HCFA HCA2 Series User manual

HCFA Corporation Limited
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HARDWARE MANUAL
HCA2 SERIES PROGRAMMABLE CONTROLLERS
Foreword.......................................................................................................................................... 2
1. Introduction.................................................................................................................................5
1.1 Model Name....................................................................................................................... 6
1.2 Rules of Expansion........................................................................................................... 6
1.3 Back up Data...................................................................................................................... 7
1.3.1 EEPROM backup................................................................................................... 7
1.3.2 Capacitor backup................................................................................................... 7
1.3.3 Initialize Latched (Keep) Devices................................................................................ 7
2. Terminal layouts.........................................................................................................................8
3. Installation Notes.......................................................................................................................9
3.1 Product Outline.................................................................................................................. 9
3.2 HCA2RUN/STOP Control...............................................................................................10
3.3 General Specifications.................................................................................................... 11
3.4 PLC Mounting Arrangements........................................................................................ 12
3.5 DIN Rail Mounting........................................................................................................... 13
3.6 Direct Mounting................................................................................................................ 14
3.7 Wiring.................................................................................................................................14
3.7.1 Termination at Screw Terminals.........................................................................14
3.7.2 Removal and installation of quick-release terminal block............................. 15
3.8 Installing Optional Units..................................................................................................16
3.8.1 Expansion Boards................................................................................................ 16
4. Power Supply........................................................................................................................... 17
4.1 Wiring Techniques........................................................................................................... 17
4.2 Wiring Cautions................................................................................................................17
4.3 Power Supply................................................................................................................... 17
4.4 Power Requirements...................................................................................................... 18
4.5 Example Wiring................................................................................................................ 19
4.5.1 AC Power supply.................................................................................................. 19
4.5.2 24V DC Power supply......................................................................................... 19
4.5.3 12V DC Power Supply.........................................................................................20
4.6 Service Power supply..................................................................................................... 21
4.7 Earthing / Grounding....................................................................................................... 21
5. Inputs.......................................................................................................................................... 21
5.1 24V DC input Specifications.......................................................................................... 21
5.1.1 Typical Wiring........................................................................................................22
5.1.2 Input Circuit Connection......................................................................................22

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5.1.3 Diodes and Inputs Connected in Series...........................................................22
5.1.4 Resistors and Inputs Connected in Parallel.................................................... 23
5.2 AC110V Input Extension Block......................................................................................23
6. Outputs.......................................................................................................................................24
6.1 Output Specifications...................................................................................................... 24
6.2 Relay Output Example....................................................................................................24
6.2.1 Product life of relay contacts.............................................................................. 24
6.2.2 Output circuit configuration.................................................................................25
6.3 Transistor Output Example............................................................................................ 27
6.3.1 Transistor Output Writing Diagram (Source Type)......................................... 27
6.3.2 Japanese Model Transistor Output (Sink Type)..............................................27
6.3.3 Response Times...................................................................................................28
6.3.4 External wiring precaution.................................................................................. 28
7. Diagnostics............................................................................................................................... 29
7.1 Preliminary Checks......................................................................................................... 29
7.2 ERROR LED ON (CPU ERROR)................................................................................. 29
7.3 Common Errors................................................................................................................29
7.4 Maintenance..................................................................................................................... 30
7.5 Operation and Error Flags............................................................................................. 30
7.6 PLC Status Registers...................................................................................................30
7.7 Error Registers................................................................................................................. 31
7.8 Error Codes...................................................................................................................... 31
7.9 Instruction List.................................................................................................................. 32
7.10 Device List...................................................................................................................... 33

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Foreword
•This manual contains text, diagrams and explanations which will guide the reader in the
correct installation and operation of the HCA2 Series Programmable Controllers. It should
be read and understood before attempting to install or use the unit.
•If in doubt at any stage of the installation of an HCA2Series Programmable Controller
always consult a professional electrical engineer who is qualified and trained to the local
and national standards which apply to the installation site.
•If in doubt about the operation or use of HCA2Series Programmable Controller please
consult the nearest HCFA Electric distributor.
•This manual is subject to change without notice.
HCA2 SERIES PROGRAMMING CAUTION
Thank you for buying The HCFA HCA2 series controller.
Please note the following.
Notes: Block Move instruction
Applicable PLC: HCA2 Ver 1.00-2.10
Applicable instructions: BMOV, BMOVP(FNC15)
If the file register parameter setting and the registers D8000-D8225 are used as the
destination devices for the BMOV (BMOVP) instruction, program steps or file register data
may be lost or damaged. All other data registers can be used safely for BMOV(BMOVP)
instruction destination registers.
Program example
Guidelines for the safety of the user and protection of the HCA2.
This manual provides information for the installation and use of the HCA2. The manual
has been written to be used by trained and competent personnel. The definition of such a
person or persons is as follows;
a) Any engineer who is responsible for the planning, design and construction of automatic
equipment using the product associated with this manual should be of a competent nature,
(trained and qualified to the local and national standards required to fulfill that role). These
engineers should be fully aware of all aspects of safety with regards to automated
equipment.
b) Any commissioning or service engineer must be of a competent nature, trained and
qualified to the local and national standards required to fulfill that job. These engineers
should also be trained in the use and maintenance of the completed product. This
includes being completely familiar with all associated documentation for the said product.
All maintenance should be carried out in accordance with established safety practices.
c) All operators of the completed equipment (see Note) should be trained to use that

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product in a safe manner in compliance to established safety practices. The operators
should also be familiar with documentation which is associated with the operation of the
completed equipment.
Note :The term ‘completed equipment’ refers to a third party constructed device which
contains or uses the product associated with this manual.
Note’s on the symbols used in this manual
At various times throughout this manual certain symbols will be used to highlight points of
information which are intended to ensure the users’ personal safety and protect the
integrity of the equipment. Whenever any of the following symbols are encountered, its
associated note must be read and understood. Each of the symbols used will now be
listed with a brief description of its meaning.
Hardware warnings
1) Indicates that the identified danger WILL cause physical and property damage.
2) Indicates that the identified danger could POSSIBLY cause physical and property
damage.
3) Indicates a point of further interest or further explanation.
Software warning
1) Indicates special care must be taken when using this element of software.
2) Indicates a special point which the user of the associate software element
should be aware of.
3) Indicates a point of interest or further explanation.
•Under no circumstances will HCFA Electric be liable or responsible for any
consequential damage that may arise as a result of the installation or use of this
equipment.
•All examples and diagrams shown in this manual are intended only as an aid to
understanding the text, not to guarantee operation. HCFA Electric will accept no
responsibility for actual use of the product based on these illustrative examples.
•Please contact a HCFA Electric distributor for more information concerning applications
in life critical situations or high reliability.
Note Concerning the CE Marking
This document does not guarantee that a mechanical system including this product will
comply with the following standards. Compliance to EMC directive and LVD directive of
the entire mechanical system should be checked by the user / manufacturer.

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For more details please contact the local HCFA Electric sales site.
Programmable logic controllers are open-type devices that must be installed and used
within conductive control boxes.
Please use the HCA2Series programmable logic controllers while installed in conductive
shielded control boxes.
Please secure the control box lid to the control box (for conduction).
Installation within a control box greatly affects the safety of the system and aids in
shielding noise from the programmable logic controller.

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1. Introduction
This manual covers hardware installation instructions for the HCA2Series PLC.
Table 1.1: HCA2Main Modules
AC Power Supply DC Power Supply DC INPUT Relay output Transistor output
Points L(mm) W(mm) H(mm)
HCA2-8X6Y(14 points) 100.2 90 81
HCA2-14X10Y(24 points) 130.2 90 81
HCA2-24X16Y(40 points) 182.2 90 83
HCA2-36X24Y(60 points) 220.2 90 83
Figure 1.1 :Main unit outline
Table 1.2: Powered Extension Units
■Input
Expansion
■Output
Expansion
■Special Expansion
Block/Analog Unit
■Input &
output
Expansion
Block
■Positioning
Control Block
■Analogue
Block
TX2N-8EX
TX2N-16E
X
TX2N-8EYR
TX2N-8EYT
TX2N-16EY
R
TX2N-16EY
T
A/D
TX2N-2A
D
TX2N-4A
D
TX2N-8A
D
D/A
TX2N-2D
A
TX2N-4D
A
TX2N-8ER
TX2N-16E
R
TX2N-32E
R
TX2N-32E
T
TX2N-48E
R
TX2N-48E
T
TX2N-1PG
TX2N-4PG
TX2N-10PG
TX2N-1RM-SE
T
TX2N-10GM
TX2N-20GM
TX0N-3A
TX2N-4AD-4D
A
TX2N-4AD-2D
A
TX2N-4AD-TC
TX2N-4AD-PT
TX2N-2LC
TX2N-1HC

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1.1 Model Name
Code Contents
1HC represents the Chinese Character Pinyin Initials ‘HeChuan’
2A2 represents series number of PLC. HC PLC Types: A1~A8
336X represents 36 input points; Input points of A2 series: 8X, 14X, 24X, 36X
424Y represents 24 output points; Output points of A2 series: 6Y、10Y、16Y、24Y
Corresponding to the combination of input & output:
A2: 14 points, 24 points, 40 points, 60 points
5R(T) represents output type of PLC R: relay output T: transistor output
6A(D) represents power supply type of PLC A: AC 85V~264V input D: DC
20.4V~26.4V input
Table : Configuration Notes
A HCA2 Series Main Unit
B HCA2 Expansion Boards for Analog
I/O
C HCA2 Expansion Boards without
Analog I/O
D Memory Cassette or Display Module
E Programming Software
F RS-232C/RS-422 Converter for PC
F’ USB/RS-422 Converter for PC
G Dedicated Programming Tools
1.2 Rules of Expansion
The maximum I/O for an HCA2system is 128 I/O points and 8 special function blocks.
The HCA2 Series can be expanded as follows when used independently.
- 2 special function blocks
- 1 special function block and up to 16 I/O points
- Up to 32 I/O points
An AC powered HCA2 can be expanded by 8 special function blocks when used in
conjunction with an HCA5 extension unit (2+6).
•If a DC powered main unit is used with a power supply of less than 24VDC -15% (20.4V
DC or less), then it cannot be fully expanded by using special function blocks or powered
extension units.
It can accommodate a maximum of an additional 32 I/O points.

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•If an HCA2 expansion board is being used, it does not alter the rules of expansion
outlined above, as it utilizes special M coils for its operation and therefore does not
contribute to the maximum 128 I/O point count. Only one special function board can be
used at any time.
See section 3.8 for more details.
1.3 Back up Data
1.3.1 EEPROM backup
Data includes the Program, Comment, File Registers (D1000 ~ D7999), and parameter
data.
This will be stored as long as the EEPROM is not damaged. HCFA Electric has
guaranteed a life cycle time of 10,000 writes to the EEPROM memory. Users may
experience operational writes to the EEPROM in excess of 10,000; however, due to
temperature effects a quantitative estimation cannot be given.
When saving the device status in the EEPROM, the electric power of the PLC's built-in
capacitor is used.
If the PLC has been powered on for five minutes or more, the following device data will be
saved in the EEPROM at power down: S0 ~ S127, M384 ~ M511, C16 ~ C31, C235
~C255, and D128 ~ D255.
When the EEPROM keep device status cannot be correctly saved to the EEPROM by
shortage of electric charge, at the next power-on the status of the device will be that which
saved to the EEPROM at the last save.
1.3.2 Capacitor backup
The capacitor backed memory includes M512 ~ M1535, S128 ~ S999, T246 ~ T255, C32
~ C199, C220 ~ C234, D256 ~ D7999 and the RTC.
The capacitor backed memory will retain data for a maximum of 10 days (Ambient
temperature: 25 °C), and requires 30 minutes to recharge upon power up.
Note: The HCA2 does not have battery backup, if a system requires backup of more than
10 days (Ambient temperature: 25 °C), a peripheral backup power source must be
provided.
1.3.3 Initialize Latched (Keep) Devices
•When using non-latched devices
To use the latched devices as the non-latched devices, reset the latched devices by an
initial pulse (M8002) in program.
•When using capacitor latched (keep) devices
If the voltage of a capacitor drops, the capacitor keep device status may be stored
incorrectly. Therefore, when using the PLC after it has been powered off for more than 10

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days (Ambient temperature: 25 °C), re-set up the required devices and the current time
after initializing capacitor latched (keep) devices before selecting RUN.
Initialization method
Latched (keep) devices can be initialized in the PLC memory by using peripheral
equipment, and the special auxiliary relay M8032, or executing the ZRST instruction. The
two major methods are described below.
•Latch memory all clear by special auxiliary relay (M8032)
When M8032 is turned ON, all latched (keep) devices (including reset coils of timers and
counters) are cleared. M8032 can be turned ON and OFF using the forced ON/OFF
operation from peripheral equipment or within the sequence program. Note that latched
devices cannot be turned ON while M8032 is ON. When turning ON M8032 within the
sequence program, note that latched devices are cleared during END processing after
M8032 is turned ON.
Program example: This program clears all latched devices.
•Reset of device by ZRST (zone reset) instruction
The ZRST instruction can clear multiple devices at once. (Because a limited device range
can be specified for the ZRST instruction, only part of the latched (keep) devices can be
cleared at a time.)
However, initialization method by the ZRST
instruction for capacitor backed timer and
counter devices
(T246 ~ T255, C32 ~ C199, C220 ~ C234)
does not reset the associated coil devices.
In order to initialize the associated coil
devices, execute the RST instruction for
the coil devices being used in the user
program as shown in the example program
on the left.
2. Terminal layouts
The following selection of terminal layouts are taken from the HCA2product range.
Note: All layouts are schematic only and are intended to aid the creation of wiring
diagrams.

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3. Installation Notes
The installation of HCA2products has been designed to be safe and easy. When the
products associated with this manual are used as a system or individually, they must be
installed in a suitable enclosure. The enclosure should be selected and installed in
accordance to the local and national standards.
3.1 Product Outline
Figure 3.1:Features of the HCA2 PLC