WEG PLC300 User Manual
Programmable Logic Controller
PLC300
User’s Manual
Motors | Automation | Energy | Transmission & Distribution | Coatings
User’s Manual
Series: PLC300
Language: English
Document Number: 10004642446 / 00
Models: with and without HMI
Publishing Date: 04/2017
Index
1 SAFETY INSTRUCTIONS ....................................................................... 1-1
1.1 SAFETY WARNINGS IN THIS MANUAL ...................................................... 1-1
1.2 SAFETY WARNINGS IN THE PRODUCT .................................................... 1-1
1.3 PRELIMINARY RECOMMENDATIONS ....................................................... 1-2
2 INTRODUCTION TO PLC300 ................................................................ 2-1
3 CONNECTORS ........................................................................................3-1
3.1 CONNECTORS PINOUTS ............................................................................3-2
4 CONNECTIONS ......................................................................................4 -1
4.1 SUPPLY .......................................................................................................... 4-1
4.2 CAN NETWORK ............................................................................................ 4 -1
4.3 DIGITAL INPUTS .......................................................................................... 4 -1
4.4 DIGITAL OUTPUTS ....................................................................................... 4-2
4.5 ANALOG INPUT ............................................................................................ 4-3
4.6 ANALOG OUTPUT ........................................................................................4-4
4.7 ENCODER INPUT .........................................................................................4-5
4.8 RS-232 INTERFACE ..................................................................................... 4-7
4.9 RS-485 INTERFACE .....................................................................................4-8
4.10 ETHERNET INTERFACE ............................................................................. 4-9
5 DESCRIPTION OF THE KEYS ..............................................................5-1
6 EXPANSIONS ..........................................................................................6-1
7 CONFIGURATION OF THE PLC300 ......................................................7-1
7.1 SET CLOCK .................................................................................................. 7-1
7.2 LANGUAGE SELECTION .............................................................................. 7-2
7.3 LCD CONTRAST ........................................................................................... 7-2
7.4 KEYBOARD BEEP ......................................................................................... 7-2
7.5 ANALOG INPUT ............................................................................................ 7-2
7.6 IOA CARD (AOS) ........................................................................................ 7-3
7.7 ENCODER SUPPLY ...................................................................................... 7-3
7.8 RS-232 SETUP .............................................................................................. 7-3
7.9 RS-485 SETUP .............................................................................................. 7- 4
7.10 CAN SETUP ................................................................................................ 7-5
7.11 LAN SETUP ................................................................................................. 7- 5
7.12 MB TCP SETUP ........................................................................................... 7-6
7.13 SD CARD – BACKUP HMI VERSION ......................................................... 7-7
7.14 USER PROGRAM ...................................................................................... 7-10
7.15 SETUP MENU PASSWORD ...................................................................... 7-10
7.16 WATCHDOG ................................................................................................7-11
8 I/O STATUS..............................................................................................8 -1
9 DESCRIPTION OF THE PLC300 OPERATION .....................................9-1
9.1 SCREEN MANAGEMENT ............................................................................. 9-1
9.1.1 Levels of Access .................................................................................. 9 -1
9.1.2 Function Keys: F1...F12.......................................................................9-2
Index
9.1.3 Composition of a Screen ...................................................................9-3
9.1.4 Text Component: Writing of Static Text ...........................................9-3
9.1.5 Numeric Input Component: Data Numeric Input ............................9-3
9.1.6 Numeric Output Component: Data Numeric Output ......................9-5
9.1.7 Message Component: Output with Texts for a Variable ................ 9-5
9.1.8 Bar Graph Component: Bar Graph ................................................... 9-6
9.1.9 Text Output .......................................................................................... 9-7
9.1.10 Text Input ........................................................................................... 9-7
9.2 AUTOMATIC SOFTWARE RECOVERY - ASR ............................................ 9-7
10 ALARMS ..............................................................................................10-1
10.1 INTERNAL ALARMS ................................................................................. 10 -1
10.2 USER ALARMS ......................................................................................... 10-2
10.3 ALARM SCREENS .................................................................................... 10-2
11 OPERATION OF THE LEDS ................................................................ 11-1
12 BATTERY REPLACEMENT ................................................................12-1
13 DESCRIPTION OF THE MODELS .....................................................13 -1
14 SELF-TEST ..........................................................................................14 -1
15 TECHNICAL SPECIFICATIONS .........................................................15 -1
15.1 STANDARDS MET ..................................................................................... 15-3
16 DIMENSIONS ......................................................................................16 -1
16.1 MECHANICAL MOUNTING ...................................................................... 16-3
Safety Instructions
PLC300 | 1-1
1 SAFETY INSTRUCTIONS
This manual contains the information for the correct use of the programmable controller
PLC300.
It was developed to be used by people with proper technical training or qualification to
operate this kind of equipment.
1.1 SAFETY WARNINGS IN THIS MANUAL
In this manual, the following safety warnings are used:
DANGER!
The procedures recommended in this warning have the purpose of protecting
the user against death, serious injuries and considerable material damages.
ATTENTION!
The procedures recommended in this warning have the purpose of avoiding
material damages.
NOTE!
The information mentioned in this warning is important for the proper
understanding and good operation of the product.
1.2 SAFETY WARNINGS IN THE PRODUCT
The following symbols are attached to the product, serving as safety notices:
High voltages are present.
Components sensitive to electrostatic discharge.
Do not touch them.
Mandatory connection to the protective earth (PE).
Safety Instructions
1-2 | PLC300
1.3 PRELIMINARY RECOMMENDATIONS
DANGER!
Only qualified personnel, familiar with PLC300 and related equipment must
plan or perform the installation, commissioning, operation and maintenance
of this equipment.
The personnel must follow the safety instructions described in this manual
and/or defined by local standards.
The noncompliance with the safety instructions may result in death risk
and/or equipment damage.
NOTE!
For the purposes of this manual, qualified personnel are those trained in
order to be able to:
1. Install, ground, power up and operate the PLC300 in accordance with
this manual and the safety legal procedures in force.
2. Use the protective equipment in accordance with the standards.
3. Give first aid.
DANGER!
Always disconnect the general power supply before touching any electrical
device associated to the PLC.
ATTENTION!
The electronic cards have component parts sensitive to electrostatic
discharge. Do not touch directly the component parts or connectors.
NOTE!
Fully read this manual before installing or operating this equipment.
Introduction to PLC300
PLC300 | 2-1
2 INTRODUCTION TO PLC300
PLC300 is a PLC with integrated HMI, developed to meet the need of interface with the
user on panels and machines and at the same time a complete expandable PLC, fast
and with several communication ports, enabling the product to be master of CANopen
networks (CAN network) and/or Modbus RTU (RS-485 network) as well as Modbus TCP
(Ethernet network).
Some important characteristics:
High processing speed:
The PLC300 uses a 32 bit ARM Cortex-M3 processor, running at 120 MHz, which provides
a high processing speed.
HMI - Human-Machine Interface:
The PLC300 has an integrated HMI with LCD display with backlight of 4 lines and 20
characters each, in addition to the keyboard with function keys programmed by the user,
all with LEDs, <ALARM> key, <HOME> key, etc., and alpha-numeric keyboard.
Version without HMI:
It is possible to assemble the PLC on a DIN rail, in a version without HMI (keyboard and
display). In this case, the back part of the product becomes the front and features a small
display of 2 lines and 16 characters with a button to check the I/O status.
Programming:
In addition to the ladder programming, the WPS allows the assembly of the screens,
graphically, configuration of the alarms, assignment of the function keys, configuration of
the equipment, besides the firmware, which can be updated directly via PC.
The programming can be done via USB, Ethernet or Serial RS232 and RS485.
Hot Download:
Allows hot loading of the resource, that is, it is possible to change the ladder program,
screens, alarms and logs with the current program running, and after the conclusion of
the download, the new program is executed automatically. For further information, refer
to the WPS manual.
Large memory capacity:
The PLC300 features a static RAM memory with battery and capacity of 1 MByte to store
screens, alarms, program and other user’s data. The memory allocation can be configured
by the user via the WPS.
Bootloader:
The bootloader is an auxiliary program that executes the main firmware of the PLC300,
which, in turn, executes all the functionalities.
It is through the bootloader that new firmware can be saved to the PLC300 via USB or Serial.
Introduction to PLC300
2-2 | PLC300
If during the update/saving of the firmware, the process is interrupted for some reason,
the message “Bootloader V6.xy” will be displayed on the screen and the red LEDs of the
Status, CAN and Serial will keep flashing. If that happens, just download the updated
firmware via WPS.
SD memory card (Secure Digital):
The PLC300 allows saving data and program, logging events, recipes in a SD memory card.
The memory card must be SD type with FAT32 formatting with capacity up to 32G. The
faster the card (class of the card), the shorter the recording time. This is important in case
of regular variable log recordings, for instance. It is recommended the use of class 10 cards.
Automatic Software Recovery - ASR:
It automatically recovers the PLC300 software, including configurations and retentive
markers.
See Section 9.2 AUTOMATIC SOFTWARE RECOVERY - ASR on page 9-7 of this manual.
RTC – Real Time Clock:
Real time clock that allows recording events such as alarms and logs, besides specific
blocks such as alarms or interruptions.
Digital, PWM and analog outputs:
8 digital, galvanically insulated, protected, 500 mA (each), 24 Vdc, PNP outputs.
The 10 bit analog output has independent terminals for current or voltage.
Fast output up to 300 kHz with capacity of 100 mA in 24 Vdc can be programmed in PWM.
It can be used as standard digital output.
Digital and analog inputs:
Ten isolated, digital inputs are available, at 24-Vdc level, able to produce interruption.
Two of them are fast and can be used to count pulses of up to 100 kHz, or as encoder
input in quadrature.
A 12-bit, differential, analog input is also available.
Encoder input:
Quadrature encoder input, with additional signals and detection of split cable with optional
alarm.
Maximum frequency: 100 kHz.
Introduction to PLC300
PLC300 | 2-3
Watchdog:
The PLC300 has a user-configurable watchdog with minimum time of 300 ms.
In case of watchdog, the state of the outputs can be configured, as well as an output for
exclusive use of the watchdog.
Expansion modules:
Up to 2 I/O expansion modules can be connected to the PLC300. The following modules
are compatible:
IOA-01: 1 analog input of 14 bits in voltage and current; 2 digital inputs; 2 analog outputs
of 14 bits in voltage and current; 2 open collector digital outputs.
IOB-01: 2 analog inputs insulated in voltage and current; 2 digital inputs; 2 analog outputs
insulated in voltage and current (same output programming of the standard CFW-11); 2
open collector digital outputs.
IOC- 01: 8 digital inputs; opto-coupled; 24 Vdc; high/low level actuation; 4 digital outputs;
relay NO contacts; capacity of 240 Vac/1 A.
IOC-02: 8 digital inputs; opto-coupled; 24 Vdc; high/low level actuation; 8 digital outputs,
open collector; 24 V/0.1 A.
IOC-03: 8 digital inputs; optocoupled; 24 Vdc; configurable, high/low level actuation;
7 PNP, protected outputs; 24 Vdc; 500 mA.
IOE-01: 5 inputs of single or triple PTC thermistors with reinforced insulation compared
to the 0 V of the PLC300.
IOE-02: 5 inputs of PT100 thermistors with reinforced insulation compared to the
0 V of the PLC300.
IOE-03: 5 thermistor inputs type KTY84 with reinforced insulation in relation to the
0 V of PLC300.
Communication interfaces:
The PLC300 has the following communication interfaces:
RS-485 insulated with Master/Slave Modbus RTU protocol.
CAN insulated with Master/Slave CANopen protocol.
RS-232 with Modbus RTU protocol for monitoring and remote programming, via modem
on telephone line, and ASCII protocol for bar code readers.
USB to communicate with the computer.
Ethernet 10/100 with Modbus TCP protocol.
Introduction to PLC300
2-4 | PLC300
Power Supply:
The PLC300 needs external supply of 24 Vdc +/-15 % with capacity of at least 500 mA.
Internally, there is an insulated DC/DC converter that provides the voltages necessary for
the product. Being insulated, it allows the user to use the same source to supply other
devices, such as the digital inputs and outputs.
Keys with functionalities at power on:
If some keys are pressed when switching on the PLC300, the following functions are
executed:
Key
Pressed Time
at Power on (t)
Functionality
SETUP t > 5 seconds. Loads factory default.
ALARM t > 5 seconds. Stops user program.
DEL t > 5 seconds. Cleans memory (deletes application, screens, …).
F6 -- Performs self-diagnosis, further details in Chapter 14 SELF-TEST
on page 14-1.
Important Note:
From the V1.50, in order to upload the factory default, stop the user’s program or clean the memory by mean
of the power on, it is necessary to type the SETUP current password for the function to be executed.
Type the current SETUP password and then press <ENTER>. In case the password is incorrect or if you
press <ESC>, the action will not be executed.
Note that when you upload the factory default or clean the memory, the SETUP password goes back to the
factory default value: '0000'.
NOTE: to clean the memory (deletes application, screens, etc.) on versions without HMI (BP and BS), turn on
the PLC300 holding the button and release it after the message “Release the Key” appears. Press the button
again for two seconds and release.
Connectors
PLC300 | 3-1
3 CONNECTORS
a)
XC3 S1 XC6
XC4
XC1
XC8
XC7
XC2
XC1 – digital and analog inputs.
XC2 – digital, PWM and analog outputs.
XC3 – encoder RS-232 and RS-485 input.
XC4 – Ethernet.
XC5 – USB.
XC6 – CAN.
XC7 – SD card.
XC8 – Power input 24 Vdc.
S1 – Turn on/off RS-485 termination resistors.
b)
Battery
Back
display
Back
key
XC11
Slot1
XC12
Slot2
XC5
XC11 – expansion slot 1
XC12 – expansion slot 2
Figure 3.1 (a) and (b) - Position of the connectors
Connectors
3-2 | PLC300
3.1 CONNECTORS PINOUTS
XC1 – Digital and Analog Inputs
Tab l e 3 .1: Function of the digital and analog input pins
Pin Function
1 DI1 - digital input 1.
2 DI2 - digital input 2.
3 DI3 - digital input 3.
4 DI4 - digital input 4.
5 DI5 - digital input 5.
6 DI6 - digital input 6.
7 DI7 - digital input 7.
8 DI8 - digital input 8.
9 DI9 - digital input 9 (fast)
(*)
.
10 DI10 - digital input 10 (fast)
(*)
.
11 Common of the inputs DI1...DI8.
12 Common of the inputs DI9...DI10.
13 (AI1+) analog input 1 (+).
14 (AI1-) analog input 1 (-).
(*) DI9 and DI10 can be used for reading encoder signals, A and B,
respectively.
XC2 – Digital, PWM and Analog Outputs
Table 3 . 2: Function of the digital, PMW and analog output pins
Pin Function
1 DO1 - digital output 1.
2 DO2 - digital output 2.
3 DO3 - digital output 3.
4 DO4 - digital output 4.
5 DO5 - digital output 5.
6 DO6 - digital output 6.
7 DO7 - digital output 7.
8 DO8 - digital output 8.
9 DO9 - fast output 9 (PWM).
10 GNDBB – 0 V digital outputs.
11 VBB – (20...30 Vdc) for the digital outputs.
12 AO1(V) – analog output 1 in voltage.
13 AO1(I) – analog output 1 in current.
14 AO1 – common.
Connectors
PLC300 | 3-3
XC3 – Encoder input, RS-232 and RS-485
Table 3 . 3: Function of the pins of the encoder, RS-232 and RS-485 input
Pino Função
1 A - encoder A signal.
2
A - encoder A signal.
3 B - encoder B signal.
4
B
- encoder B signal.
5 Z - encoder Z signal.
6
Z - encoder Z signal.
7 +5/12 Vdc - encoder supply.
8 0 V – encoder supply.
9 RS-232 rate.
10 RS-232 RX.
11 RS-232 GND.
12 RS-485 signal A (-).
13 RS-485 signal B (+).
14 RS-485 GND (insulated).
XC6 – CAN
Table 3 . 4 : Function of the pins of the XC6 - CAN
Pin Function
1 V -
2 CANL
3 SHIELD
4 CANH
5 V + (11 to 30 Vdc)
XC8 – Power Supply
Table 3.5: Function of the pins of the XC8 - Power Supply
Pin Function
1 V+ (20 to 28 Vdc)
2 GND
3 Ground
XC4 – Ethernet
Ethernet standard connector.
Connectors
3-4 | PLC300
Connections
PLC300 | 4-1
4 CONNECTIONS
4.1 SUPPLY
The PLC300 must be powered by a power supply of 24 Vdc ± 15 % with capacity of at
least 500 mA.
The grounding connection is important.
1 2 3
Figure 4.1: XC8: Power connector of the PLC300
4.2 CAN NETWORK
See the CANopen manual.
4.3 DIGITAL INPUTS
The 10 insulated digital inputs must be excited by an external source of 24 Vdc. The inputs
are bidirectional, which means the input common can be connected to either the GND or
the VDC of the supply.
Two common pins are provided: one for DI1 to DI8 and another for DI9 to DI10.
Thus, you can connect one group in VDC and another in the GND, providing more flexibility
to the project by allowing both contacts NPN and PNP of any device to be connected to
the PLC300 inputs.
All the DIs can generate interruption in the user program and can be used as count task.
The DIs 9 and 10 are faster and can read a signal of up to 100 kHz, and they can also
operate as encoder input. The other DIs can count up to 4 kHz.
The drive levels for the DIs are from 10 to 30 Vdc for high level and less than 3 Vdc for
low level.
Connections
4-2 | PLC300
24 Vcc
XC1
24 Vcc
PNP
XC1
PNP or NPN
DI
1
1 74 102 85 11 12 13 143 96
DI
9
DI
5
DI
3
COM1COM2AI1
(+)
AI1
(-)
DI
7
DI
2
DI
10
DI
6
DI
4
DI
8
(-)
(-)
(+)
(+)
Figure 4.2: Example of connection of the digital inputs (XC1)
Notes about the example:
1. Inputs DI1 to DI8 are bidirectional, that is, they can operate as NPN or PNP. The fast
inputs DI9 and DI10 are PNP.
2. PNP is the type of input whose common is connected to the GND and the input is
excited by the VDC.
3. NPN is the type of input whose common is connected to the VDC and the input is
excited by the GND.
Encoder function DI9 and DI10:
Inputs DI9 and DI10 can also operate for the reading on an encoder in quadrature or to
count pulses.
In case of quadrature, connect signal A of the encoder to the input DI9, and signal B to
input DI10.
For pulse count, input DI9 will determine the count direction (incrementing or decrementing)
and input DI10 will receive the pulses.
Those configurations should be performed via WPS.
4.4 DIGITAL OUTPUTS
The PLC300 has eight insulated and protected digital outputs, besides a fast PWM output
that can generate pulses of up to 300 kHz with variable duty cycle from 0 to 100 %.
This output can also be used as a standard digital output, but it is not protected.
Connections
PLC300 | 4-3
The circuit of the digital outputs must be externally powered by a supply of 24 Vdc,
connected to the pins VBB(+) and GNDBB(-)
(1)
.
The outputs DO1 to DO8 are of PNP
(2)
type and can provide a current of up to 500 mA each.
DO9 is a Push-Pull
(3)
output, PWM type, and can supply up to 100 mA.
(1) See description of XC2.
(2) PNP Output: activate load connected to GNDBB.
(3) Push-Pull Output: Bi-directional, i.e., activates the load connected to GNDBB or to VBB.
Supply
24 Vdc
XC2
L1 L2 L3
L4
DO
1
1 74 102 85
11 12
13
143 96
DO
9
DO
5
DO
3
VBB
COM
AO1
AO1
(I)
AO1
(V)
DO
7
DO
2
GND
BB
DO
6
DO
4
DO
8
(-)
(+)
Figure 4.3: Example of connection of the digital outputs (XC2)
Notes about the example:
1. The example shows two standard loads, L1 and L2, connected to the DO3 and DO5
outputs, which, when driven, apply VBB to the load (PNP outputs).
2. Loads L3 and L4 are connected to DO9, in push-pull format, i.e., when L3 is energized,
L4 is not, and vice-versa.
4.5 ANALOG INPUT
The analog input AI1 is differential, 12 bits, and can read signals from a voltage or current
source. If the signal source is far from the PLC, it is advisable to use a shielded cable.
Connections
4-4 | PLC300
By means of the equipment setup, you can choose among the modes: voltage 0 to 10 V,
current 0 to 20 mA or current 4 to 20 mA.
When in current mode 4 to 20 mA, a broken wire alarm can be programmed. In this case,
if the input signal is below 2 mA, the alarm is generated, indicating the opening of the
current loop.
Below, a simple example of connection.
0 to 10 V
0 to 20 mA,
or
4 to 20 mA,
XC1
DI
1
1 74 102 85
11 12
13 143 96
DI
9
DI
5
DI
3
COM1COM2AI1
(+)
AI1
(-)
DI
7
DI
2
DI
10
DI
6
DI
4
DI
8
Figure 4.4: Example of connection of the analog input (XC1)
Note: AI1 operating mode must be chosen in the PLC setup: ‘Voltage 0 to 10 V’, ‘Current
0 to 20 mA’ or ‘Current 4 to 20 mA’.
4.6 ANALOG OUTPUT
The analog output AO1, 10 bit resolution, has output in current and/or voltage, with
independent terminals, which means there is no need to configure the operating mode;
simply connect the load to the correct terminal, in voltage or current.
In voltage, the output varies between 0 and 10 V. In current, the output range is from 0 to
20 mA, for a resistive load lower or equal to 500 Ω.
The voltage and current outputs can be used simultaneously, but obviously with the same
value, since they are the same output, just in different ways.
Connections
PLC300 | 4-5
XC2
L2
I
L1
+
V
-
DO
1
1 74 102 85 11 12 13 143 96
DO
9
DO
5
DO
3
VBB
COM
AO1
AO1
(I)
AO1
(V)
DO
7
DO
2
GND
BB
DO
6
DO
4
DO
8
Figure 4.5: Example of connection of the analog output (XC2)
4.7 ENCODER INPUT
The PLC300 features an insulated input for differential encoder, with its own supply of 5 or
12 V. The maximum frequency of the pulses is 100 kHz. Maximum length of the encoder
cable: 30 m. This input has a circuit that detects fault in the encoder signals, in case of
encoder with complementary signals. This fault can generate an alarm that must be
enabled on the WPS. A non-complementary encoder can also be used, but, in this case,
the fault circuit must remain disabled.
An internal insulated supply of 5 or 12 Vdc, with capacity of up to 300 mA, is available for
the encoder. The selection between 5 or 12 V must be done in the PLC setup. The default
value is 5 V.
The ladder offers a READENC block (encoder counter), that must be used to count.
A system marker indicates the encoder speed in hertz (Hz). The direction of rotation is also
informed by a system marker.
Connections
4-6 | PLC300
(*)
5/12 V
A A B B Z Z 0 V
ENC
XC3
+V*
ENC
A
ENC
A
ENCBENCBENCZENCZENC
+V*
ENC
0 V
232TX232RX232
GND
485A485B485
GND
1 74 102 85 11 12 13 14
3
96
Figure 4.6: Encoder connection
24 V Encoder : You can connect a 24 V encoder, since externally powered and only signals
A, B, and Z are used.
The 0 V of the encoder must be connected to 0 V of XC3 (pin 8)
A, B and Z
signals are NOT tolerant to 24 V.
The signals A, B and Z can be used to fast counting and interrupts, also in 24 V.
Encoder PNP: if an encoder with PNP outputs is used, resistors of 1 K ohm must be
connected from the used signals to the 0 V.
E.g.: PNP encoder with A and B signals.
Connections
PLC300 | 4-7
A
1KR 1KR
B
0 V
(*)
5/12 V
ENC
XC3
+V*
ENC
A
ENC
A
ENCBENCBENCZENCZENC
+V*
ENC
0 V
232TX232RX232
GND
485A485
B
485
GND
1
7
4
10
2 85
11 12
13
14
3
9
6
Figure 4.7: PNP encoder connection with signals A and B
4.8 RS-232 INTERFACE
This non-insulated RS-232 serial interface is intended to point-to-point communication.
It was developed for remote connection, through a modem connected to the telephone
line. All the operations performed by the USB via WPS, can be done by this interface, i.e.,
programming, monitoring, setup, etc.
The configuration of this interface is done by the setup menu.
ATTENTION!
Do not connect the GND of the RS232 (pin 11) to the ground of the system.
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