kv-5000/3000 tutorial for...

KV-5000/3000 Tutorial for Beginners

(Basic Ladder Circuit)

This tutorial is for people who are using a programmable logic controller for the first time. It extracts frequently used commands from the User's Manual and describes them accordingly. In addition, it is possible to input commands to the KV-5000/3000 and do programming based on the explanations in this book. However, if you want to try it without connecting to the KV-5000/3000, please replace the R000 to R005 with MR000 to MR005, etc. and perform the contacts' ON/OFF operation using the ladder diagram software. (When operation is based on a simulator, it can also be performed without changing the R000 to R005.) Please read this tutorial in combination with the actual KV-5000/3000.

KEYENCE Corporation Control System Division

sakuramachi-takashi

Typewritten Text

[KV0971GB]

sakuramachi-takashi

Typewritten Text

sakuramachi-takashi

Key Stamp

- 1 -

Content

Chapter 1 What is KV-5000/3000?

What is the KV-5000/3000? ........................... P2 Control in FA ................................................ P3 What is Sequential Program Control? ............ P4 Functions of the KV-5000/3000 ...................... P5

Chapter 2 Programming of the KV-5000/3000

What is a Ladder Program? ........................... P6 Programs of the KV-5000/3000 ...................... P7 Structure of Devices of the KV-5000/3000 ...... P8 Startup of the KV STUDIO ........................... P9 New Programming Method with Ladder Diagram and Initial Setting of the Units ....................... P10 Writing Ladder Programs (① LD OUT) ........... P12 Transfer and Monitoring of Ladder Programs.. P14 Writing Ladder Programs (② LDB OUT) ...............P16 Writing Ladder Programs (③ AND circuit) ...... P18 Writing Ladder Programs (④ OR circuit) ........ P19 Writing Ladder Programs (Self⑤ -hold circuit) P20 Relationship between Control and Time ......... P21 Control Based Upon an ON Delay Timer...............P22 Application of the an ON Delay Timer ...................P23 Control Based Upon an OFF Delay Timer ....... P24 Control Based Upon a One-Shot Timer .......... P25 Summary of Control Based Timers ................. P26 Flexible Use of Counters ............................... P27 Control of Counters ..................................... P28 Ideas About Scan Time/Dual Coil ................... P30 Principle of A Dual Coil ................................. P31 Questions Sum-up ........................................ P32 Answers to Questions ................................... P33 Convenient Commands ............................... P35 Simulator Function ...................................... P37

- 2 -

Chapter 1 What is the KV-5000/3000?

[What is KV-5000/3000?]

KV-5000/3000 is a programmable logic controller with a built-in CPU and memory. It is a device that can conveniently and freely control external output devices (such as indicator lights or cylinder shape coils) through the operation of various external input devices (push buttons, limit switches, etc.) equipped on the control panel and equipment. From a PC with the dedicated ladder support software (KV STUDIO) installed, programs can be written into the internal memory of the KV-5000/3000.

★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★ To use the KV-5000/3000, computer knowledge is not necessary. Simply imagine the KV-5000/3000 as a box which contains a large number of relays, timers, and counters.

☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆

Push button

Switchover switch

Limit switch

Relay contact

Photoelectric sensor

Proximity sensor

Various sensors

Other

Indicator light

Digital indicator

Cylinder shape coil

Solenoid valve

Electromagnetic clutch

Contactor

Motor

Other Various external input devices

Inputcircuit

Memory

Micro Computer

Output circuit

Various external output devices

KV-5000/3000

Control section

- 3 -

[Control in FA]

Control in FA is briefly described below. What is "FA"? ＝ Factory Automation

To make manufacturing systems automatic, labor saving, and unattended.

What is "Control"? ＝ The operation that is performed to make the machinery/devices keep their target status. Why should we strive for automation? The following are some advantages of automation:

・ Reduction in production costs

・ Increase in production output

・ Extended running time

・ Decrease in the rate of defects.

★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★ "Control" mentioned in FA industry refers to:

"Sequential Program Control"

Sequence Control (Continuous) (To realize desired operationtate)

Control is performed according to a sequence determined in advance.

☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆

- 4 -

[What is Sequential Program Control?]

The flow of sequential program control will be explained by using a real-life example of a piece of equipment. Example

■ When playing a claw machine ■ When using a fully automatic

game in an arcade. washing machine.

① Determine the object ① Inject water ② Align the horizontal position ② Wash ③ Align the back and forth position ③ Drain water Grab the presents ④ ④ Inject water ⑤ Wash ⑥ Drain water ⑦ Dry

★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★ The PLC will verify the condition changes under the above-mentioned sequential program control, and is responsible for performing control tasks until the next process. It is referred to as a “programmable controller".

☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆

［What is a PLC?］

"PLC" is short for "Programmable Logic Controller". It means "a logic controller device that can be programmed". To put it simply, it is a computer that is used in a factory.

- 5 -

[Functions of the KV-5000/3000]

The KV-5000/3000 Series are PLCs with high performance and high expansibility. In this tutorial, we will only discuss the basic aspects of the controller. However, it can also be used in the following controls, in order to deepen the understanding of the KV-5000/3000 PLCs.

■ An example of the functions/expansibility of the KV-5000/3000 Series

● Analog control Through super high conversion speed of 25 μ s/ch and analog control with a resolution of 1/20000, the measurement data of the displacement sensor can be loaded into the PLC in real time.

● Positioning control It is possible to control the motor used for positioning. Possible to perform correct positioning control of the XY table etc. (CPU unit also has a built-in positioning function.)

●Ethernet function Communication with PC/external equipment communication used for production management or operation management etc., possible to realize the communication between the field PLC and PC. Also possible to realize a high speed connection to multiple touch panels and image sensors.

●FL-net function It is possible to realize a high speed/high volume data connection to PLCs of various manufacturers using the CPU unit.

● Logging/tracking function

Through the built-in memory card slot in the main unit, it is possible to write data onto a memory card.

Ethernet

FL-net

Other PLCsOther PLCs

Displacement sensor

Pressure sensor Flowmeter

CPU functions Functions that can be realized through special units

- 6 -

Chapter 2 Programming of the KV-5000/3000

To make the PLC perform controller operation, a program is required. This program is called a “ladder program”. In Chapter 2, we will describe the steps for actual programming.

[What is a Ladder Program?]

A ladder program is a program in which the wiring diagram has been simplified. What steps need to be taken to complete a ladder program? Please look at the following diagram.

Wiring diagram of units Sequential program diagram Ladder program First, verify the wiring diagram of units. This is the wiring diagram for a battery and a switch that we have tested in previous physical experiments. Actually, this switch may be a sensor or a limit switch, and the light may be a solenoid valve, a motor, etc. In such a case, the actual unit wiring is relatively hard to view. We can then put the "+" and "-" end of the battery on the left and right side respectively, and represent the switch (PB) and the light (PL) using symbols, then a easy-to-view sequential program diagram is completed. A sequential program diagram is composed of graphs and symbols developed in order to simplify the wiring diagram when performing relay sequential program control. However, it is necessary to further simplify it when performing control through a PLC. The reason is that the actual inputs and outputs are not limited to PB (push buttons) or PL (indicator lights), a variety of other equipment may also be included. No matter what equipment is connected, they all can be represented only by the connected terminal numbers. The R000 or R500 shown in the diagram is the number for the PLC.

★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★ The shape of the completed program is like a ladder, so it is called "ladder program".

☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆

PB1 PL1 R000 R500

END

ENDH

+ －

- 7 -

[Programs of the KV-5000/3000]

A program of KV-5000/3000 is written using many commands. These commands are composed of an instruction (symbol) and a device number (element number), and are divided into basic commands, application commands, arithmetic commands, etc. Generally, basic commands can be used to write a program, and application commands can be used to simplify a program or to perform more complicated control. A device number (element number) refers to the number of an input relay, an output relay, a timer, a counter, or an internal auxiliary relay, etc. It can freely use any number within the number range in the KV-5000/3000 PLC.

★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★ For the range of device numbers that can be used, please refer to the list of devices in section "1-3 Devices and Constants" in the "KV-5000/3000/1000 Instruction Reference Manual".

☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆

R000 R500

Device no.

Instruction(symbol)

- 8 -

[Structure of Devices of the KV-5000/3000]

The main devices of the KV-5000/3000 are divided into the following types. Please verify according to each device.

◆Bit device◆

【Input relay】 R The device used to load ON/OFF information from external equipment.

【Output relay】 R The device used to output ON/OFF information from external equipment.

【Internal auxiliary relay】 MR The device that can only be used inside a CPU ※ When a relay circuit is used and the same relay contact is used many

times in the circuit, sometimes multiple relays with the corresponding number of times of use have to be used. Since the internal auxiliary relay functions only on the program level, it completely eliminates the complexity of the relay circuit, making circuit design easier.

【Control relay】 CR The device used to control functions of the PLC or get its states. ※ The control relay has been assigned with special functions in advance

according to the device number. 【Timer】 T

1ms/10ms/100ms down timer and 10ms up/down timer ※ It is possible to assign settings respectively according to different devices.

The number of counts that can be used is 4000. 【Counter】 C

Up counter/up and down counter ※ It is possible to assign settings respectively according to different devices.

The number of counts that can be used is 4000. In addition, there are also latching relay (LR), link relay (B), etc.

◆Word device◆

【Data memory】 DM The device used to store digital data in the PLC. Data will be processed in 16-bit unit. ※ For example, it is used when performing arithmetic operation in the PLC.

The data stored in the data memory will be kept even if the PLC is turned off.

【Control memory】 CM The device used to control functions of the PLC or get its states. ※ The control memory has been assigned with special functions in advance according to

the device number. In addition, there also expansion data memory (EM), file register (FM), link register (W) and index register (Z), etc.

★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★ Bit Only processes ON/OFF Word Processes numerical value 1 word = 16 bit (to process

216=65535) ☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆

- 9 -

［Startup of the Ladder Support Software "KV STUDIO"］

A ladder program is written through the dedicated ladder support software. The ladder support software installed on the KV-5000/3000 Series PLCs is "KV STUDIO". Here, we will actually start the KV STUDIO support software.

★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★ For the installation procedure of the software, please refer to Chapter 1 of the "KV STUDIO User's Manual".

☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆

After installation, let’s start the software! ① Double click the KV STUDIO icon on the desktop to start the KV STUDIO.

The title screen of KV STUDIO ② After the title screen appears, the edit screen will be displayed. Let’s try to write an actual ladder diagram.

The edit screen after startup

- 10 -

[New Programming Method with Ladder Diagram and

Initial Setting of the Units]

Before writing a ladder program with KV STUDIO, set up the unit first. Follow the instructions below.

① Click the "New project" icon. ② Enter the project name. The project name is the name that

corresponds to the file name of the ladder program.

Please enter suitable names for equipment/objects.

③ A "Setup initial unit configuration?" message

will appear. Select "Yes(Y)". ・ If you select "Yes", the Unit Editor will be started, and you can perform initial setup for

the units in it. ・ If you select "No", the edit screen will be displayed. You can also start the Unit

Editor while editing the ladder program. ・ If you select "Read unit configuration", the unit configuration information will

be read from the KV-5000/3000. At this point, the PC (with KV STUDIO) should be connected to the KV-5000/3000.

- 11 -

④ Start the Unit Editor. Here, you can perform unit setup of the KV-5000/3000 Series PLC.

What is unit setup? To specify the units that need to be added to the

KV-5000/3000 and perform basic settings for the units (the range and functions of the device number used).

The operation of unit addition is done by dragging/dropping and connecting the CPU unit from the "Unit selection(1)" tag on the right of the Unit Editor screen, and the added units can be set up through the "Unit setting(2)" tag.

⑤ To perform assignment setting of relays/DMs,

click the icon below. Here, you can perform unit setup of the

KV-5000/3000 Series PLC.

What is the assignment setting of relays/DMs? To setup the leading device number of each unit.

For the CPU, it is fixed within R000-R015 (input)/R500-R507 (output); For the added units, it can be set up freely in the range of R1000 (10ch)-R99900 (999ch) for both inputs and outputs.

※ The initial value uses R30000 (300ch)-。

⑤ The initial setup is now complete. Click "Close" icon to exit the Unit Editor.

- 12 -

[Writing a Ladder Program ①（LD OUT）]

After the initial setting of the units is completed, an actual ladder program will be written as follows.

■ Example 1：a program for LD＋OUT

We will write a basic program first. ・ When R000 is ON, the light R500 will be ON (light up).

For the convenience of operation, program input can be done without many input methods. The method used in this example is the "direct input method" in which instructions are input directly using the keyboard. In this case, move the green cursor on the KV STUDIO screen to the position where an instruction is to be input (a cell), and input directly using the keyboard.

END and ENDH commands represent the end of the ladder program. They have to be entered at the very end of the ladder program. ※ When writing a new module, the END/ENDH commands will be added

automatically at the end of the program.

★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★ "A_0" is the short form for "LD_0". "LD" stands for "LOAD", and has the same meaning as a-contact (normally open contact). In addition, the OUT (output) command can also be abbreviated into "O_500". Since they are commonly used commands, please memorize them through unique input forms. For the short input forms for other commands, please refer to the "KV-5000/3000/1000 Command Reference Manual". Attention！＿ refers to a space. It is actually blank.

☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆

Input A (blank) 0 Enter . (Processed as "LD_0'" in the program, so the result is the same as that of entering LD (blank) 0 Enter. )

(Processed as "OUT_500" in the program. "O" is the short input form of "OUT".

By pushing － , enter a connection line. Draw the connection line up to the right end with the Alt + Enter key.

- 13 -

What is the Relay Number (Device Number) of the Built-In

I/O of the KV-5000/3000?

A relay number (device number) refers to the number used to distinguish between the input equipment (sensors or switches) and output equipment (lights or motors) that are connected to the KV-5000/3000 or the expansion units. Up to 16 input devices can be connected to KV-5000/3000 (R000-R015), and up to 8 output devices can be connected (R500-R507).

R000 R500

Terminal No. of the connector

Input/output connector

- 14 -

[Transfer and Monitoring of Ladder Programs]

After writing a program, please transfer it and verify its operation. Transfer the completed ladder program to the KV-5000/3000 series PLC, and verify the actual operation. ① Connect the KV-5000/3000 to a PC (with KV STUDIO ).

★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★ When the operating system is Windows XP/2000, it is necessary to install the driver for KV-5000/3000 only when connecting the KV-5000/3000 to the PC for the first time. For more information on how to install the USB driver, please refer to the "KV STUDIO User's Manual".

☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆ ② Click the "PLC transfer"→”Monitor mode" icon.

(Cable length: 3m) USB connector

PC

- 15 -

③ The dialog box for confirming project transfer appears. Click the "Execute" button.

④ The program transfer starts. ⑤ The dialog box for confirming the operationtate

of PLC appears. Click the "Yes" button.

After "Yes" is clicked, it will say "RUN" state. ⑥ After the monitor is displayed, verify that it is in the "RUN" state. If "PROG" is displayed in the lower part

of the screen instead of "RUN", it indicates that the program has been started.

Current operation mode of KV STUDIO is displayed.

PLC not running. (PROG mode)

PLC running. (RUN mode)

Monitor

- 16 -

⑥ When the R000 of KV-5000/3000 is ON, the input R000 on the ladder diagram will

light up green, and the R500 will be ON (light up green).

[Writing Ladder Programs (② LDB OUT)]

LD (LOAD) represents N.O.(normally open) = a-contact (normally open contact) LDB (LOAD BAR) represents N.C. (normally closed) = b-contact (normally closed contact). Please write a ladder program and verify its operation. The ladder diagram will add records to the program of "LD OUT" just entered. When adding the logging program, it is necessary to leave space (a blank line) after the END command. Additional lines can be done as shown below. Method for inserting and deleting a line.

■ Inserting a line Move the cursor to the place for inserting a line, and press the "Shift+Enter" buttons to insert a line.

■ Deleting a line Move the cursor to the place for deleting a line, and press the "Shift+Delete" buttons to delete a line.

R000 R500

R000 R500

- 17 -

■ Example 2: a program for LDB OUT When the switch R001 is OFF, R501 will be ON.

After the program is entered, please transfer the program and verify its operation.

★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★ "B_0" is the short form for "LDB_0". "LDB" stands for "LOAD BAR", and has the same meaning as b-contact (normally closed contact). Attention！＿ refers to a space. It is actually blank.

☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆

- 18 -

[Writing Ladder Programs (③ AND circuit)]

If a circuit is ON when both contacts are ON, then it is called an "AND" circuit. Please write a ladder program and verify its operation. Add a ladder program after operation of line insertion has been performed.

■ Example 3: a program of an AND circuit (AND command) When both the switch R002 and R003 are ON, the light R502 will be ON.

■ Example 4: a program of an AND circuit (ANB command) When the switch R004 is ON and the switch R005 is OFF, the light R503 will be ON.


Processed as "AND_3" in the program. The same result will appear even if you have input "AND_3" or "LD_3".

Processed as "ANB_5" in the program. The same result will appear even if you have input "ANB_5" or "LDB_5".

- 19 -

[Writing Ladder Programs (④ OR circuit)]

If a circuit will be ON when one of the two contacts is ON, it is called an "OR" circuit. Please write a ladder program and verify its operation. After deleting the program that has been written up to now through the line deletion operation, rewrite the ladder program.

■ Example 5: a program of an OR circuit (OR command)

When either switch R000 or switch R001 is ON, the light R500 will be ON.

■ Example 6: a program of an OR circuit (ORB command)

When the switch R002 is ON or the switch R003 is OFF, the light R501 will be ON.


・The vertical connection line is input through the F8 key.

・ The vertical connection line is deleted through the Shift ＋ F8 key.

・The vertical connection line is input through the F8 key.

・ The vertical connection line is deleted through the Shift ＋ F8 key.

Processed as "OR_1" in the program. After "OR_1" is input, the vertical line will be drawn at the same time.

Processed as "ORB_1" in the program. After "ORB_1" is input, the vertical line will be drawn at the same time.

- 20 -

[Writing Ladder Programs (Self⑤ -hold circuit)]

If the output of a circuit will be ON continuously once the contact is ON, this circuit is called a self-hold circuit. Please write a ladder program and verify its operation. After deleting the program that has been written up to now through the line deletion operation, rewrite the ladder program.

■ Example 7: a program of a self-hold circuit When the switch R000 is ON, the light R500 will be ON. Even if the switch R000 is OFF, the light R500 will remain ON. When the switch R001 is ON, the light R500 will be OFF.

★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★ Such a circuit as the above one is called a self-hold circuit. The program flow: at the moment when the input R000 is ON, the output R500 will be ON, and the second contact R500 will also be ON. Since the R500 itself is ON, so it will keep its own output at the ON state (hold), even if the input R000 is OFF. This is a basic circuit that is effective for control when input time is short (single pulse). Attention！The self-hold circuit must contain a reset input.

(In this example, input R001 is the reset input.) POINT The commands that have the same functions include KEEP

and SET/RES commands, etc. Please verify them in the KV-5000/3000 Command Manual.

☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆

The coil and contact are ON at the same time

- 21 -

[Relationship between Control and Time]

Often, time has to be considered when performing controlling devices. The function of adjusting time through control is called "Timer" function.

① Verify a signal input error, and make buzzer sound after 1 second. ② Verify that a work-piece has arrived, and set the cylinder to ON after 1

second. ③ After the conveyor belt has verified passing of the workpiece, it will still

move for a certain time.

[Timers of the KV-5000/3000]

The processing of timers is an important element of control. Of course, PLCs represented by the KV-5000/3000 are also equipped with timers. It is possible to realize time control only with the KV-5000/3000. The timer commands of the KV-5000/3000 are divided into the following 3 types.

Command Symbol Mnemonics Function

Timer

TMR Decrement delay in 0.1 s unit ON timer

High speed timer

TMH

Decrement delay in 0.01 s unit ON timer

High speed 1ms timer TMS

Decrement delay in 0.001 s unit ON timer

Timer number and settings XXX ： Number of timers. PLCs represented by the KV-5000/3000 equipped with

many timers. To distinguish between various timers, we add a number to each timer in order

to facilitate management. The number of timers that can be used depends upon the PLC model. KV-5000/3000 may use 4000 counts between T0000-T3999. ddddd ： The time before the timer becomes ON (setting). The setting range of this value of the KV-5000/3000 is #0-#4294967295.

Possible timing range: Timer (TMR): 0-429496729.5 s (4971 days) High speed timer (TMH): 0-42949672.95 s (497 days) High speed 1ms timer (TMS): 0-4294967.295 s (49 days)

★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★ In addition, KV-5000/3000 also has a built-in calendar timer. Through this calendar timer, it is possible to realize control based on "Year/Month/Day/Hour/Minute/Second/Week" system.

☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆

XXX#dddd

XXX#dddd

XXX#dddd

Example

- 22 -

[Control Based Upon ON Delay Timer]

In the following section, we will describe the controls in which timers are used.

On Delay Timer・・・・The timer that makes the next operation (action) delay to ON. To perform ON delay Example: to analyze an output error.

× Without a timer ◎ With a timer

When there is no timer, or the error signal vibrates, the buzzer will sound for a short period. When there is a timer, the buzzer will sound only after an error signal is actually detected to prevent mis-operation.

Please write a ladder program and verify its operation. After deleting the program that has been written up to now through the line deletion operation, rewrite the ladder program.

■ Example 8: a program of an ON delay timer When the switch R000 is ON, the light R500 will be ON after 3 seconds. When the switch R000 is OFF, the light R500 will be OFF immediately.


Error signal ON

Buzzer sounds instantly

Error signal ON

Error lasts 1 s

Buzzer sounds

- 23 -

[Application of the ON Delay Timer]

In this section, we will discuss the controls in which the timer functions of KV-5000/3000 are flexibly used. First, let us consider a control combined with an ON delay timer and a self-hold function. For example, let's try to analyze the operation of a conveyor belt. Please write a ladder program and verify its operation. After deleting the program that has been written up to now through the line deletion operation, rewrite the ladder program.

■ Example 9: a program combined with an ON delay timer and a self-hold circuit


On delay timer

Start switch

Conveyor belt starts moving

Stop switch

Conveyor belt stops moving

① After the start switch R000 is ON

⑤ The output R500 of KV-5000/3000 is OFF

④ After the stop switch R001 is ON

② Wait 3 seconds (ON delay)

③ When the timer is ON, the output R500 of KV-5000/3000 will be ON and self hold.

- 24 -

[Control Based Upon OFF Delay Timer]

Off Delay Timer a timer that enables a signal in ON state to perform OFF delay.

For example, let's try to analyze the operation of a conveyor belt. Please write a ladder program and verify its operation. After deleting the program that has been written up to now through the line deletion operation, rewrite the ladder program.

■ Example 10: a program of an OFF delay timer


Conveyor belt starts moving

Photoelectric switch ON

Photoelectric switch OFF

Timer OFF delay

Stop moving

① After the photoelectric switch detects a workpiece

⑤ Output of the KV-5000/3000 is OFF

④ 3 seconds after the detection signal is OFF

② Output of the KV-5000/3000 is ON

③ The conveyor belt will continue to move for some time even if the work-piece has passed the sensor completely

- 25 -

[Control Based Upon a One-Shot Timer]

One-Shot Timer A timer that generates a signal that will be ON for a certain time.

For example, let's try to analyze the operation of a buzzer.

■ Example 11: a program of a one-shot timer After the program is entered, please transfer the program and verify its

operation.

Buzzer sounds

Push button ON

Single shot timer

Buzzer stops

① Operator sets the push button switch R000 to ON state

④ After 1 second, the output will be OFF

② Output R500 of KV-5000/3000 turns ON immediately

③ The buzzer will sound continuously for 1 second even if the switch is OFF

- 26 -

Single-shot

[Summary of Control Based Timers]

Do you understand control based timers? The program charts of timers used as control centers are summed up below, so be sure to remember them. They can help reduce the time required to write programs. In addition, an operation timing sequence is listed on the right of the ladder for easy understanding. Please verify the actual operation according to the timing sequence.

ON delay timer When switch R000 is ON, light R500 will be ON after 3 seconds. Output R500 will not be ON within 3 seconds after input R000 is ON.

OFF delay timer

When input R000 is ON, output R500 will be ON. After R000 is OFF, R500 will be OFF after 3 seconds.

After R000 is ON, output R500 will be ON, and will be OFF after 3 seconds.

R000

R500

3 s 0.5 s

R000

R500

3 s

R000

R500

3 s 3 s

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

- 27 -

[Flexible Use of Counters]

The KV-5000/3000 PLCs can perform counting. The device that is used to count during control is called a counter. Let’s analyze the controls in which a counter is used.

① Counting of production quantity

② Counting of the quantity of defective products

[Counters of the KV-5000/3000]

Counters play an important role in control. Of course, PLCs represented by the KV-5000/3000 are also equipped with counters. It is possible to realize counting control only with the KV-5000/3000. The counting commands of the KV-5000/3000 are shown as follows.

Command Symbol Mnemonics Function

Counter

C

Up counter ※Counts according to

nnnnn, and resets when the execution condition is OFF.

OUT Counter

OUTC

Up counter ※Counts according to the

execution condition, and resets through the RES command.

Counter number and settings XXX ： Number of the counter. PLCs represented by the KV-5000/3000 equipped with

many counters. To distinguish between various counters, we add a number to each counter to

facilitate management. The number of counters that can be used depends upon the PLC model. KV-5000/3000 may use 4000 counts between C0-C3999. ddddd ： The value until the counter is ON (setting). The setting range of this value of the KV-5000/3000 is #0-#4294967295. nnnnn ： The number of the contact used to perform counting input. Specifies the input relay for which the value of connected switch is to be

counted.

★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★ Whereas timer command is always decrement operation, counter command is always increment operation. The reason is that a counter needs to realize overflow counting (i.e., it will continue to count even if the setting value is reached).

☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆

Example

XXX #dddd

nnnnn

XXX #dddd

- 28 -

[Control of Counters]

Let’s write a control program that uses a counter. For example, let's try to analyze the management of production quantity. The finished products will be checked using a photoelectric sensor and will be counted using a counter of the KV-5000/3000. A light will light up when the number of products reaches 10, notifying the operator that production is finished. After verifying, the operator will press the push button switch to turn off the light, and reset the counter of the KV-5000/3000 (return to 0).

■ Timing sequence

KV-5000/3000

R000 （Count）

R001 （Reset）

Setting 10 C0 (Current value）

C0 （Contact）

R500 （Output）

（Reset）

（Output）

- 29 -

Please write a ladder program and verify its operation. After deleting the program that has been written up to now through the line deletion operation, rewrite the ladder program.

■ Example 12: a program of counter


★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★ Write input conditions through the B-contact before the counter command. (It is LDB_1 in the above ladder) Since B-contact is used, the power of the counter will always be ON. (When the input R0 is ON, counting will be performed all the time) When this contact is disconnected, the current value of the counter will be reset (the power of the counter is turned off).

★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★

The contact is ON, the counter will reset.

Setting value of the counter

Counting input

After the current value of the counter changes to 10, contact C0 will be ON.

- 30 -

The concepts of scan time and dual coil that are familiar to us will be described here.

［Concept of scan time］

The KV-5000/3000 PLCs can complete operations of the entered program through repeatedly performing a sequence of operation called "scan execution". As shown below, scan execution is composed of three elements: input processing, program execution processing and output processing, and the time required for "scan execution" is called "scan time". The ON/OFF state of the input will be loaded during input processing; during output processing, the results of the program execution will be output collectively. ★☆★ The PLC with shorter scan time can write a program for a device that can perform tasks faster ★☆★

［Concept of a dual coil］ Here, we describe the "dual coil" concept that has to be considered when writing a ladder program. The way in which the KV-5000/3000 executes a program is line by line from top to bottom (from left to right). PLC-specific rules apply for the steps of executing a program. Please write a ladder program and verify its operation. After deleting the program that has been written up to now through the line deletion operation, rewrite the ladder program.

■ Example 13: a program of a dual coil


Scan time

Input processing

Program execution processing Output processing

Output R500 is used many times.

After the above ladder program is executed, the output R500 will not be ON even if the contact R000 or R001 is ON. Only when R002 is ON, will R500 be ON.

- 31 -

[Principle of a Dual Coil]

Here we describe the reason why execution of the verified program will cause the operations shown in Example 13.

A ladder program will not output a result after each command execution. ★ Incorrect

R500：ON R500：ON R500：OFF ☆ Correct (refresh method)

R500：ON R500：ON R500：OFF

As described above, the PLC will not output a result after each command execution, instead it will output total results at the end of the scan time. Obviously, to easier for a PLC with shorter scan time to realize high speed control.

・・・・①

・・・・②

・・・・③

・・・・④

① ② ③

output output output

① ② ③ output

④

- 32 -

[Questions Summary]

Please consider the following issues after you have learned about circuits from this tutorial. Normal controls as shown below can be realized by combining the basic circuits together.

■ Question You are a responsible person for Production Technique in a food processing company. In order to produce and sell new products for Christmas, it is necessary to rebuild the production equipment. Please try to write a program for realizing the following operation. Example ①： Whether the produced chocolate products are good or defective needs

to be decided. After being detected by the decision sensor (R000), defective products are to be pushed out using a 3-second push lever (R500).

Example ②：Good chocolate products are transferred on the conveyor belt. After 12 products are detected by the sensor (R001), the buzzer (R501) will

sound for 5 seconds. (The counter will be reset automatically after counting is finished.) Example ③： 12 chocolates are put in one box. The number of boxes is counted through a sensor (R002); the job

completion light will turn ON when 10 boxes are reached. The job completion light will remain in an ON state, until operator A presses

the confirmation switch (R004).

- 33 -

[Answers to Questions]

Example ① ☆ The key point is to use a single-shot timer.

Example ②

☆ The key point is to perform a counter reset when the buzzer begins to sound

Will be ON when setting of the counter is reached

It also seems possible to perform a counter reset through the buzzer output R501; however, if the buzzer output R501 is used, the subsequent workpieces cannot be counted, since the reset operation will be performed all the time while the buzzer is sounding (5 seconds). Therefore, the correct answer is that you should perform counter reset through the signal that is output when the counter reaches its setting value (C0).

Setting

Sensor input

3-second timerPush lever

3-second timer Push leverNG signal input

Reset signal Counter

Counter 5-second timer Self-hold circuit

5-second timerSelf-hold circuit

- 34 -

Example ③ ☆ The key point is to build a self-hold circuit through the signal of the counter.

Will be ON when setting of Self-hold circuit reset the counter is reached

Counter reset is done still by the signal of C1. When composing a self-hold circuit, don't forget the reset signal!

★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★ The commands that have the same functions as in the self-hold circuit include KEEP and SET/RES commands, etc. Please verify using the following reference ladder diagrams. Please refer to Chapter 2 "Basic Commands" in the KV-5000/3000/1000 Command Manual.

★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★ ※SET/RES command ※KEEP command

Setting

Sensor input Counter

Job completion indicator light

Self-hold circuit

- 35 -

[Convenient Commands]

In order to make composing ladder diagrams easier, the KV-5000/3000 Series PLCs are equipped with many convenient commands. Here we will describe some of the commands. Be sure to use them flexibly in subsequent programming. The circuits described in this tutorial are frequently used circuits when building any control schemes. The KV-5000/3000 PLCs have added the most frequently used common circuits that can be used for the ON delay or OFF delay ladder programs as new commands. A circuit with multiple lines is changed into one command through new commands (convenient commands), which reduces the time required for programming and realizes efficient program operation. Example ① The ON delay timer circuit

The ON delay timer circuit we discussed on the last page is shown as follows. The two-line program can be realized using one line in a convenient command.

★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★ A convenient command also has advantages/disadvantages. The advantages are: the program is simplified, time for programming is reduced, and scan time is shorter. In addition, it can be used without limit, since no timer number is required. The disadvantages are: the timer unit is only 0.01 s, and the current value cannot be displayed during monitoring, etc. (The normal timer can monitor the decrement state.) Please use normal commands and convenient commands flexibly according to different conditions.

★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★

NOTE The unit of the timer is 0.01s. Therefore, a setting value of 3 s should be entered by ＃300.

- 36 -

Example ② The OFF delay timer circuit

The ON delay timer circuit we discussed on last page is shown below. The two-line program can be realized through one line in a convenient command. The following convenient commands are included in the KV-5000/3000. ・ SET command ・ RESET command ・ ON delay command ・ OFF delay command ・ Blinking command ・ Single-shot command ・ Alternating command

★ Be sure to try to using them in the program and verify their operation!

- 37 -

[Simulator Function]

Until now, switches and other devices have been used to verify operation after a program is transferred to the KV-5000/3000 unit. However, when configuring a device, the PLC unit is often connected to the device. Even if you want to perform a program test (debugging), sometimes it is not possible to verify before the device installation is finished. In order to avoid this kind of debugging problem, the KV-5000/3000 is equipped with a "simulator function" in the ladder support software "KV STUDIO", through which it is possible to debug a program without transferring the ladder program to the unit. Here, we will describe how to use the simulator.

■ The method used until now

■ The simulator function of the KV STUDIO

★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★ The following page will describe how to start the simulator. After confirmation, please practice the programs you have learned until now (self-hold or timer/counter) by using the simulator. In addition to having the simple timer/counter function, this simulator function is very useful for operation programs used in the future. Be sure to understand it.

★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★☆★

The ladder diagram is transferred to the PLC, and operations of the program are verified.

It is possible to verify operation of the program by only using a PC.

- 38 -

① First, write the program as shown below. This is the program written by using the ON delay timer through a common method,

in which convenient commands are used. After the input R000 is ON, it is possible to verify that the normal command and the

convenient command have set output R500 and R501 to ON simultaneously. ② Click the "Simulator" icon to run the simulator. ③ Change to the simulator screen, and click the "Execute continuous scan" icon. The ladder program will run on the PC.

Output R500

Output R501

Pay attention to the unit!

- 39 -

④ On the simulator screen, double click a contact on the ladder program to switch the input ON/OFF。

Try to double click the input R000. The input will be ON, and the timer will begin to operate.

⑤ After 3 seconds, both inputs will be ON. ⑥ On the simulator screen, double click the contact on the ladder program again. The input R000 will turn OFF, and the timer will reset.

Double click the cell for the contact R000

- 40 -

MEMO

- 41 -

［End］

Were you able to understand and grasp the content in this tutorial? If you have any questions about the content in this tutorial, please contact our company's business office. The personnel of each business office are ready to help you. You are also welcome to purchase any of our products in the future.

※All of the content in this tutorial is copyrighted. Reprinting or reproduction is not allowed without permission. Model ※ number, specifications, and other information are subject to change without notice

1094-1 600F63

kv-5000/3000 tutorial for...

Documents