HollySys LK Series User guide

LK Series Programmable Logic
Controller
System Manual
Version: V1.2
January, 2018

Copyright Notice
The text, illustrations, charts, marks, trademarks, product models, programs, page layout and other
contents included in this manual are under protection of “Copyright Law of the People’s Republic of
China”, “Trademark Law of the People’s Republic of China”, “Patent Law of the People’s Republic of
China” and the laws of applicable international conventions regarding copyright, trademark right,
patent right or other property ownership, and they are owned or possessed exclusively by Beijing
HollySys Intelligent Technologies Co., Ltd..
Since the equipment explained in this manual has a variety of uses, the user and those responsible for
applying this equipment must satisfy themselves as to the acceptability of each application and use of
the equipment. Under no circumstances will Beijing HollySys Intelligent Technologies Co., Ltd. be
responsible or liable for any damage, including indirect or consequential losses resulting from the use,
misuse, or application of this equipment.
Due to the many variables associated with specific uses or applications, Beijing HollySys Intelligent
Technologies Co., Ltd. cannot assume responsibility or liability for actual use based upon the data
provided in this manual.
This manual is provided only for commercial users to read. Without prior written permission of Beijing
HollySys Intelligent Technologies Co., Ltd., no part of this manual should be reproduced and
transmitted in any forms by any means, including electronic, mechanical or otherwise regardless of
whatever reasons and purposes. We will investigate violator’s legal liability in accordance with the
relevant laws.
The text HollySys, and the logos are registered trademarks of Beijing HollySys
Intelligent Technologies Co., Ltd..
All other trademarks are the property of their respective holders.
All rights reserved for Beijing HollySys Intelligent Technologies Co., Ltd..
Address: Di Sheng Middle Road, No.2,
Economic-Technological DevelopmentArea, 100176, Beijing, China
Business Tel: [phone]
Consulting Hotline: [phone]
Technology Request Tel: [phone]
Technology Request Phone: [phone]
Fax: [phone]
Web: http://www.hollysys.com
Email: [e-mail]
Sina weibo: http://weibo.com/hollysysplc

Beijing HollySys Intelligent Technologies Co., Ltd. All Rights Reserved I
CONTENTS
Chapter 1 About This Book.............................................................................................................1
1.1 Document Update..................................................................................................................1
1.2 Purpose...................................................................................................................................1
1.3 Intended Audience.................................................................................................................1
1.4 Document Conventions........................................................................................................1
1.4.1 Menu.................................................................................................................................1
1.4.2 Mouse...............................................................................................................................1
1.4.3 Keyboard..........................................................................................................................2
1.4.4 Important Information.......................................................................................................2
1.5 Catalog....................................................................................................................................2
1.6 Terminology ...........................................................................................................................3
1.7 Abbreviations.........................................................................................................................3
Chapter 2 Overview..........................................................................................................................5
2.1 System characteristic ...........................................................................................................5
2.1.1 High Reliability..................................................................................................................5
2.1.2 Fast Response.................................................................................................................5
2.1.3 Large Capacity.................................................................................................................5
2.1.4 Easy Maintenance............................................................................................................5
2.2 Hardware components and structures ...............................................................................6
2.3 Hardware Product List........................................................................................................11
2.4 Model Selection and Planning ...........................................................................................14
2.4.1 Power Capacity Calculation and Configuration .............................................................14
2.4.2 Ethernet Connection ......................................................................................................14
2.4.3 PROFIBUS-DP Network Connection and Calculation...................................................17
2.4.4 PROFIBUS-DP Bus Scanning Period............................................................................17
2.5 System Specification ..........................................................................................................17
2.6 Product Storage and Transport .........................................................................................19
2.6.1 Storage...........................................................................................................................19
2.6.2 Transport........................................................................................................................19
Chapter 3 Installation and Wiring.................................................................................................21
3.1 Layout Planning and Installation.......................................................................................21
3.1.1 Space Layout .................................................................................................................21
3.1.2 Backboard Installation....................................................................................................22
3.1.3 Protection Key................................................................................................................24
3.1.4 Module Installation and Disassembly.............................................................................25
3.1.5 Installation of LK910.......................................................................................................28
3.1.6 Installation of LKA104....................................................................................................29
3.1.7 Installation of Power Supply Box ...................................................................................29

Contents
II Beijing HollySys Intelligent Technologies Co., Ltd. All Rights Reserved
3.2 System Wiring......................................................................................................................30
3.2.1 Power Wiring..................................................................................................................30
3.2.2 Redundancy Communication Wiring..............................................................................31
3.2.3 PROFIBUS-DP Wiring ...................................................................................................32
3.2.4 I/O Cable........................................................................................................................36
3.3 Grounding ............................................................................................................................38
Chapter 4 System Configuration..................................................................................................41
4.1 Hardware Configuration......................................................................................................41
4.1.1 Configure DP Slave Devices..........................................................................................41
4.1.2 Configure HOLLITCP Slave Devices.............................................................................49
4.1.3 Configure MODBUS TCP Protocol................................................................................54
4.2 System Running ..................................................................................................................61
4.2.1 Required Devices...........................................................................................................61
4.2.2 Device Wiring.................................................................................................................61
4.2.3 Network Connection.......................................................................................................62
4.2.4 Example Program...........................................................................................................64
4.2.5 Download Program ........................................................................................................65
Chapter 5 Master Control Unit......................................................................................................69
5.1 LK130 4-slot Backboard Module.....................................................................................69
5.1.1 Module Composition ......................................................................................................69
5.1.2 Installation Dimension....................................................................................................70
5.1.3 Technical specifications.................................................................................................71
5.2 LK921 24V Power Switching Module..............................................................................71
5.2.1 Operating Principle.........................................................................................................72
5.2.2 Wiring .............................................................................................................................72
5.2.3 Status Indication.............................................................................................................73
5.2.4 Installation Dimension....................................................................................................73
5.2.5 Technical Specifications.................................................................................................73
5.3 LK220 Master Control Module.........................................................................................74
5.3.1 Features.........................................................................................................................74
5.3.2 Appearance....................................................................................................................75
5.3.3 Operating Principle.........................................................................................................76
5.3.4 Status Indication.............................................................................................................77
5.3.5 Interface Specification....................................................................................................78
5.3.6 Key Switch......................................................................................................................80
5.3.7 Reset..............................................................................................................................81
5.3.8 Power Fail Safeguard.....................................................................................................83
5.3.9 Backup Battery...............................................................................................................83
5.3.10 MODBUS Communication Settings...............................................................................83
5.3.11 Redundancy Data Area..................................................................................................90
5.3.12 Technical Specifications.................................................................................................90
5.4 LK249 DP Master Station Communication Module.......................................................91
5.4.1 Features.........................................................................................................................91
5.4.2 Appearance and Size.....................................................................................................92
5.4.3 Status Indication.............................................................................................................93
5.4.4 Operating Principle.........................................................................................................94
5.4.5 Terminal Definition .........................................................................................................94
5.4.6 Diagnosis........................................................................................................................95
5.4.7 Set Baud Rate................................................................................................................95

Contents
Beijing HollySys Intelligent Technologies Co., Ltd. All Rights Reserved III
5.4.8 Technical Specifications.................................................................................................95
5.5 LK240 Redundancy Communication Module ................................................................96
5.5.1 Appearance and Size.....................................................................................................97
5.5.2 Status Indication.............................................................................................................98
5.5.3 Operating Principle.........................................................................................................99
5.5.4 Wiring .......................................................................................................................... 100
5.5.5 Set A/B Frame............................................................................................................. 100
5.5.6 Master-slave Determination........................................................................................ 101
5.5.7 Conditions of Master-slave Switchover....................................................................... 101
5.5.8 Technical Specifications.............................................................................................. 102
5.6 LK141-A Empty Module................................................................................................. 103
Chapter 6 IO Unit......................................................................................................................... 105
6.1 Power Module ................................................................................................................... 105
6.1.1 LK910 24VDC Power Module .................................................................................. 105
6.2 Extension Backboard....................................................................................................... 109
6.2.1 Interface Specification................................................................................................. 110
6.2.2 Communication Address............................................................................................. 112
6.2.3 LK117 11-slot Extension Backboard........................................................................ 113
6.2.4 LK118 5-slot Extension Backboard.......................................................................... 114
6.3 Communication Module....................................................................................................117
6.3.1 LK232 PROFIBUS-DP Bus Repeater Module ......................................................... 117
6.3.2 LK233 PROFIBUS-DP Bus Optoelectronic Transceiver.......................................... 121
6.3.3 LK234 Ethernet Interface Module............................................................................. 128
6.3.4 LK239 MODBUS Master/Slave Communication Extension Module........................ 139
Chapter 7 IO Module................................................................................................................... 173
7.1 LK610 16-channel Leaking Type Digital Input Module............................................... 173
7.1.1 Basic Features ............................................................................................................ 173
7.1.2 Operating Principle...................................................................................................... 173
7.1.3 Indicator Lamps........................................................................................................... 174
7.1.4 Wirings......................................................................................................................... 174
7.1.5 Diagnosis..................................................................................................................... 176
7.1.6 Reverse Supply Protection.......................................................................................... 177
7.1.7 Parameters.................................................................................................................. 178
7.1.8 Technical Specifications.............................................................................................. 178
7.2 LK710 16-channel Source Type Digital Output Module............................................. 179
7.2.1 Basic Features ............................................................................................................ 179
7.2.2 Operating Principle...................................................................................................... 180
7.2.3 Indicator Lamps........................................................................................................... 180
7.2.4 Wirings......................................................................................................................... 181
7.2.5 Functions..................................................................................................................... 182
7.2.6 Diagnosis..................................................................................................................... 183
7.2.7 Parameters.................................................................................................................. 185
7.2.8 Data Area.................................................................................................................... 185
7.2.9 Technical Specifications.............................................................................................. 186
7.3 LK410 8-Channel Voltage Type Analog Input Module................................................ 187
7.3.1 Basic Features ............................................................................................................ 187
7.3.2 Operating Principle...................................................................................................... 187
7.3.3 Indicator Lamps........................................................................................................... 188

Contents
IV Beijing HollySys Intelligent Technologies Co., Ltd. All Rights Reserved
7.3.4 Wirings..........................................................................................................................189
7.3.5 Functions......................................................................................................................191
7.3.6 Diagnosis......................................................................................................................192
7.3.7 Parameters...................................................................................................................196
7.3.8 Technical Specifications...............................................................................................200
7.4 LK411 8-channel Current Type Analog Input Module .................................................201
7.4.1 Basic Features .............................................................................................................201
7.4.2 Operating Principle.......................................................................................................202
7.4.3 Indicator Lamps............................................................................................................202
7.4.4 Wirings..........................................................................................................................204
7.4.5 Functions......................................................................................................................205
7.4.6 Diagnosis......................................................................................................................206
7.4.7 Parameters...................................................................................................................211
7.4.8 Technical Specifications...............................................................................................214
7.5 LK412 6-channel Isolation Analog Input Module.........................................................215
7.5.1 Basic Features .............................................................................................................215
7.5.2 Operating Principle.......................................................................................................216
7.5.3 Status Indicator ............................................................................................................216
7.5.4 Wirings..........................................................................................................................218
7.5.5 Functions......................................................................................................................219
7.5.6 Diagnosis......................................................................................................................221
7.5.7 Parameters...................................................................................................................228
7.5.8 Technical Specifications...............................................................................................230
7.6 LK430 6-channel Thermal Resistance Analog Input Module.....................................232
7.6.1 Basic Features .............................................................................................................232
7.6.2 Operating Principle.......................................................................................................232
7.6.3 Status Indicator ............................................................................................................233
7.6.4 Wirings..........................................................................................................................234
7.6.5 Functions......................................................................................................................235
7.6.6 Diagnosis......................................................................................................................237
7.6.7 Parameters...................................................................................................................240
7.6.8 Technical Specifications...............................................................................................242
7.7 LK441 8-channel Thermocouple Analog Input Module ..............................................244
7.7.1 Basic Features .............................................................................................................244
7.7.2 Operating Principle.......................................................................................................244
7.7.3 Status Indicator ............................................................................................................245
7.7.4 Wirings..........................................................................................................................247
7.7.5 Functions......................................................................................................................248
7.7.6 Diagnosis......................................................................................................................250
7.7.7 Parameters...................................................................................................................255
7.7.8 Technical Specifications...............................................................................................258
7.8 LK620 2-channel counting module...............................................................................260
7.8.1 Basic Features .............................................................................................................260
7.8.2 Operating Principle.......................................................................................................260
7.8.3 Operating Mode............................................................................................................261
7.8.4 Status Indicator ............................................................................................................265
7.8.5 Wirings..........................................................................................................................266
7.8.6 Function Description ....................................................................................................268
7.8.7 Diagnostic Instructions.................................................................................................280
7.8.8 Debounce Filtering.......................................................................................................281
7.8.9 Parameter Specifications.............................................................................................282

Contents
Beijing HollySys Intelligent Technologies Co., Ltd. All Rights Reserved V
7.8.10 Data Area.................................................................................................................... 285
7.8.11 Technical specifications.............................................................................................. 287
7.9 LK510 4-channel Inter-channel Isolated Voltage Type Analog Output Module....... 289
7.9.1 Basic Features ............................................................................................................ 289
7.9.2 Operating Principle...................................................................................................... 289
7.9.3 Wirings......................................................................................................................... 290
7.9.4 Functions..................................................................................................................... 291
7.9.5 Parameter.................................................................................................................... 293
7.9.6 Technical Specifications.............................................................................................. 294
7.10 LK511 4-channel Inter-channel Isolated Current Type Analog Output Module....... 295
7.10.1 Basic Features ............................................................................................................ 295
7.10.2 Operating Principle...................................................................................................... 296
7.10.3 Status Indicator ........................................................................................................... 297
7.10.4 Wirings......................................................................................................................... 298
7.10.5 Data Format ................................................................................................................ 299
7.10.6 Functions..................................................................................................................... 301
7.10.7 Diagnosis..................................................................................................................... 302
7.10.8 Parameters.................................................................................................................. 304
7.10.9 Data Area.................................................................................................................... 305
7.10.10Technical Specifications.............................................................................................. 306
Chapter 8 Accessory.................................................................................................................. 309
8.1 LKA101 PROFIBUS-DP Bus Connector Module......................................................... 309
8.1.1 Appearance and Size.................................................................................................. 309
8.1.2 Operating Principle...................................................................................................... 310
8.1.3 Terminal Matching Resistance.................................................................................... 310
8.1.4 Wiring .......................................................................................................................... 311
8.1.5 Installation ................................................................................................................... 312
8.1.6 Technical Specifications.............................................................................................. 312
8.2 LKA102 LK220 Battery Power Box Module................................................................. 312
8.2.1 Appearance................................................................................................................. 313
8.2.2 Installation Dimension................................................................................................. 314
8.2.3 Installation ................................................................................................................... 314
8.2.4 Battery Replacement................................................................................................... 314
8.2.5 Technical specifications.............................................................................................. 314
8.3 LKA103 LK220 Capacitance Power Box Module........................................................ 315
8.3.1 Appearance................................................................................................................. 315
8.3.2 Installation Dimension................................................................................................. 316
8.3.3 Installation ................................................................................................................... 316
8.3.4 Battery Replacement................................................................................................... 316
8.3.5 Technical Specifications.............................................................................................. 316
8.4 LKA104 PROFIBUS-DP Bus Connector Module......................................................... 316
8.4.1 Appearance and Size.................................................................................................. 317
8.4.2 Operating Principle...................................................................................................... 317
8.4.3 Terminal Matching Resistance.................................................................................... 318
8.4.4 Wiring .......................................................................................................................... 319
8.4.5 Installation ................................................................................................................... 319
8.4.6 Technical Specifications.............................................................................................. 319
8.5 LKA105 Optical Fiber..................................................................................................... 320
Chapter 9 Fault and Treatment.................................................................................................. 321

Contents
VI Beijing HollySys Intelligent Technologies Co., Ltd. All Rights Reserved
9.1 Fault Mechanism ...............................................................................................................321
9.1.1 Serious Failures ...........................................................................................................321
9.1.2 General Failures...........................................................................................................322
9.2 Troubleshooting Way........................................................................................................323
9.2.1 Indicator Lamp..............................................................................................................323
9.2.2 View Tool Information ..................................................................................................323
9.2.3 View Diagnosis Information .........................................................................................324
9.2.4 Example for Troubleshooting.......................................................................................325
9.3 Fault Phenomenon and Causes.......................................................................................327

Beijing HollySys Intelligent Technologies Co., Ltd. All Rights Reserved 1
Chapter 1 About This Book
1.1 Document Update
Version
Description
Date
V1.0
New
2016.06.14
V1.1
Add LK234
2017.04.11
V1.2
1. Update temperature and humidity
2. Update module name: LK610,LK710,LK441,LK511
3. Add LK410, LK510,LK620
2018.01.10
1.2 Purpose
This Manual mainly introduces the operational principle, major functions, wiring instructions,
configuration settings, technical specifications and so on of LK large-scale programmable controller
hardware products. It helps users to use the product properly.
1.3 Intended Audience
This Manual is applicable to the following people:
Engineers in charge of system engineering implementation.
Technicians in charge of system maintenance.
Installation personnel.
1.4 Document Conventions
1.4.1 Menu
The menu commands are described as [], such as [Reset], [Download], [Add Device].
The names of window and dialog are described as bold font, such as Device Library, Library,
Device Property.
1.4.2 Mouse
Point to: move mouse pointer on an object.
Press: press the left mouse button once and keep.

Chapter 1 About This Book
2 Beijing HollySys Intelligent Technologies Co., Ltd. All Rights Reserved
Click: Press the left mouse button once and release.
Right-click: Press the right mouse button once and release.
Double click: quickly press the left mouse button two times and release.
Drag: Press and hold the left mouse button while moving the mouse.
1.4.3 Keyboard
The names of keys on the keyboard are described with bold style, such as Shift、Enter、Shift+F2.
1.4.4 Important Information
1.5 Catalog
HollySys Programmable Logic Controller PLC Instruction Manual
AutoThink V3.1 User Manual_Project Configuration
LK Series Programmable Logic Controller System Manual
Danger icon. Indicates a potentially hazardous situation that could result in death or
serious injury.
Electric shock icon. Indicates a potentially hazardous situation that could result in
electric shock accident.
Warning icon, indicating that the operation may lead to the potential threats of failure
or damage to software and hardware equipments.
Important icon, identifies important information about the operations or functions
which need to be understood.
Operation icon. Indicates the operation method of an object.
Reference icon. Provides additional sources of the information.

Chapter 1 About This Book
Beijing HollySys Intelligent Technologies Co., Ltd. All Rights Reserved 3
1.6 Terminology
Terminology
Description
Profibus –DP
Standard bus protocol
MRAM
Magnetic random access memory, a nonvolatile memory
MODBUS
A serial interface industrial bus protocol, used for communication between electron
devices
PHY
PHY refers to the physical layer, the lowest level of OSI. It is the medium access
control and medium interface of the data link layer
PCIE
Peripheral Component Interface Express, a quick and peripheral interconnection
standard
1.7 Abbreviations
Abbreviations
Full Name
PLC
Programmable Logical Controller
I/O
Input / Output
DC
Direct Current
FPGA
Field Programmable Gate Array
TCP/IP
Transmission Control Protocol/Internet Protocol
Profibus
Process Field Bus
AI
Analog Input
AO
Analog Output
DI
Digital Input
DO
Digital Output
TC
Thermocouple Assembly
RTD
Resistance Temperature Detector
RTC
Real-Time Clock
HMI
Human Machine Interface
STP
Shielded Twisted Pair

Beijing HollySys Intelligent Technologies Co., Ltd. All Rights Reserved 5
Chapter 2 Overview
LK220 Master Control Module act as the master control unit for the medium and large PLC system in
hollysys company, which has high reliability, high performance, and fast response characteristics, can
be widely used in a variety of application scenarios, such as subway, water treatment, high-end
equipment, complex machines, and production line control. The redundant system is composed of the
controller, IO and configuration software, which can realize the functions of data acquisition, logic
calculation, output execution, human-computer interaction, data exchange and so on.
2.1 System characteristic
2.1.1 High Reliability
(1) Dual backplane redundant structure includes power redundancy, controller redundancy and
network redundancy.
(2) In redundancy mode, the system can run when there is a single fault.
(3) The system is based on the TCP/IP protocol to realize safety and reliable network
communication, and defense tens of thousands of zero day vulnerabilities and other
undisclosed vulnerabilities or risks. System has passed Wurldtech's Achilles international
certification.
(4) Support three proofing: moisture proofing, salt spray proofing and fungus proofing, satisfying
GB2423 • 3/ GB2423 • 17/ GB2423 • 16.
2.1.2 Fast Response
(1) The time for redundancy switching is no more than 130ms.
(2) The minimum time of task scheduling is less than100 us.
(3) The loop response time of system is less than 200ms.
2.1.3 Large Capacity
(1) Single-DP network, 124 IO slaves can be added.
(2) The IO capacity supported by the system is more than 10,000 points.
2.1.4 Easy Maintenance
(1) Reading Log tool can record abnormal operations, faults and other information, and more
than 10,000 logs.
(2) Module information and diagnostic information of each module can be obtained respectively
through Module Information Instruction Library and System State Instruction Library.
(3) Each module is hot-swappable.
(4) You can update the firmware via SD card orAutoThink software.

Chapter 2 Overview
6 Beijing HollySys Intelligent Technologies Co., Ltd. All Rights Reserved
2.2 Hardware components and structures
LK series large-scale PLC system adopt the dual backplane redundant structure, a large universal
controller is mounted separately on two backplanes, respectively,A series and B series. Each
redundant controller set consists of the following components:
Figure 2-1 LK Controller Components
1：LK921 24V power switching module
2：LK220 master control module
3：LK240 redundancy communication module
4：LK249 DP master station communication module
5：LK130 4-slot backboard module
1. 24V power switching module
Dual 24V DC inputs are converted to single 24V DC output by redundant processing, it provides
redundant 24VDC power supply for the 4 slot backboard.
2. Master control module
Master control module LK220 is redundant in configuration. Module contains two 10/100 Mbps
Ethernet interface for connection to a program computer, to download the user program and upgrade

Chapter 2 Overview
Beijing HollySys Intelligent Technologies Co., Ltd. All Rights Reserved 7
controller. And also as a MODBUSTCP master/slave station to communicate with other devices. You
can upgrade controller and store user files via SD card slot in panel. The controller runs in the different
mode by changing the position of key switch. In redundancy mode, two controllers are in master –
slave relationship, and the master switches to slave when fault occurs in master station.
3. Redundancy communication module
It is used to complete the redundant communication betweenA and B frame with fiber cable.
4. DP master station communication module
LK249 module includes two DB9 communication interface, connected to the expansion backboard
LK117 / LK118 by DP bus, establish the communication connection with IO module. LK249 module
exchanges data with master control module via the bus in backboard.
5. 4-slot backboard module
It is used to install the master control module, 24 V power switching module, redundancy
communication module, DP master station communication module. It supports both high-speed local
backboard bus and PROFIBUS-DP bus for data exchanging between modules.
LK249 and LK234 are used respectively to extend the IO modules, topological structure schematic
diagram of LK redundancy system in the two power supply ways as shown below:
Please note that you can exchange the installation slot of LK240 and LK249, both of
them can working normally.
LK220, LK240, LK249, LK921 and LK130 need to be installed in the cabinet.

LK220, LK240, LK249, LK921 and LK130 are designed for use in pollution degree 2.
Above modules should be installed inside a metal cabinet, IP rating of the cabinet no
less than IP41.

Chapter 2 Overview
8 Beijing HollySys Intelligent Technologies Co., Ltd. All Rights Reserved
Power
Module
1 2
2
External AC power supply 1
External AC power supply
Power
Module Power Module
3 4
Power
Module
Switch
PC
LK117/LK118
Switch
IO
LK117/LK118
IO
LK117/LK118
IO
Internal bus in
backboard
Backboard
Frame AFrame B
Backboard Internal bus in
backboard
LK220 LK240LK921 LK249 LK220 LK240LK921 LK249
(a)