules

(1) Read conditions for the ON/OFFchanges of the input signals are:

Input ON time^ON delay time (OFF->ON)+lnput reading cycle input OFF time^OFF delay time (ON->OFF)+lnput

Where the “input reading cycle“ means PLC scan cycle for the refresh input, or the execution interval of a direct input instruction when the instruction is used.

(2) For some external contacts, the input current (10 mA/24V for

DI334; 5 mA/24V for DI335) of modules may not be able to maintain contact reliability. In this case, install a bleeder resistor between the input and common terminals to increase the contact current.

(An example of selecting a bieeder resistor R) Input voltage V=24 Vdc Input module DI334 (10 mA/24 Vdc) When the contact requires 50 mA current; Resistance value R of a bleeder resistor=0.6[kQ] Wattage P of the bleeder resistor=3[W]

reading cycle

Contact Input module

—

---

------

0 O—'

”

—\

ill

COM

Wattage P> X(2.5~3)

48 PROSEC T3

(3) If a switch with an LED display is used, the current (leakage

current) through the LED may cause the erroneous input (always ON). In this case, install a bleeder resistor to lower the input impedance.

LED

(Example of selecting a bieeder resistor R) When the voltage between input terminals is Vd at the switch OFF state (with no bleeder resistor), the resistance (R) and the wattage (P) of the bleeder resistor can be selected as follows.

Page 57

3. Precautions for I/O Modules

(V-Vd) Vo

V(Vd-Vo)

P= (2.5~3)

In case of DI334,

V=24 Vdc, Vo=3-5 Vdc, Zi=2.4 kCl

If Vd=5 Vdc, R can be calculated as follows.

R[kQ]<_l

As a result,

R<4.4[kQ]->3kQ P=(2.5~3)X

Also, when the bleeder resistor is selected in the above manner, the contact current at the switch ON state should be checked.

Contact current=24[V]X

(4) If the two-wire proximity switch and other solid-state switches

are used, be sure that there is no possibility of mis-inputting

because of the leakage current, as in procedure (3). (See (3) for details on how to select a bleeder resistor.) Also in this case, because of the effect of the saturation voltage

(voltage drop) at ON, regardless of whether the switch is ON, the input terminal voltage may not be able to reach the ON voltage, thereby failing to read as input ON.

if input voltage is low or if input wiring is too long, special

measures are necessary.

Two-wire proximity switch , ^ module

(24-5) X3.5

----------1-----24X(5-3.5)

2 V: Input voltage

X2.4IkQ]

{2AW

3000[Q]

Vo: Max. OFF voltage of the input module Z i: Input impedance of the input module

0.5W

2.4IkQ]+R

2.4[kQ]XR

^18[mA]

Cable resistance (R) moouie

■ CD---

----------

if the cable resistance value is expressed as R[Q], Vd[V] for the voltage drop of the proximity switch, and Zi[Q] for the input impedance of the input module, the voltage Vi[V] applied between the input module terminals will be as expressed below (when the proximity switch is ON):

V-Vd

Vi=

2R+Zi

If the above Vi is lower than the minimum ON voltage of the input module, input voltage V must be raised or the value of the

cable resistor R must be made smaller.

User's manual - Hardware 49

Page 58

3. Precautions for I/O Modules

(5) Because the input filter time constant of the high-speed

response input module (DI334H, D1335H) is set to small, the input module may read the wrong input due to chattering of the contact. Use the high-speed response input module to connect

with solid-state devices. Also, take measures to suppress noise.

(6) If input wiring is too long, take measures to prevent erroneous

input caused by noise, as follows.

•Wiring length must be minimized. Do not make unnecessary loops.

•Keep the input wires away, at least 200 mm, from power cables and high frequency lines, or shield the input cables with a metal plate.

•If possible, use relays at the leading in the control panel.

•For some cases, use a shielded cable or twisted-pair cable.

•Install a bleeder resistor to reduce input impedance.

(7) If dynamic scan input is configured using a DC input module and

a DC output module, in addition to the response-delay of output and input, consider the difference of timing caused by the PLC scan. Moreover, diodes must be installed to prevent erroneous input caused by detour circuit, (the figure below is an example of 4X4 input)

Input module

Output module

For example, when contact a is ON, the change timing between

output 0 and input 0 is as follows :

PLC scan cycle

-Output 0 ^internal) Output 0 (external)

Input 0 (external) Input 0 (internal)

T1 : Output response

T2: Input response

Note that the change timing of output 0 and input 0 will be

affected with the scan time of the PLC and the response time of

input and output.

67a oTe 6jj 6|n

"6| n

delay

50 PROSEC T3

Page 59

3.2

Precautions in applying

AC input modules

3. Precautions for I/O Modules

(1) The conditions to read the ON/OFF state of the input signal are

as follows:

Input ON time^ON delay time (OFF->ON)+input reading cycle Input OFF time^OFF delay time (ON->OFF)+lnput reading

cycle

The input reading cycle means PLC scan cycle for the refresh

input, or the execution interval of the direct input instruction when using a direct input instruction.

(2) When an AC output sensor is connected to the I/O module, due

to the leakage current from the sensor at OFF, there may be a

voltage which exceeds the maximum OFF voltage between the input terminals. This will make the PLC unable to read input OFF when the sensor is OFF. In this case, install a bleeder resistor between the input terminals to lower the input impedance.

For selecting a bleeder resistor, refer to 3.1 (3).

(3) if external lines for AC input become longer with using a multi

core cable, induced current may flow to an open wire from

charged wires due to the electrostatic capacity of the cable,

causing an erroneous ON input. In this case, install a bleeder

resistor between the input terminals to lower the input impedance. Or, you had better apply the DC input.

User's manual > Hardware

Page 60

3. Precautions for I/O Modules

(4) If the AC lines are installed in parallel with high frequency or

power lines, induced current may cause erroneous input. In this

case, take necessary countermeasures as follows:

• Change the installation route of AC input lines so that they are not parallel with power lines and high frequency lines.

• Use twisted-pair cables as input lines.

• Use shielded cables as input lines.

• Use relays at the leading in the control panel (the relay

must satisfy larger ON current).

• Install a bleeder resistor to lower the input impedance.

(5) If the input module and an inductive load are connected in

parallel, a surge voltage generated at both-ends of the load when the contact is changed to OFF may cause a malfunction of the PLC. In this case, install a surge absorption element in

parallel with the load to suppress the surge voltage.

----------------------------------------------------------

Input module

)

---------

Inductive load

-0^

^ ^ Surge absorption element (snubber circuit, etc.)

Hl-O-

)

52 PROSEC T3

Page 61

3.3

Precautions for DC

output modules

3. Precautions for I/O Modules

(1) The DC output module needs an externa! power supply to drive

output transistors. For each common, connect the load power to

the appropriate terminal. (For details, see 2.3, I/O module

specifications) If the wrong polarity of the power supply to the terminal is connected, the module will be damaged. Check the polarity before connection. For the D0333 and D0334 modules, if their built-in fuse is blown out or if the external power supply is not supplied, the front LED (FL, FH) of the module lights.

(2) Protection coordination against over-current of DC output

module

Type of module

D0333 <16-point output)

D0334 (32-point output)

D0335 (64-point output)

A fuse of 6 A per common (8 points) is built in mis DC

output module. For an overload and load short-cir

cult, the transistor will not be protected. This fuse,

however, protects the DC output module and the

external cable from burn-out.

A fuse of 6 A per common (16 points) is built in this DC output module. For an overload and load short-circuit, the transistor will not be protected. This fuse, however,

protects the nrodule and the external cable from bumout.

Because a protection fuse is not built in this DC output module, the load short-circuit, etc. will cause bum-out of the module and external cable, Therefore, install an

appropriate fuse on the outside to prevent accidental

bum-out.

Protection

(3) A diode as shown in the figure below is built in to protect the

transistor from transient overvoltage.

D: Bypasses transient overvoltage to the power supply and suppresses the voltage between the collector and emitter of the transistor.

User's manual - Hardware

Page 62

3. Precautions for I/O Modules

(4) If a capacitive load is connected, rush current will flow when

output is changed to ON. At that time, necessary measures must be taken to protect the output transistor from being destroyed by the rush current. To limit the rush current there are two effective measures. One is to connect a resistor to the load in series. The other is to apply dummy current to the load by connecting a resistor between the output terminals.

(5) If an inductive toad is connected, transient overvoltage will occur

when the output is changed to OFF. This surge voltage will be absorbed into the diode D mentioned

before so that the transistor will be protected. However, if the output cable is Installed closely to other signal lines, the surge voltage may cause other problem. In this case, install a flywheel diode in parallel with the inductive toad (as near as possible to

the toad.)

Output module

Rywtiee) diode Reverse withstand voltage:

3 times or more of the circuit

voltage Forward current: load current

or more

If a flywheel diode is connected, the OFF restoration time of the toad will become longer. If this becomes a problem, connect a CR snubber circuit to the toad, similar to the countermeasure

taken for surge voltage in AC output.

54 PROSEC T3

Page 63

3.4

Precautions for AC

output modules

3. Precautions for I/O Module

(1) The AC output module (AC363, AC364) has a built-in fuse of 6A

per common. For a load short-circuit, fusing will protect the

triacs. However, in this case, semiconductor devices may be

damaged to some extent. Therefore, take measures to prevent it.

in the case of fusing, or when the external power Is not supplied,

the LED {FL, FH) on the front of the module will light.

(2) If a capacitive load is connected, rush current will flow when the

output is changed to ON. Take necessary measures to suppress this rush current at a value lower than the allowable limit of the module. Allowable inrush current :

AC363 ... 20 A/20 ms (point), 40 A/20 ms (common) AC364 ... 20 A/20 ms (point and common)

(3) If an inductive load is connected, transient overvoltage will be

generated at the output is changed to OFF. To prevent

malfunction caused by this surge voltage, a CR snubber circuit is installed in the AC output module. However, to prevent the

problem for other signal systems, install a surge absorption element in parallel with the inductive load (install a surge absorption element as near as possible to the inductive load).

Output module

Surge absorption element:

• Varistor (for the voltage clamp)

• Snubber (CR) circuit (for high-frequency attenuation)

oHi—o—o c(mF)* —JL (I ■-peak value of load

(4) Because the AC output module does not have a zero-cross

function, the OFF->ON occurs regardless of the load voltage

phases. However, the ON->OFF change occurs when toad current is near zero. Check this point in load response.

---------

Bi-directional overvoltage absorption element with a rated voltage of approx. 1.2 times of the max. voltage (peak voltage)

R (Q)=DC resistance value of the load

10 20 current in ordinary time)

Surge absorption eiement

User's manual - Hardware

Page 64

3. Precautions for I/O Modules

3.5

Precautions for relay

output modules

(1) The relay output module (R0364, R0363S) needs external 24

Vdc power for driving relays. (For details, see 2.3, I/O module specifications.)

If external 24 Vdc power is not supplied, the LED (F) in the front

of the module will light.

(2) Because the relay output module does not have an built-in fuse

to protect from overcurrent, install a fuse appropriate to the load current on the external wire. If the protective fuse is not inserted, module patterns could be burn out when a load is shorted.

R0364

56 PROSEC T3

(3) The relay output module does not have a built-in surge

absorption element. To connect an inductive load, always install a surge absorption element in parallel with the load. For details on selecting a surge absorption element, see 3.3 (5) and 3.4 (3).

Page 65

4. Installation and Wiring

4.1

Operating environment Do not install the T3 in the following locations :

• Where the ambient temperature drops below 0*C (32“F) or exceeds 55‘C (13l“F)

• Where the relative humidity drops below 20% or exceeds

90%

• Where there is condensation due to sudden temperature

changes

• Where there are vibrations that exceed the tolerance of the T3

• Where there are shocks that exceed the tolerance of the T3

• Where there are corrosive or inflammable gases

(The installation location should be below 0.05 ppm of sulfurous acid gas, below 0.01 ppm of hydrogen sulfide.)

• Where there are dust, machining debris or other particles

• In locations exposed to direct sunlight

Observe the following precautions when installing

enclosures for mounting the T3 :

• Provide the maximum possible distance between high-

voltage or high-power panels. This distance must be at least 200 mm (8 in).

• If the enclosures are installed near high-frequency

equipment, be sure to ground the enclosures correctly.

• When sharing the channel base with other panels, check for leakage currents from the other panels or equipment.

User's manual - Hardware

Page 66

4. Installation and Wiring

4.2

Installing units

Installation precautions:

• Because the T3 is not dust-proof, install it in a dust-proof

• Do not install the unit directly above equipment that generates a

• Do not install the unit within 200 mm (8 in) of a high-voltage or

• Allow at least 100 mm distance (4 in) on all sides of the unit for

• For safety during operation and maintenance, install the unit as

• If the unit is installed on a horizontal panel, ambient

• Decide the units mounting position with considering the length of

• Install the units in fully contacting with the mounting frame in

enclosure.

large amount of heat, such as a heater, transformer, or large-

capacity resistor.

power cable.

ventilation.

far as is possible from high-voltage or power equipment. Alternatively, isolate the unit using a steel plate or similar separator.

temperature should be less than 40’ C.

the expansion cables.

order to equalize the potentials of basic and expansion units.

The unit mounting dimensions are as follows:

BUSI 5 and Buass

[units : mm]

58 PROSEC T3

Page 67

4.3

Mounting modules

4. Installation and Wiring

The power supply module must be mounted in the slot at the

extreme left of the rack. Install the expansion interface module in the slot next to the power supply module, and the CPU module (for the basic unit only) and I/O modules in the following slots : The modules, except for the expansion interface module, must be

installed as follows:

1. Slide back the slide lock on the top of the module to release the lock lever.

2. Hang the bottom of the

module on the rail of the rack and push up the lock lever.

3. While setting the bottom of the module as the

supporting point, install the module in the slot to match

the connector.

4. Release the lock lever and

lock the module in the rack.

Pull the slide lock towards

you and lock the lever.

Lock lever

Screw

Slide lock

CAUTION •

TAT .

Mount an expansion interface module by using a screw in the slot next to the power supply module slot as follows:

1. Insert the expansion interface module into the connector next to the power supply module.

2. Tighten screws on top and bottom of the module.

CAUTION For safety, turn off power to the T3 before Installing or

While operating, fix the module with a screw at the

bottom of the module. Remove the module in the reverse procedure for installation. Connector covers are attached to the rack and module connectors. Remove the connector

covers when a module is installed.

removing a module. Also, refer to Section 6.8 I/O module replacement during operation.

User's manual - Hardware

Page 68

4. Installation and Wiring

4.4

Connecting expansion

units

Standard expansion This type of expansion configuration uses the standard type

Up to three expansion units can be connected to the T3 basic unit. Either the standard type or the long-distance type of expansion configuration can be selected. For details, see 1.2 Unit configuration.

expansion interface modules (1F311 for basic unit, and 1F351 for expansion unit).

Expansion cable

CS3R5(0.5m) CS301(1m) CS302{2m)

60 PROSEC T3

The length of the expansion cable between the units is up to 2

meters, and 6 meters in total length.

The expansion cable connects IN and OUT. Correctly connect

IN and OUT. Keep the expansion cable away - at least 50 mm (2 inch) - from

the I/O signal cables.

For details on whether a power supply module for an expansion unit is necessary, see 1.9 Examining the power supply capacity.

Change the power supply mode plug of the IF351, depending on

the power supply being used. For details, see 1.6 Expansion interface module.

Page 69

4. installation and Wiring

Long-distance

expansion

The following figure outlines the long-distance expansion

configuration using the long-distance type expansion interface modules (IF312 for basic unit, 1F352 for middle expansion unit and IF353 for end expansion unit).

©Long-distance type expansion interface module IF312

(for basic unit)

©Long-distance type expansion interface module IF352 (for

middle expansion unit)

©Long-distance type expansion interface module IF353 (for end

expansion unit)

©Expansion cable (for long-distance expansion)

CL3R5 (0.5m) CL301 (1m) CL305 (5m) CL310(10m) CL320 (20m) CL340 (40m)

• Maximum total length of the expansion cables is 40m.

• Connect IN and OUT of the expansion cable. To prevent mis-connection, a colored mark is attached on each

connector of the expansion cable and the module.

• The expansion cable must be separated as far as possible

from power cables and I/O wires.

• Use the IF353 on the end expansion unit for termination.

User's manual - Hardware

Page 70

4. Installation and Wiring

4.5

Grounding

To maintain the safety and stable operation of the T3, grounding is very important. Read and follow the check points below before grounding.

Check points for

grounding

Grounding of controi panei

Check the grounding against the following criteria: (1) The T3 must not become a path for ground current. High-

frequency current is particularly harmful.

(2) Equalize the ground potentials of the basic and the

expansion units. Ground them at a single point.

(3) Do not connect the ground of the T3 to that of high-power

systems.

(4) Do not use a ground that has an unstable impedance, such

as painted screws, or grounds subject to vibration.

In some cases, the T3 unit becomes a path of ground current from a

power panel or high-frequency equipments.

^Change

62 PROSEC T3

Isolate the T3 mounting panel and connect to the ground point separately.

Isolate the T3 from the mounting frame and connect to the ground point separately.

Page 71

Ground connection

between units

4. installation and Wiring

2 mm2

or more

Connect the FG terminal of the power supply module to the unit

mounting screw, and to the ground bar in the panel by 2 mmi^ or larger wire in shortest possible distance. Use a dedicated ground for the control circuit, and keep the ground cable away from that for high-power systems. 100Q or less to earth is recommended.

User's manual - Hardware

Page 72

4. Installation and Wiring

Grounding of long

distance expansion

Basic unit

Expansion unit

In principle, ground a long-distance expansion unit as shown in the above figure. If the potential changes at the grounding point, causing malfunctions of the T3, isolate the expansion unit from the mounting frame, and ground it with a dedicated cable (2 mnf or more).

Basic unit

Ground bar in the panel

2mm=

or more

Expansion unit

_____

ili

Isolation

panel

Line filter ground (LG)

64 PROSEC T3

terminal

The LG terminal is a neutral point of the primary power supply line filter. It can suppress the effect caused by the noise from the power

supply line, by grounding the LG terminal. Therefore, normally, ground the LG terminal together with the FG terminal.

However, depending on the power system, leakage current to the

ground from the LG may cause problems. In this case, install an

isolated transformer in the power line, or open the LG terminal. If the unit Is installed in isolation, open the LG terminal.

Do not connect the LG and FG terminals without grounding them.

Page 73

4.6

Wiring of the power

supply

4. Installation and Wiring

Wire the external power supply to the T3 power supply module. When using the expansion unit, supply the power simultaneously to the basic and expansion units.

(1 ) Power conditions

85 to 132 Vac/170 to 264 Vac,

Power voltage

50/60 Hz (PS361)

20.4 to 28.8 Vdc (PS332)

Power consumption (per one PS)

Retentive power interruption

(2) Correctly set the voltage switch terminals of the PS361

according to the power voltage. (100 to 120 Vac: short,

200 to 240 Vac: open)

(3) Install an electrostatic shielded transformer or a noise filter if the

power contains noise. See the figure at the bottom.

(4) Use twisted-pair cables (1.25 mm^) as the power supply cable.

Keep the cable as far as possible from the I/O cables.

(5) If the expansion unit with a power supply module is used, the

power for the basic and expansion units should be supplied from

the same source. Apply power at the same time or in the order

of the expansion unit then the basic unit.

(6) If a CVCF or UPS supplies power to the T3, observe waveforms

of the power supply; the peak voltage must be more than 130V

for the 100 to 120 Vac setting or 260V for the 200 to 240 Vac

setting.

Noise Yielded

filter trasformer

Power

Doc cooiO(

80 VA or less (PS361)

sow or less (PS332)

10 ms or less

Basic unit

* !

30C

-o

--0

-OL

-ON

* Voltage switch terminals

100 to 120 Vac ... short 200 to 240 Vac ... open

Expansion

[

unit

-o

* !

•o

-OL

-ON

User's manual ■ Hardware 65

Page 74

4. Installation and Wiring

Wiring of the power supply module

AC power supply

(PS361)

DC power supply

(PS332)

CAUTION (1) The size of the terminal screw is M3.5. Use an

appropriate crimp-style terminal with a width of 7 mm (0.27 In) or less for the M3.5 screw.

(2) The terminal block can be removed. Turn OFF the

power before removing the terminal block for safety.

(3) The recommended cable size for the power supply

module is 1.25 mm^

PBOSECT3

Page 75

4. Installation and Wiring

4.7

I/O wiring The following module layout is recommended for noise immunity.

Duct for

low-voltage

signals

DC input module

Analog input module DC output module

Analog ou^ut module AC output module

Pulse input module

ASCII module

Data link module

I/O modules for

low-voltage system

Duct for

power signals

I/O modules for

power system

AC input module

Relay output module

Power caUes

(1) To improve the unit's resistance to signal interference, install

modules for low-voltage signals toward the left of the unit, and

modules for power signals toward the right. Also, separate the wires of each,

(2> Allow at least too mm (4 in) clearance between the units and

between other control equipment to allow access for maintenance and ventilation,

(3) When installing the unit near high-voltage or high-power

equipment, leave at least 200 mm (8 in) clearance, or shield the

unit with a steel plate.

User's manual - Hardware 67

Page 76

4. Installation and Wiring

(4) Refer to the following table for the size of I/O cables.

Type of module

16-point module 0.75~1.25 mm2 32-point module 64-point module 0.1 —0.3 mm2

Cable size

0.5-0.75 mm2

Use a larger size cable for the common line. For the field-wiring cable, \ .25 mm^ or larger cable is recommended.

(5) The M3.5 screw is used as a terminal screw. Use an

appropriate crimp-type terminal with a width of 7 mm (0.28 in) or

less for the M3.5 screw.

(6) Do not bind the I/O signal cables and high-voltage or power

cables. Separate them as far as possible. If separation is

difficult, use shielded cables for the I/O signals and ground the shield at the leading-in point of the control panel.

68 PROSEC T3

Page 77

5.1

Daily checking items

S.Maintenance and Checking

To maintain the system and to prevent troubles, check the following points on dally basis.

Item

LEDs on the power supply and CPU modules

Input LEDs (digital input)

Output LEDs

(digital output)

Content of checking

POV\ER (green): Ut when 5V power normal

RUN (green): Ut when operating normally

FAULT (red): Not Ht when the CPU normal.

I/O (red): Not tit when the I/O modules normal.

ВАТТ (green): Lit when the battery voltage normal.

Ut when the corresponding input signal is ON.

Lit when the output is ON and the corresponding external load should operate. Also, check that the LEDs (FL, FH, or F), which indicate a blown fuse and/or abnormal external power, are not lit.

Corrective measures

If the LEDs are abnormal, see Section 6, Troubleshooting.

•Check that the input voltage is within the spedfied range.

• Chedc that the input terminaJ block is not loose.

•Check that th modules are instdled securely.

•Qieck that the external load voltage is within the specified range.

• Check the built-in fuses.

•Check that the output terminal blodc is not loose.

•Check that the modules are installed securely.

Switches on the CPU module

Ched( №at the operation mode switch (HALT/RUN/P-RUN) and the RAM^OM switch are at the correct position. Operations are executed when the mode switch is set to RUN or P-RUN.

Change the switch to the correct position.

CAUTION If a serious error (e.g., the system RAM abnormal) is

detected when the power is turned ON, the FAULT and

I/O LEDs will blink. In this state, communication with the programmer is not possible. If that error continues even if the power is again turned ON, replace the CPU module.

User's manual - Hardware

Page 78

S.Maintenance and Checking

5.2

Periodical checking

items

Check the T3 based on the following points every six months. Also perform checks when the operating environment is changed.

Item

Power supply

Installation condition

Programmer

I/O modules

Environment

Program

Battery

Content of checking

Measure the voltage of the power (at the terminal of the module)

Check that the terminal screw of the module is not loose.

Check that wiring cable is not damaged.

Check that the basic unit is installed securely.

Check that the expansion unit is installed securely.

Check that each module is irrstalled securely.

Check that each expan^n cable connector is not loose; and the cable is not damaged.

Check that the functions of the programmer are norrrral.

Check that the connector and the cable are not damaged.

Measure the vdtage of each of

the I/O modules at the terminal

block.

Check the LED of the input status display.

Check the LED of the output

status display.

Check tiiat the I/O teminal block is installed securely.

Check that the terminal screw is not loose and the terminal has a sufficient distance to the next terminal.

Check that the wiring cat^e is not damaged.

Check that the temperature, humidity, vibration, dust, etc. are within the specified range.

Check that the content of the PLC program and the master program (e.g., saved on a floppy disk) are the same.

Check whether the battery must be replaced. (The installed date is written on the rear of the CPU battery cover.)

Check that the connector of the battery is inserted firmly.

Corrective measures

85 to 132/170 to 264 Vac

20.4 to 28.8 Vdc

Check that the terminal screw of

the module is not loose.

Check that wiring cable is not damaged.

Not loose, no play

Not loose, not damaged

Try executing simple operations.

Not damaged

The voltage must be within the spedtied range.

The LED must light normally.

Not loose, no play

Not loose, and not contacting the next terminal

Not darrraged

Must be within the general specification range.

Check that these programs are identical by comparison.

Replace the current bettery if

more than two years has elapsed.

Not loose

70 PROSEC T3

Page 79

5.3

Maintenance parts

S.Maintenance and Checking

To recover from failure quickly, it is recommended to keep the following spare parts:

5.4

Replacing battery

Part

I/O module

Fuse

Battery

CPU module 1

Power supply module

Programmer

Master program

Quantity Remarks

One of each

type used

Number to be

used

1 1

As required

Check the service life of the relay output. See Sectiofi 2.3.

See Section 5.5.

For emergency. See Section 5.4. Prepare at least one each to minimize

the down-time of the system.

Useful for the troubleshooting procedure. Saved in a disk, or other media.

Do not store spare parts in high temperature and humidity locations. Keep the temperature at ordinary room temperature or below because the battery discharges when the ambient temperature is high.

The lithium battery Is used for maintaining the T3's RAM memory

during power OFF. The battery is installed at factory shipment. The installed date of the battery is marked on the rear of the battery cover of the CPU module. Under normal service conditions, it is

recommended to replace the battery every two years. Check the installed date and replace the battery with a new one if two years have elapsed.

The LED (ВАТТ), which indicates the battery voltage is normal, is

installed in the front of the CPU module. The LED lights when the battery voltage is normal. If this LED does not light or blinks, the service life of the battery has ended. Replace the battery within 14 days. To maintain the RAM program, it is recommended to keep the power ON until the battery is replaced.

Connector

CPU module

Batte^ containig case

Battery

battery.

case.

User's manual - Hardware

Page 80

5. Maintenance and Checking

5.5

Replacing fuses

CAUTION 1

The battery can be replaced either with power ON or with power OFF.

However if the battery is replaced with power OFF, insert a new battery within five minutes after the old battery is removed. If the new battery is not inserted quickly, the data in FIAM memory wiil be tost. Keep the following points in mind when handling

batteries.

• Do not replace a lithium battery with a manganese dry cell or an alkaline battery since their voltages are not compatible with the former.

• Do not short the + (positive) and the - (negative) terminals of the battery.

• Do not dismantle, or apply heat to, or throw the

battery into fire.

• Do not try to charge a battery. This is dangerous.

The battery is dedicated for Toshiba PLC. Order it from Toshiba. (Part code: TBT911*AS)

The following modules have buitt-in protection fuses.

Name of module

(type)

AC power supply (PS361)

DC power supply (PS332)

DC output fD0333) FU916

DC output (D0334) FU916 AC output (AC363) AC output (AC364)

FU913 FU916

FU916 2

Fuse type

Number of units

1 1

2 250 Vac - 6A 2 250 Vac - 6A

Fuse rating

250 Vac - 3A 250 Vac - 6A

250 Vac - 6A 250 Vac - 6A

72 PROSEC T3

The AC and DC power supply modules have a built-in protective fuse to prevent burn-out of internal circuits of the modules.

Over long term use, ON/OFF changes of the power may cause fatigue; check the fuse periodically (a spare fuse is attached). The above output modules have protective fuses to prevent their

internal circuits from burn-out when short-circuit occur.

In the front of each output module, the LEDs (FL, FH or F) which

indicate the status of fuses are provided. When a fuse is blown, these LEDs light.

Page 81

5. Maintenance and Checking

Replacing the fuse of the power supply module

Power supply module

Fuse holder

CD Install a new fuse. 0 Attach the fuse holder.

Fuse

User's manual • Hardware

Page 82

5. Maintenance and Checking

5.6

1C memory card

handling

By inserting the 1C memory card (type: ME914) into the CPU module, program loading/saving between the 1C memory card and

T3’s memory or use of expanded file registers become available.

(For details, refer to the “13 User’s Manual - Functions” in a separate volume.) By inserting the 1C memory card which stores a user program, the program can be transferred to the RAM of the CPU without using the programmer. Use the following procedure: © Turn OFF power. Insert the 1C memory card into the CPU

module.

® Set the RAM/ROM switch of the CPU module to ROM, and set

the operation mode switch to HALT. (D Turn ON power. The above procedure enables the program stored in the 1C memory card to transfer the RAM memory of the T3.

Note the following points when handling the iC memory card.

(1) The IC memory card can be inserted or ejected while power

ON.

(2) To maintain the memory, the IC memory card has a built-in

battery (coin type lithium battery CR2325, approx, one year of service life at 20'C), If power Is applied to the IC memory card for more than ten minutes before removing the card, it can maintain the memory

for approx. 30 minutes after the lithium battery is removed.

However, memory on the IC memory card disappears if a longer

time has elapsed.

74 PROSEC T3

Page 83

6.1

Troubleshooting

procedure

6. Troubleshooting

If a trouble occurs, determine whether the cause lies on the mechanical side or on the control system (PLC) side. A problem may cause a secondary problem, therefore, try to determine the cause of the trouble by considering the whole system.

If the problem is found in the T3 or in the T3’s I/O operation, check

the following points:

If the user program operation is abnormal, follow the procedure in

6.4, Checking the program.

If an abnormalit/ is found in an

input module, follow the procedure in 6.5, Checking input.

If an abnormality is found in an output module, follow the procedure in 6.6, Checldng ou^ut.

If the problem appears temporary and is synchronous with the operation of the system/equipment, the external environment (noise, voltage fluctuations, etc.) may have caused it. For details, follow Section 6.7.

User's manual - Hardware

Page 84

6. Troubleshooting

Checking the power

supply

If the POWER LED in the front of the power supply module does not light after power ON, check the following points:

76 PROSEC T3

CAUTION (1) Turn OFF power before disconnecting cables and

removing modules.

(2) The blown fuse of the power supply may be caused

by a failure of an internal circuit.

Page 85

6.3

Checking the CPU

6. Troubleshooting

If the POWER LED is lit, but the RUN LED is not lit, check the

following points:

Change to RUN or P-RUN.

If the switch is in RAM, the CPU does not enter into the RUN mode automatically. (Stand-by mode)

The blinking RUN LED indicates In the HOLD mode. Check that the

HOLD device (S0401) is not used in the program.

6.4

Checking program

An error-down has occurred.

Check the error by following the

procedure in Section 6.9.

Check the program based on the following points if it is running but the operation does not work as intended. (1) Output is not carried on the same coil or register of two or more

locations during one scanning: the devices for coil instructions and for function instructions are not overlapping.

(2) The signal which changes faster than the scanning cycle is not

Input. (3) Timer register or counter register is not duplicated. (4) When an interrupt is used, the device/register which is used in

the main program is not operated erroneously in the interrupt

routine.

User's manual - Hardware

Page 86

6. Troubleshooting

6.5

Checking input

If the program is running, but the input signal is not read normally,

check the following points:

78 PROSEC T3

Page 87

6.6

Checking output

6. Troubleshooting

If the output to registers and devices is normal, but the actual output to equipment is abnormal, check the following points:

User's manual - Hardware

Page 88

6. Troubleshooting

6.7

Troubles due to

external factors

If one of the following abnormalities occurs in the system, check possible external factors.

(1) If an abnormality occurs synchronously with the operation of I/O

equipment: The noise caused at ON/OFF of the output equipment may be the source of the abnormality. Take necessary measures

mentioned in Section 3 Precautions for I/O modules.

(2) If an abnormality occurs synchronously with the operation of

surrounding equipment or high-frequency equipment: The noise induced on I/O signal lines may be the source of the abnormality. The surge voltage, voltage fluctuations, or differences of grounding potentials may have caused the abnormality, depending on the power supply system or the grounding system. Check the abnormality in accordance with the precautions in Section 4 Installation and Wiring. For some cases, isolation from the ground may lead to the stable operation.

(3) If an abnormality occurs synchronously with the operation of

machinery:

The vibration of the equipment may have caused the

abnormality. Check that the installation status of the units and modules and

take necessary measures, including the use of vibration-proof

installation.

(4) If a similar failure is repeated after the module is replaced:

Check that no metal debris or water drops have been entered into the unit/module. Apart from the above points, consider environmental conditions,

if the ambient temperature is beyond the specified range, stable

operation of the system is not guaranteed.

80 PROSEC T3

Page 89

6.8

I/O module replacement

during operation

6. Troubleshooting

If an I/O module becomes abnormal during operation, the module can be replaced with a new one during the system operation. The procedure is as follows: © Connect the programmer to the CPU module, d) From the programmer, specify the module for removal. (The

module is disconnected from the T3 operation.) (D Remove the failed module. 0 Insert a new module. CD By using the programmer, cancel the function for removal.

This function can be applied to the following failures of discrete I/O modules.

• An input module does not read the specific signal (failure of the

input photo-coupier, etc.).

• An output module does not output a specific signal (failure of the

output device, etc.).

• The fuse of an output module has blown out.

CAUTION (1) Except when using this function, turn OFF power

before replacing a module. Exercise caution when

this function is used for safety.

(2) Effective I/O modules for this function are the discrete

I/O modules. (See separate T3 User's Manual-Fanctions, for

details.)

(3) Refer to 4.3 Mounting modules, for replacing I/O

modules.

User's manual • Hardware

Page 90

6. Troubleshooting

6.9

List of self-diagnostic

items

If an error is found through the self-diagnostic check of the CPU of the T3, error messages (and related information) shown in the tables on the following pages will be recorded in the T3's event

history table. If the error is so severe and continuation of operation

is not possible, the T3 turns OFF all outputs and stops the operation

(error-down). The iatest 30 error messages and the time and date of the errors

are stored in the event history table. Those error messages can be

displayed on the programmer. (Power ON/OFF is also registered.)

If the T3 has entered to error-down, connect the programmer to the T3 to confirm the error message in the event history table. The

procedure to display the event history is as follows:

via dedicated cable.

(D Turn ON the power of the programmer (T-PDS). The power of

the T3 must be turned ON in advance,

d) Type "TPDS 0" from the programmer (T-PDS) to start the T-

PDS.

time, check that "Receive timeout" is not displayed on the screen.

(D in this state, type the S and E keys to display the event history.

82 PROSEC T3

(An example of the event history display)

Bate Tlae Evoit

H-04-12 83:23:89 I/O do msver

94-84-12 89:18:88 SysteM pover on

94-83-2S 13:27:38 Systen |wer off

94-83-25 13:18:84 LP exec tlDCOiit

94-83-25 13:81:81 exec tiMoot

6. 94-83-25 12:54:86 LP exec tlseoat 1

7. 94-83-25 11:58:23 Bmndary error 255

94-83-25 18:44:88 SysCen pover on 94-83-23 14:38:47 Systen power off

18.

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Page 91

6. Troubleshooting

When “Receive timeout“ is displayed on the screen, communications between the programmer (T-PDS) and T3 are not

established. Blinking FAULT or I/O LEDs indicates a failure of the CPU. If this state continues even after the power turned ON again, replace the CPU module with a new one. If “Receive timeout“ is displayed on the screen while FAULT or I/O is ON and not blinking, check the setting environment of the programmer (T-PDS) and the connection cable. If these are correct, the communication circuit of

the CPU module or programmer may have become abnormal.

When the event history is displayed, check the error messages registered. Error message No.1 indicates the latest event registered.

The following pages of this manual explain, error messages and related information, relevant special relays, the status of LEDs after event occurrences, and their meanings. If an error occurs, identify

the cause of the error based on the error message on the screen

and take necessary measures.

In the error-down state, operations to correct the program are not accepted. In this case, execute Error reset from the programmer to return to the HALT mode before starting the correction operation. To activate RUN again, turn the operation mode switch to HALT and change to RUN (or P-RUN), or execute an operation command from the programmer.

CATION If the CPU module has an EEPROM or an IC memory

card, the program of the EEPROM or the IC memory card will be transferred to RAM when the RAM/ROM

switch is set to ROM and RUN is activated (except when the operation mode switch is set to P-RUN): in this case, the corrections on RAM memory will be lost. Therefore,

to check the operation of a program corrected in the RUN

mode, turn the RAM/ROM switch to RAM before

activating RUN.

The meanings of LED displays shown in the tables on the following

pages and onward are as follows;

• :U

0;Not Lit 3: Blinking —: No effect on state

User's manual - Hardware

Page 92

“0 X

О со

Part

Power supply

Memory

Error message and related information

Error message

System power on System power off

Expansion unit err'

Power Interrupt

Power intr resumed

RAM check error Address of

Program BCC error BCC

Batt voltage drop

Information1Information2Information

the error occurred

error data

Relevant

special

Error data Test data S0004

relay

S0005 S0024

S001D

S001C

S0012

S0006 S0030

SOOOF

LED displays

RUN FAULT

О •

о • о

о • О

о •

—

Meaning of the error and

I/O

Power ON (no error) Power OFF (no error)

The 5-volt power of the expansion unit, or

•

the termination of the expansion IF module is not normai. Check whether power suppiy to the expansion unit is oveiioad; the power suppiy of the basic unit Is ON but the power supply of the expansion unit is OFF; and the expansion IF module is terminated correctly.

A power interruption is detected. When the power interruption detecting function is used, the operation is stopped if a power interruption longer than the specified time is detected.

The power interruption has been

recovered.

When the hot restart function is used, the

operation is restarted without initialization,

An abnormality has been found in executing rea^write check on the user data memory (RAM), if the abnormality continues after the power supply is turned ON again, replace the CPU module.

BCC check of the user program

memory (RAM) has detected an abnormality. After "clear memory" is executed, reload the program.

When turning the power ON, the voltage

■ ■“

drop of the battery to back up the RAM memory has been detected. (The ВАТТ LED is off. No error-down.) Replace the battery with a new one.

countermeasures

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Page 93

со

со"

X D

Part

Memory

CPU

Error message and related Information

Error message

EEPROM BCC error

EEPROM warning

Sys RAM check err Address of

Sys ROM BCC error

Peripheral LSI err

Information1Information2Information

BCC error data

Number of times of writing exceeded

the error occurred

Abnormal BCC data

Error code

Relevant

special

Error data Test data S0004

relay

S0004 S0023

S0007

soon

S0004 S0010

S0004 S0016

LED displays

RUN FAULT I/O

О • О

О э О

о э

э Ф

•

Meaning of the error and

countermeasures

BCC abnormality has been detected in the user program of the EEPROM (transfer is not executed). Check the program and try writing into the EEPROM again.

The number of times of writing into the EEPROM has exceeded the service life (100,000 times). Because the possibility of an abnormaiity in writing into the EEPROM wiil rise, replace the CPU module with a new one.

Read/write check of the system memory (RAM) has detected an abnormality. If the abnormality continues after turning

ON the power again, replace the CPU module.

The BCC check of the system ROM has detected an abnormality, if the abnormaiity remains after the power is turned ON again, replace the CPU module.

Checking the peripheral control LSI of the CPU module has detected an abnormality. If the abnormality continues after the power is turned ON again, replace the CPU module.

О)

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Page 94

■0

CO m

Error message and related information

Part

CPU

I/O

Error message

Clock-calendar err

Illegal sys Intrpt

WD timer error

I/O bus error

1/0 mismatch Unit No. -

I/O no answer

I/O parity error Unit No. -

Information

Interrupted ' address 1

Address 1

Unit No. Data

Slot No.

Unit No. Slot No.

Slot No.

Information

Interrupted

address 2

Address 2 S0004

Information

Relevant

special

relay

SOOOA

S001F

S0005 S0020

S0005 S0021

S0005 S0022

S0005 S0023

LED displays

RUN

o • o

FAULT

• •

Meaning of the error and

I/O

An abnormality has been detected in the data of the built-in calendar LSI (No error-down occurs). If the abnormality remains after the calendar is reset, replace the CPU.

The CPU module received a request for interrupt not registered (No error-down occurs). If the abnormality occurs frequently, replace the CPU module.

A watchdog timer error has been detected.

If the abnormality occurs frequently, replace the CPU module.

An abnormality has been detected in I/O bus checking. Check that the connection of cables and the mounting conditions of the modules are correct.

The I/O allocation information and the actual I/O module mounting are not identical. Set the I/O allocation information correctly.

I/O modules are not mounted in the slots where I/O allocation is specified. Mount modules in the slots, or activate the system in the RUN-F mode (forcible operation).

A parity error has been detected when transferring data from/to I/O modules. Check the mounting condition of the I/O modules.

countermeasures

O) «

□r

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mmm

Page 95

w (D T. w

-M

Part

I/O

Proc essing

Error message and related Information

Error message

Invalid I/O intrpt

Duplicate I/O reg

Illegal I/O reg

LP function error

LP reg FVW error

LP exec timeout

Scan time over

Relevant

Information1Information

Unit No. -

Slot No.

Unit No. Slot No.

Error code Error data

Port No. Error data Test data S0004

Scan time S0006

No.

Information

special

relay

S0005 S0025

S0005

S0021

S0005 S0021

S0004 S0015

S0015

S0004 S0015

S0031

LED displays

RUN

O • o • o •

o •

FAULT

•

Meaning of the error and

I/o

A request for I/O interrupt from an interrupt module not registered has been detected (No error-down occurs). Register the interrupt module, or do not mount that interrupt module.

An overlap is detected in allocating I/O

• registers to I/O modules. Correct the I/O

allocation Information.

The allocation of I/O modules to I/O

• registers has exceeded the limit. Reduce

the number of allocations to I/O modules. An abnormality is detected in the language

processor (LP). If the abnormality remains after power cycle, replace the CPU module.

At initial setting of the language processor

(LP), an abnormality has occurred in the read/write checking. If the abnormality remains after power cycle, replace the CPU module.

The execution of the language processor

(LP) did not finish within a time specified. Reduce the program execution time or use

the "WOr instruction.

If the situation is repeated after power

cycle, replace the CPU module.

The scan time exceeded 200 ms.

Reduce the scan time or use the "WDT" instruction.

countermeasures

O) H

(n D" O O

Page 96

00 00

73 O

(/>

Part

Program

Error message and related information

Error message

END/IRET error

Pair inst error

Operand error Program

Invalid program

Jump target error

Information1Information Program

type-

Block No.

Program typeBlock No.

typeBlock No.

Program typeBlock No.

Program

type-

Block No.

2 Address in the block

Address in the block

Address in the

block

Information

Jump label

No.

Relevant

special

relay

S0006 S0030

soooe

S0030

LED displays

RUN FAULT I/O

• O

O • O

o • O o • o

Meaning of the error and

countermeasures

The "END” instruction has not been found in the main program or in the subprogram, or the "IRET” instruction has not been found in the interrupt program. Write the "END" instruction or the "IRET" instruction at the end of the program.

An abnormality has been found in combination of the MCS/R and JCS/R instructions. Check the combination of MCS/R and JCS/R instructions is correct.

Specifying the operand for the coil instruction or the FUN instruction is abnormal. Check that an input (X) is not allocated to an output operand.

An abnormality is detected in the program management information. Execute "Clear memory" and re-load the program.

The "LBL" instruction for the "JUMP" instruction is not programmed in the same program type. Or, the "LBL" instruction is programmed at an address before the "JUMP" instruction (backward jump). Insert the "LBL" instruction at the right position.

cn o

^mm

Page 97

Part

Program

Error message and related information

Error message

No sub-r entry

No RET error

Sub-r nesting err

Loop nesting error Program

SFC step No. error

SFC macro No. err

information1Information

Program typeBlock No.

Program typeBiock No.

Program typeBtock No.

type-

Block No.

Program type-

Block No.

Program typeBiock No.

Relevant

information

2 Address in the

block

Address in the biock

Address

in the

biock

Address In the block

Step No. S0006

Macro No.

Subroutine No.

special

relay

S0006 S0030

S0030

S0006 S0030

LED displays

RUN FAULT

o O

•

• 0

•

• 0

• o

•

Meaning of the error and

I/O

The "SUBR" instruction of the subroutine

No. specified by the "CALL" instruction is not programmed. Insert the "SUBR" instruction.

The "RET" instruction is not programmed in the subroutine. Insert the “RET" instruction.

The number of nesting of subroutines

exceeds six overlays. Change the program to reduce the number of nesting overlays to six or fev^rer.

The number of nestings of "FOR" and "NEXT" instructions exceed six overlays.

Reduce the number of overlays of the "FOR" and "NEXF instructions to six or fewer in the program.

Step No. is duplicated in the SFC program, or the step Nos. specified by the initial step and the end step are not identical. Change the step No., or check the step No. of the end step.

Macro No. is duplicated, or the same

macro program is called from two or more locations. Change the macro No. Or, limit the catling of the macro program to one location.

countermeasures

^mrn

Page 98

■0 3D

O CO

Part

Program

Error message and related information

Error message

No SFC macro entry Program

Information

typeblock No.

Information

Macro No.

Information

Relevant

special

relay

S0006 S0030

LED displays

RUN

o •

FAULT I/O

Meaning of the error and

countermeasures

The macro program specified by macro step is not programmed. Check that the macro program has been programmed, and that the macro No. is correct.

■

o c cr

(0 3T

o o

SFC jump label err

No SFC jump label

Duplicate SFC No.

Invalid SFC prog

Illegal inst

Invalid Fun inst

Boundary error

Duplicate entry No.

Program typebloclr No.

Program typeblock No.

Program

type-

block No.

Program typeblock No.

Program

type-

block No.

SFC label No.

SFC program No.

Address in the block

Address In the block

S0006 S0030

FUN No.

FUN No. 50064

Entry No.

S0006 S0030

or 50065

S0006 S0030

o • o •

O •

— —

The SFC label No. is duplicated. Change

the SFC label No.

The SFC label instruction specified by the

SFC jump instmction is not programmed. Insert the SFC label instruction.

The SFC program No. is duplicated.

Change the SFC program No.

The correspondences between the initial

step and end step or SFC end, or macro entry and macro end do not match. Change the program so that the correspondence match.

An illegal instruction has been detected in

the program.

After executing "Clear memory," reload the program.

An instruction which is not su|:^orted by

T3 has been detected. Erase the relevant

instruction.

The operand specified by Indexed FUN

—

instruction has exceeded the limit. Check

the value of the index register.

•

"LBL" or "SUBR" instruction is duplicated.

Check the program.

Page 99

Part

memory

card

Error message and related Information

Error message

1C card BCC error

1C card type error

Information1Information2Information

Relevant

special

relay

S0004 S0014

LED displays

RUN FAULT I/O

Meaning of the error and

countermeasures

BCC error has been detected in the

user program stored In the tC memory card (transfer is not executed).

When the Initial load is executed from the

IC memory card at power up, loading cannot take place because the program capacity In the IC memory card Is greater than the RAM capacity of the T3

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Page 100

TOSHIBA

TOSHIBA INTERNATIONAL (EUROPE) LTD.

1 Roundwood Avenue StocKley Park. Uxbridge Middlesex. ENGLAND UB11 1AR Tel: 0181 -848 4466 Fax: 0181 -848 4969

TOSHIBA INTERNATIONAL CORPORATION

Industrial Division 13131 West Little York Road Houston. TX. 77041. U.S.A. Tel: 713-466-0277 Fax:713-466-8773

TOSHIBA INTERNATIONAL CORPORATION PTY. LTD.

Unit 1. 9 Orion Road. Lane Cove N.S.W. 2066. AUSTRALIA Tel: 02-428-2077

TOSHIBA CORPORATION

Industrial Equipment Department

1-1. Shibaura 1-chome, Minato-ku

Tokyo 105, JAPAN Tel: 03-3457-4900

Toshiba T3 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Important Information

General Information

Hazard Classifications

Safety Precautions

Installation:

Wiring:

Operation:

A CAUTION

Maintenance:

A CAUTION

Safety Label

T3 User's Manual - Hardware

T3 User's Manual - Functions

T-series Instruction Set

T-PDS Basic Operation Manuai

T-PDS Command Reference Manual

T-series Computer Link Function

Contents

Contents

Power supply module

CPU module

Rack

Expansion interface module

Expansion cable

Unit configuration

POWER LED (green):

Fuse:

Run signal output terminals

Voltage switch terminals:

Power supply input terminals :

Line filter ground terminal (LG):

Frame ground terminal (FG):

Status display LED:

RAM/ROM switch

Operation mode switch :

Battery cover:

RS232C port for the programmer :

RS485 port for the computer link:

IC memory card slot:

Expansion cable

General Specifications

External Dimensions

32-point DC input

32-point AC input

16-point DC output

32-point DC output

64-point DC output

16-point AC output

32-point AC output

32-point relay output

Grounding

Grounding of controi panei

Maintenance parts

Replacing fuses

TOSHIBA INTERNATIONAL (EUROPE) LTD.

TOSHIBA INTERNATIONAL CORPORATION