Kinco K5 Series User manual

Kinco K5 PLC
HARDWARE MANUAL

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User’s Manual
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Contents
CONTENTS………………………………………………………………………………………………………1
PART I GENERAL INTRODUCTION.................................................................................................................6
CHAPTER I SYSTEM OVERVIEW ....................................................................................................................7
1.1 APPLICATION SCOPE OF THE PRODUCT.............................................................................................................. 7
1.2 GENERAL DESIGNATION IN THE MANUAL......................................................................................................... 7
1.2.1 Vocabulary of Terms................................................................................................................................. 7
1.3 NAME RULES FOR THE PRODUCT....................................................................................................................... 9
1.3.1 Description of the Product Name............................................................................................................. 9
1.3.2 Description of Order Number ................................................................................................................ 12
1.4 PRODUCT LIST OF KINCO-K5.......................................................................................................................... 13
PART II HARDWARE MANUAL......................................................................................................................15
CHAPTER I APPLICATION OF KINCO-K5 SERIES MICRO PLC................................................................16
1.1 ARCHITECTURE OF KINCO-K5...................................................................................................................... 16
1.1.1 Overview................................................................................................................................................ 16
1.1.2 Allowable System Scales........................................................................................................................ 16
1.1.3 Communicating over a Network............................................................................................................. 17
1.2 POWER SUPPLY DESIGN................................................................................................................................... 18
1.2.1 DC24V Power Supply calculation.......................................................................................................... 18
1.2.2Expansion power supply calculation ...................................................................................................... 19
1.2.3Input power of the CPU.......................................................................................................................... 20
1.3 OPERATION ENVIRONMENTAL CONDITION....................................................................................................... 20
CHAPTER II CPU PRINCIPLE AND APPLICATION......................................................................................22
2.1 OVERVIEW ..................................................................................................................................................... 22
2.1.1 Front view.............................................................................................................................................. 22

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2.1.2CPU Types .............................................................................................................................................. 22
2.2FUNCTIONS ..................................................................................................................................................... 24
2.2.1OperationMode....................................................................................................................................... 24
2.2.2Communication Port............................................................................................................................... 25
2.2.3Data Keep-in and Back Up..................................................................................................................... 25
2.2.4Real-time Clock (RTC)............................................................................................................................ 26
2.2.5High-speed counter and High-speed pulse output .................................................................................. 26
2.2.6 Trigger interrupt .................................................................................................................................... 26
2.3 WIRING DIAGRAM.......................................................................................................................................... 27
2.4SPECIFICATIONS .............................................................................................................................................. 35
2.4.1CPU Specifications................................................................................................................................. 35
2.4.2 CPU DI Specifications........................................................................................................................... 36
2.4.3 CPU DO Specifications(Transistor) ...................................................................................................... 37
2.4.4 CPU Output Specifications(Relay) ........................................................................................................ 37
2.4.5 AI channel parameters on CPU............................................................................................................. 38
2.4.6 AO Channel Parameters on CPU .......................................................................................................... 38
CHAPTER III DI (DIGITAL INPUT) MODULES.............................................................................................39
3.1 DI 8*DC24V................................................................................................................................................. 39
3.1.1 Wiring Diagram..................................................................................................................................... 39
3.1.2 Technical Data....................................................................................................................................... 40
3.2 DI 16*DC24V............................................................................................................................................... 41
3.2.1 Wiring Diagram..................................................................................................................................... 41
3.2.2 Technical Data....................................................................................................................................... 42
CHAPTER IV DO (DIGITAL OUTPUT) MODULES .......................................................................................43
4.1 DO 8*DC24V ............................................................................................................................................... 43
4.1.1 Wiring Diagram..................................................................................................................................... 43
4.1.2 Technical Data....................................................................................................................................... 44
4.2 DO 8*RELAY ................................................................................................................................................. 45
4.2.1 Wiring Diagram..................................................................................................................................... 45

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4.2.2 Technical Data....................................................................................................................................... 46
4.3 DO 16*DC24V ............................................................................................................................................. 47
4.3.1 Wiring Diagram..................................................................................................................................... 47
4.3.2 Technical Data....................................................................................................................................... 48
4.4 DO 16*RELAY............................................................................................................................................... 49
4.4.1 Wiring Diagram..................................................................................................................................... 49
4.4.2Technical Data........................................................................................................................................ 50
CHAPTER V DI/O MODULES..........................................................................................................................51
5.1 DI/O, DI4*DC24V DO4*DC24V................................................................................................................. 51
5.1.1Wiring Diagram...................................................................................................................................... 51
5.1.2Technical Data........................................................................................................................................ 52
5.2 DI/O,DI 4*DC24VDO 4*RELAY .................................................................................................................. 54
5.2.1Wiring Diagram...................................................................................................................................... 54
5.2.2Technical Data........................................................................................................................................ 54
5.3 DI/O, DI 8*DC24VDO 8*DC24V................................................................................................................ 56
5.3.1Wiring Diagram...................................................................................................................................... 56
5.3.2Technical Data........................................................................................................................................ 56
5.4 DI/O, DI 8*DC24V DO 8*RELAY................................................................................................................. 58
5.4.1Wiring Diagram...................................................................................................................................... 58
5.4.2Technical Data........................................................................................................................................ 58
CHAPTER VI AI (ANALOGINPUT) MODULES.............................................................................................60
6.1 AI 4*IV, MULTI-SIGNAL INPUT ...................................................................................................................... 60
6.1.1Wiring Diagram...................................................................................................................................... 60
6.1.2Measurement Ranges and The measured value Representation.............................................................. 61
6.1.3Technical Data........................................................................................................................................ 61
6.2 AI 4*RD, RTD INPUT .................................................................................................................................... 62
6.2.1Wiring Diagram...................................................................................................................................... 62
6.2.2Measurement Ranges and The measured value Representation.............................................................. 62
6.2.3Technical Data........................................................................................................................................ 63

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6.3 AI 4*TC, THERMOCOUPLE INPUT ................................................................................................................... 64
6.3.1Wiring Diagram...................................................................................................................................... 64
6.3.2Measurement Ranges and The measured value Representation.............................................................. 65
6.3.3 Technical Data....................................................................................................................................... 65
CHAPTER VII AO (ANALOG OUTPUT) MODULES.....................................................................................66
7.1 AO 2*IV, MULTI-SIGNAL OUTPUT ................................................................................................................. 66
7.1.1Wiring Diagram...................................................................................................................................... 66
7.1.2Output Ranges and the Output Value Representation ............................................................................. 66
7.1.3Technical Data........................................................................................................................................ 67
CHAPTER VIII AI/O (ANALOG INPUT/OUTPUT) MODULES ....................................................................68
8.1 AI/O, AI 2×IVAO 2×IV, MULTI-SIGNAL OUTPUT........................................................................................ 68
8.1.1Wiring Diagram...................................................................................................................................... 69
8.1.2Measurement Ranges and The measured value Representation.............................................................. 69
8.1.3 Output Ranges and the Output Value Representation ............................................................................ 69
8.1.4Technical Data........................................................................................................................................ 70
CHAPTER IX EXPANSION FUNCTION MODULES......................................................................................71
9.1 K541, CAN BUS MODULE.............................................................................................................................. 71
9.1.1 Main Features........................................................................................................................................ 71
9.1.2Terminals and Status LEDs..................................................................................................................... 72
9.1.3Wiring and Arranging............................................................................................................................. 73
9.1.4Technical data......................................................................................................................................... 74
9.2 EXPANSION POWER MODULE ......................................................................................................................... 75
9.2.1 Main Specifications................................................................................................................................ 75
9.2.2 PS580 used in the actual application..................................................................................................... 76
9.2.3 CPU selection and PS580 Calculation .................................................................................................. 76
9.2.4 Technical Data....................................................................................................................................... 78
CHAPTER X INSTALLATION&WIRING GUIDELINES................................................................................79
10.1 PLASTIC CASE DIMENSION ........................................................................................................................... 79

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10.2 INSTALLATION GUIDELINES .......................................................................................................................... 80
10.2.1 Module Connection.............................................................................................................................. 80
10.2.2 Installing the KINCO-K5 modules....................................................................................................... 81
10.3 INSTALLATION AND REMOVING THE WIRING TERMINAL ROW........................................................................... 83
10.3.1 Remove wiring terminal row................................................................................................................ 83
10.3.2 Install the terminal row........................................................................................................................ 83
10.4 PROTECTION CIRCUIT AND GROUND CONNECTION.......................................................................................... 84
10.4.1 Protection function of transistor digital Output................................................................................... 84
10.4.2 Protection function of Relay output...................................................................................................... 84
10.4.3 Grounding......................................................................................................................................... 85

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Part I
General Introduction

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Chapter I System Overview
This chapter will briefly introduce the Kinco-K5 series micro PLC (Programmable Logic Controller) and
focuses on the explanation of the terms related to Kinco-K5 with a purpose of facilitating you to understand the
contents in the following part of this manual. The main content of this chapter covers: application scope of the
product, explanations on relevant terms, rules for nomenclature, etc.
1.1 Application Scope of the Product
According to the accepted classification rules for PLC, Kinco-K5 series PLC falls into the range of micro PLC.
Therefore, it can be used to control machines and small-scale process. Kinco-K5 series PLC can well satisfy the
demands in the following application areas (including but not limited to these applications):
Packing machinery textile machinery building material machinery
Food machinery plastic machinery numerical control machine
Printing mechanism central air conditioner
Environmental Machinery individual process control device
1.2 General Designation in the Manual
1.2.1 Vocabulary of Terms
▪Micro PLC (Programmable Logic Controller)
According to the general classification rules, micro PLC generally refers to the type of PLC with the IO number
less than 128. This type of PLC usually adopts compact structure, that is, a certain number of I/O channels,
output power supply; high-speed output/input and other accessories are integrated on the CPU module.
▪CPU body
Namely, the CPU module, it‟s the core of the control system. The user program is stored in the internal storage of
the CPU module after being downloaded through the programming software, and will be executed by the CPU.
Meanwhile, it also executes the CPU self diagnostics: check each modules‟ operation status and operation error of
user program
▪Expansion module & expansion bus

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The expansion module is used to extend the functions of the CPU body and it contains expansion I/O module
(to extend the input/output channels of the system) and expansion functional module (to expend the functions of
CPU).
The expansion bus connects the CPU and expansion modules, and the 16-core flat cable is adopted as the
physical media. The data bus, address bus and the expansion module‟s working power supply are integrated into
the expansion bus cable.
▪KincoBuilder
The programming software for Kinco-K5 series PLC, accords with IEC61131-3 standard. KincoBuilder presently
provides LD and IL languages for convenience and efficiency in developing the control programs for your
applications. KincoBuilder provides a user-friendly environment to develop and debug the programs .
▪CPU firmware
It is the “operating system” of the CPU module and it is stored in the Flash memory. When powered on, it starts
to manage and arrange all the tasks of the CPU module.
▪User program
It‟s also called user project or application program, the program written by the user to execute some specific
control functions. After the user program is downloaded to the CPU module, it is stored in the FRAM. When
powered on, the CPU module shall read it from FRAM into RAM to execute it.
▪Main program and scanning cycle
The CPU module executes a series of tasks continuously and cyclically, and we call this cyclical execution of
tasks as scanning.
The main program is the entry of application program. In the CPU, the main program is executed once per
scanning cycle and there is only one main program in application program, user can call multiple sub-routines in
from main program.
▪Free-protocol communication
The CPU body provides serial communication ports that support the special programming protocol Modbus RTU

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protocol (as a slave) and free protocols. Free-protocol communication mode allows your program to fully control
the communication ports of the CPU. You can use free-protocol communication mode to implement user-defined
communication protocols to communicate with all kinds of intelligent devices. ASCII and binary protocols are
both supported.
▪I/O Mapping Area
The memory area of physical I/O terminals, which is including input mapping area and output mapping area. In
order to ensure data consistency in one scanning cycle and to improve the program execution speed, CPU will
read the status of physical inputs to input mapping area at the beginning of a scanning cycle and send the output
mapping area data to physical output channels at the ending of scanning cycle. The IO address in this manual,
like I0.0, Q1.0, AIW0, AQW0 and so on , they are all I/O mapping area address.
▪Retentive Area Range and Data backup
In “Hardware” configuration of KincoBuilder, you can define four retentive ranges to select the areas of the
RAM which you want to retain on power loss. In the event that the CPU loses power, the instantaneous data in
the RAM will be maintained by the lithium cell, and the data in retentive ranges will be retentive at next power
on. The retaining duration is 3 years at normal temperature.
Data backup is hat PLC has a particular memory area in FRAM. The data in this area will be permanent storage
automatically. Note: Every type of permanent memory has its own expected life, for example, E2PROM allows
100 thousand of times of writing and FRAM provides unlimited read/write endurance.
1.3 Name Rules for the product
1.3.1 Description of the Product Name
The “product name” of Kinco-K5 PLC is used to indicate the main functions and applications of the product.
The “product name” is not for any individual product but the general name for a type of products. The “product
name” is defined according to the following principle:
Product name: module type + 5 + subtype + serial number + function identification
Module type is indicated by the following English letters
CPU CPU module
PM expansion I/O module