LS Industrial Systems SV-iS7 PLC User manual

Right choice for ultimate yield
LSIS strives to maximize customers' profit in gratitude of choosing us for your
partner.
iS7 PLC Option User Manual
SV-iS7 PLC Option Card
z Read this manual carefully before
installing, wiring, operating, servicing
or inspecting this equipment.
zKeep this manual within easy reach
for quick reference.

Chapter 1 General
1.1 Guide to Use This Manual··············································································1 - 1
1.2 Features ·······································································································1 - 2
1.3 Terminology ··································································································1 - 3
Chapter 2 system Configuration
2.1 Overall System Configuration ······································································2 - 1
2.1.1 Basic System ·······················································································2 - 1
2.1.2 Product Block Diagram ········································································2 - 2
2.2 Exterior of Product ························································································ 2 – 3
Chapter 3 General Specification
3.1 General Specification ···················································································3 - 1
Chapter 4 CPU Function
4.1 CPU Performance Specification ···································································4 - 1
4.2 Operation Processing ··················································································· 4 - 2
4.2.1 Operation Processing Method ·····························································4 - 2
4.2.2 Operation Processing at Momentary Power Failure Occurrence ··········4 - 3
4.2.3 Scan Time ····························································································4 - 3
4.2.4 Scan Watchdog Timer ··········································································4 - 4
4.2.5 Timer Processing ·················································································4 - 4
4.2.6 Counter Processing ··············································································4 - 7
4.3 Program ········································································································4 - 9
4.3.1 Classification of Program ·····································································4 - 9
4.3.2 Program Execution Procedure ···························································4 - 10
4.3.3 Interrupt Program ·········································································· 4 - 11
4.3.4 Error Handling ··················································································· 4 – 13
4.4 Operation Mode ··························································································4 - 14
4.4.1 RUN mode ·························································································4 - 14
4.4.2 STOP mode ························································································4 - 15
4.4.3 PAUSE mode ·····················································································4 - 15
4.4.4 Operation mode change method ·······················································4 - 15
4.5 Function ······································································································4 - 17
4.5.1 Self-diagnosis ·····················································································4 - 17

4.5.2 Forced Input/Output On/Off function……………………………………·4 - 17
4.5.3 Direct I/O operation function ······························································4 - 20
4.5.4 System Error History ··········································································4 - 20
4.6 Memory Configuration ················································································4 - 22
4.7 RTC Function ·····························································································4 - 23
4.7.1 Usage···································································································4 - 23
Chapter 5 Input and Output Function
5.1 Input and Output Specification ·····································································5 - 1
5.2 Digital Input Specification ············································································ 5 – 2
5.3 Digital Output Specification ········································································· 5 – 4
Chapter 6 Usage of Various Function
6.1 Built-in Functions ························································································· 6 – 1
6.1.1 Pulse Catch Function ···········································································6 - 1
6.1.2 Input Filter Function ·············································································6 - 3
6.1.3 External Interrupt Function·····································································6 - 4
6.1.4 PID Control Function············································································· 6 – 6
Chapter 7 Exclusive Functions for iS7 Inverter Control/Monitoring
7.1 Outline and Installation···················································································7 - 1
7.1.1 Outline and Major Components of the Product ····································7 - 1
7.1.2 Detail description of the components ···················································7 - 3
7.2 Functions of PLC option card exclusively for iS7 inverter ····························7 - 9
7.2.1 List of the special D registers for iS7 inverter control and monitoring ··· 7 - 9
7.2.2 Control (PLC Option ÆInverter)·························································7 - 10
7.2.3 Monitoring (PLC Option Inverter) ····················································7 - 14
Chapter 8 Modbus Communication
8.1 Modbus Communication··············································································· 8 – 1
8.1.1 Introduction ····························································································8 - 1
8.1.2 Basic Specification ···············································································8 - 1
8.1.3 Parameter Setting ················································································8 - 4
8.1.4 Instruction ·························································································· 8 – 6

Chapter 9 Maintenance
9.1 Maintenance and Inspection ········································································9 - 1
9.2 Daily Inspection······························································································9 - 1
Chapter 10 Troubleshooting
10.1 Basic Procedures of Troubleshooting ························································10 - 1
10.2 Troubleshooting··························································································10 - 1
10.2.1 Troubleshooting flowchart used when the ERR LED is flickering······10 - 2
10.2.2 Troubleshooting flowchart used when the RUN LED turns off. ·········10 - 3
10.2.3 Troubleshooting flowchart used when the I/O part doesn’t operate normally
······················································································································10 - 4
10.2.4 Troubleshooting flowchart used when a program cannot be written to the CPU
part ················································································································10 - 6
10.3 Troubleshooting Questionnaire ··································································10 - 7
10.4 Troubleshooting and Countermeasure ·····················································10 - 8
10.4.1 Input circuit troubles and corrective actions·······································10 - 8
10.4.2 Output circuit troubles and corrective actions ··································10 - 9
10.5 Error Code List ······················································································· 10 - 11
Appendix
Appendix 1. System Definitions ·························································Appendix 1 - 1
Appendix 2. Flag List··········································································· Appendix 2 – 1
Appendix 3. Control and Monitoring Specific Inverter Data ·················Appendix 3 - 1
Appendix 4. Common Area Parameter of iS7 Inverter·························Appendix 4 - 1

Safety Instructions
1
Before using the product …
For your safety and effective operation, please read the safety instructions thoroughly before using the product.
► Safety Instructions should always be observed in order to prevent accidents or risks with the safe and
proper use of the product.
► Instructions are separated into “Warning” and “Caution”, and the meaning of the terms is as follows;
This symbol indicates the possibility of serious injury or death if some applicable
instruction is violated
This symbol indicates the possibility of slight injury or damage to products if some
applicable instruction is violated
► The marks displayed on the product and in the user’s manual have the
following meanings.
Be careful! Danger may be expected.
Be careful! Electric shock may occur.
► The user’s manual should be kept available and accessible to any user of the product even after it’s been
read.
SAFETY INSTRUCTIONS
Warning
Caution

Safety Instructions
2
Design Precautions
Install a safety circuit external to the PLC that keeps the entire system safe even when
there are problems with the external power supply or the PLC module. Otherwise,
serious trouble could result from erroneous output or erroneous operation.
-Outside the PLC, construct mechanical damage preventing interlock circuits such as
emergency stop, protective circuits, positioning upper and lower limits switches and
interlocking forward/reverse operation.
When the PLC detects the following problems, it will stop calculation and turn off all output in
the case of watchdog timer error, module interface error, or other hardware errors.
However, one or more outputs could be turned on when there are problems that the PLC
CPU cannot detect, such as malfunction of output device (relay, transistor, etc.) itself or I/O
controller. Build a fail safe circuit exterior to the PLC that will make sure the equipment
operates safely at such times. Also, build an external monitoring circuit that will monitor any
single outputs that could cause serious trouble.
Make sure all external load connected to output does NOT exceed the rating of output
module.
Overcurrent exceeding the rating of output module could cause fire, damage or erroneous
operation.
Build a circuit that turns on the external power supply when the PLC main module
power is turned on.
If the external power supply is turned on first, it could result in erroneous output or erroneous
operation.
Warning

Safety Instructions
3
Safety Instructions for design process
Installation Precautions
Do not bunch the control wires or communication cables with the main circuit or power wires, or
install them close to each other. They should be installed 100mm (3.94inch) or more from each
other.
Caution
Use the PLC option card in an environment that meets the general specification contained in
this manual or datasheet.
Using the PLC option card in an environment outside the range of the general specifications could
result in electric shock, fire, erroneous operation, and damage to or deterioration of the product.
Completely turn off the power supply before loading or unloading the module.
Not doing so could result in electric shock or damage to the product.
Make sure all modules are loaded correctly and securely.
Not doing so could cause a malfunction, failure or drop.
Make sure I/O and extension connector are installed correctly.
Poor connection could cause an input or output failure.
When install the PLC option card in environment of much vibration, be sure to insulate the
PLC option card from direct vibration.
Not doing so could cause electric shock, fire, and erroneous operation.
Be sure to there are no foreign substances such as conductive debris inside the module.
Conductive debris could cause fires, damage, or erroneous operation.
Caution

Safety Instructions
4
Wiring Precautions
Completely turn off the external power supply when installing or placing wiring.
Not doing so could cause electric shock or damage to the product.
Make sure that all terminal covers are correctly attached.
Not attaching the terminal cover could result in electric shock.
Be sure that wiring is done correctly be checking the product’s rated voltage and the terminal
layout.
Incorrect wiring could result in fire, damage, or erroneous operation.
Tighten the terminal screws with the specified torque.
If the terminal screws are loose, it could result in short circuits, fire, or erroneous operation.
Be sure to ground the FG or LG terminal to the protective ground conductor.
Not doing so could result in erroneous operation.
Be sure there are no foreign substances such as sawdust or wiring debris inside the module.
Such debris could cause fire, damage, or erroneous operation.
Warnin
g
Caution

Safety Instructions
5
Startup and Maintenance Precautions
Disposal Precaution
Do not touch the terminals while power is on.
Doing so could cause electric shock or erroneous operation.
Switch all phases of the external power supply off when cleaning the module or retightening
the terminal or module mounting screws.
Not doing so could result in electric shock or erroneous operation.
Do not charge, disassemble, heat, place in fire, short circuit, or solder the battery.
Mishandling of battery can cause overheating or cracks which could result in injury and fires.
Do not disassemble or modify the modules.
Doing so could cause trouble, erroneous operation, injury, or fire.
Switch all phases of the external power supply off before mounting or removing the module.
Not doing so could cause failure or malfunction of the module.
Use a cellular phone or walky-talky more than 30cm (11.81 inch) away from the PLC option
card.
Not doing so can cause a malfunction.
When disposing of this product, treat it as industrial waste.
Not doin
g
so could cause
p
oisonous
p
ollution or ex
p
losion.
Warnin
g
Caution
Caution

Chapter 1 General
1-1
Chapter 1 General
1.1 Guide to Use This Manual
This manual includes specifications, functions and handling instructions for the PLC
option card for dedicated iS7 inverter. This manual is divided up chapters as follows:
No. Title Contents
Chapter 1 General Describes configuration of this manual, unit’s for features
and terminology.
Chapter 2 System
Configuration
Describes available units and system configuration in the
iS7 PLC option card.
Chapter 3 General
Specification
Describes general specifications of units used in the PLC
option card.
Chapter 4 CPU
Chapter 5 Input and Output
Chapter 6 Usage of Various
Functions
Describes each kind of Manufactured goods’ usage and
specifications.
Chapter 7
iS7 Inverter
Control/Monitoring
Function
Describes the most important function which is
control/monitoring of PLC option card of iS7 inverter.
Chapter 8 Communication
Function
Describes the built-in communication function of PLC option
card.
Chapter 9 Maintenance Describes the items to be checked for long-term normal
operation of the iS7 PLC option card.
Chapter 10 Troubleshooting Describes the various operation errors and corrective
actions.
Appendix 1 System Definitions Describes parameter setting for basic I/O and
communications module.
Appendix 2 Flag List Describes the types and contents of various flags.
Appendix 3
Control and
Monitoring Specific
Inverter Data
Describes enables control or monitoring of the specific
data of inverter.
Appendix 4
Common Area
Parameter of iS7
Inverter
Describes the common area parameter of iS7 inverter need
ed for control/monitoring of iS7 inverter.
Remark
-. This manual does not describe the programming method. For their own functions, refer
to the related user's manuals.

Chapter 1 General
1-2
1.2 Features
1) iS7 PLC option card is compact type which is integrated the function of CPU, Input and output,
and communication function. PLC option card has features of below described.
(1) High speed processing
High speed processing of 0.1μs/Step
(2) Various built-in functions
PLC option card can perform the various system by just using the one option card.
•Fast processing applications
- Pulse catch:
Allows the option card to read a pulse which has a width as small as 10 ㎲ .
- External interrupt: Using in various applications with built-in 6 interrupt input that
high-priority event which requires immediate responses.
•The input filter function helps to reduce the possibility of false input conditions from
external noise, such as signal chattering. The filter time can be programmed from 0 to
1000ms.
•Using RS-232C and RS-485 built-in port, the option card can connect with external
devices, such as personal computers or monitoring devices and communicate 1:N
with external device.
•Using built-in PID control function, PID control system can be constructed without
using separate PID module.
(3) Battery-less
The user’s program can be saved permanently without battery, because it is stored in
EEPROM.
(4) When program is edited during processing, it is stored in EEPROM automatically.
(5) It supports the Master function at Modbus-RTU protocol.
(6) It can easily do On/Off of the system, using RUN/STOP switch.
(7) it can save the program permanently in EEPROM by easy editing with KGLWIN.
(8) Strong self-diagnostic function
It can detect the cause of errors with more detailed error codes.
(9) It can prevent unintentional reading and writing, using password.
(10) Various program execution functions
External and internal interrupt program as well as scan program can be executed by
setting the execution condition. Therefore, user can set various program execution
modes.

Chapter 1 General
1-3
1.3 Terminology
The following table gives definition of terms used in this manual.
Terms Definition Remarks
KGLWIN
A programming and debugging tool for the MASTER-K
series. It executes program creation, edit, compile and
debugging (A computer software).
-
I/O Image Area Internal memory area of the CPU module which is used
to hold I/O statuses.
-
RTC
Abbreviation of ‘Real Time Clock’. It is used to call
general IC that
contains clock function.
-
Watchdog Timer
Supervises the pre-set execution times of programs and
warns if a program is not completed within the pre-set
time.
-

Chapter 2 System Configuration
2-１
Chapter 2 System Configuration
2.1 System Configuration
2.1.1 Basic System
Input points 6 Points (NPN/PNP))
Output points Relay output 4 points
RS232C 1 port (Program download from KGLWIN)
RS485 1 port (Modbus-RTU Master/Slave)
Display LED 2 ea (Green: RUN LED, Red: ERROR LED)
Switch 3 step switch for RUN, PAU/REM, STOP
Clock function Built-in RTC (Real Time Clock)
Data Back-up Data of latch area and RTC data through using CR2032 lithium
battery)

Chapter 2 System Configuration
2-２
2.1.2 Product Block Diagram
PLC option card for iS7 inverter series’ block diagram is as following.
Input Signal
Built-inRS-232C I/FOutputSignal
Classification Main Function
CPU •Signal processing
-. Operating System function
-. Application program saving function
-. Data saving function
-. Application execution function
Input •Convert the input signal and data to proper signal level from
controlled device.
Output •Convert the output signal and data to proper signal level from
actuator and display device.
Communication •Configure the 1:1 communication system to connect with PADT
(KGLWIN) or built-in RS-232C/RS485 communication.
Comm
Input
Output
CPU
Built-in RS-485

Chapter 2 System Configuration
2-３
2.2 Exterior of Product
Symbol Name Usage
LED1 RUN LED On state: Local Run (SW1 position is RUN) or Remote Run (SW1
position is PAU/REM) and Select the RUN icon at KGLWIN.
LED2 ERR LED 1) Flickering : It flickering when Error is occurred.
2) OFF : It is Off at normal operation.
SW1 Mode Switch
1) RUN position : Program Execution
2) PAU/REM position : Temporary stop, Remote Rung/Stop
Execution etc.
3) STOP position : Program Stop
J1 PLC OS Download
Jumper
1) Factory default state. Do not use other setting. Please
contact LSIS customer service center.
2) Do not operate the jumper as below setting. Please
contact LSIS customer service center.
J2 Terminal Selection
Jumper
1) ON: Select the communication terminal resistor of RS485.
(Built-in resistor 120 ohm.)
2) OFF: None
Normal
State
OS Download mode

Chapter 2 System Configuration
2-４
Symbol Name Usage
J3 NPN/PNP
Selection jumper
1) NPN mode: Connect terminal input (P00~P05) with 24G.
2) PNP mode: Connect the terminal input (P00~P05) with
24P.
CON1 RS232C
communication
connector
Connector to communicate with KGLWIN
Battery Battery Insertion
part
1) Function : Maintaining of the Latch area data and RTC
data at power failure
2) Battery type: Coin type lithium battery (CR2032)
3) Life : about 4 years with power off (normal temperature,
capacity 220mAh assumed)
1: S+(RS485) 2: S-(RS485)
3: 24G 4: Terminal InputP00
5: Terminal InputP01 6: Terminal InputP02
7: Terminal InputP03 8: Terminal InputP04
9: Terminal InputP05 10: 24G
11: 24P (output 24V) -
12: Terminal Output P40 13: Terminal Output P40C
14: Terminal Output P41 15: Terminal Output P41C
16: Terminal Output P42 17: Terminal Output P42C
TB1 Terminal Blcok
18: Terminal Output P43 19: Terminal Output P43C
NPN mode
PNP mode

Chapter 3 General Specifications
3-1
Chapter 3 General Specifications
3.1 General Specifications
The following table shows the general specifications of the PLC option card for iS7 inverter series.
No. Item Specifications References
1 Operating ambient
Temperature 0 ~ 55 °C -
2 Storage ambient
Temperature −25 ~ +70 °C -
3 Operating ambient
Humidity 5 ~ 95%RH, non-condensing -
4 Storage ambient
Humidity 5 ~ 95%RH, non-condensing -
Occasional vibration - -
Frequency Acceleration Amplitude Sweep count
10 ≤f <57Hz −0.075mm
57 ≤f ≤150Hz 9.8m/s2{1G} −
Continuous vibration
Frequency Acceleration Amplitude
10 ≤f <57Hz −0.035mm
5 Vibrations
57 ≤f ≤150Hz 4.9m/s2{0.5G} −
10 times for
each
X, Y, Z axis
IEC 61131-2
6 Shocks
•Maximum shock acceleration: 147 m/s2{15G}
•Duration time: 11ms
•Pulse wave: half sine pulse (3 shocks per axis, on X, Y, Z axis) IEC 61131-2
Square wave
Impulse noise ±1,500 V LSIS’ Internal
Standard
Electronic
discharge Voltage: 4 kV ( Discharge by contact ) IEC 61131-2,
IEC 1000-4-2
Radiated
electromagnetic
field noise
27 ~ 500 MHz, 10 V/m IEC 61131-2,
IEC 1000-4-3
Item Power
supply
Digital I/O/Analog I/O
Communication Interface
7 Noise Immunity
Fast transient &
Burst noise Voltage 2kV 1kV
IEC 61131-2
IEC 1000-4-4
8 Atmosphere Free of corrosive gases and excessive dust -
9 Altitude Up to 2,000m -
10 Pollution degree Less than 2 -
11 Cooling method Air-cooling -
1) IEC (International Electrotechnical Commission): An international civilian institute who establishes
international standards in the area of electric and electronics.
2) Pollution degree: An indicator, which indicates pollution degree, which determine insulation
performance of equipment.
* Pollution degree 2: Normally, only non-conductive pollution occurs. Occasionally, however, a
temporary conductivity caused by condensation shall be expected.
REMARK

Chapter 4 CPU Function
4 - 1
Chapter 4 CPU Function
4.1 CPU Performance Specification
The following table shows the general specifications of the PLC option card of iS7 inverter.
Item Specifications Remark
Program Control Method
Cyclic execution of stored program, Time-driven interrupt, Process-
driven interrupt -
I/O Control Method Indirect mode(Refresh method), Direct by program command -
Program Language Ladder Diagram Program, Instruction List Program -
Basic 29 -
Number of
Instruction Application 223 Instructions (note 1) -
Program Capacity 2 ksteps -
I/O Points Digital Input 6 points/Digital Output (Relay) 4 points -
P P000 ~ P0005 (External Input), P0040 ~ P0043 (External Output) I/O Relay
M M000 ~ M191F Internal Relay
K K000 ~ K31F Keep Relay
L L000 ~ L63F Link Relay
F F000 ~ F63F Special Relay
T
- 100ms: T000 ~ T191 (192 points)
- 10ms: T192 ~ T250 (59 points)
- 1ms: T251 ~ T255 (5 points), Adjustable by parameter setting
Timer
C C000 ~ C255 Counter
S S00.00 ~ S99.99 Step Relay
Memory
Device
D D0000 ~ D4999 Data Register
Operation Methods RUN, STOP, PAUSE -
Self-diagnosis Functions Detects errors of scan time, memory, I/O and power supply -
Data Back-up Method at
Power Interruption
Data of Latch and RTC area at basic parameter is reserved when
power is turned Off/On with mercury battery (CR2032). -
PID Control
Function
Controlled by commands, Relay and PRC auto tuning,
PWM output, manual output, adjustable operation scan time,
Anti-windup, SV-Ramp, Delta MV, Position and Velocity algorithm
-
Cnet I/F
Function
MODBUS protocol supported (RS-485 1 port) -
External
Interrupt
6 points -
Input Filter 0 ~ 1000 ms (Adjustable via Basic Parameter) -
Built-in
Function
RTC Function Year/Month/Day/Time/Minute/Second (Available to set by KGLWIN) -
(note 1) Except for DRCV, DSND, HMDA, HMDAP, HMDB, HMDBP, HSC, HSCST, PLSOUT, POSCTR, POSDST, POSIST,
POSJOG, POSORG, POSPRS, POSSOR, POSVEL, PWM, SCAL, SCALP, SND8, SNDCOM Instructions

Chapter 4 CPU Function
4 - 2
4.2 Operation Processing
4.2.1 Operation Processing Method
1) Cycle operation
A PLC program is sequentially executed from the first step to the last step, which is called scan. This sequential
processing is called cyclic operation. Cyclic operation of the PLC option card continues as long as conditions
do not change for interrupt processing during program execution. This processing is classified into the following
stages:
Stages Processing
-
Stage for the start of a scan processing. It is executed only one
time when the power is applied or reset is executed. It executes
the following processing.
I/O reset▶Execution of self▶-diagnosis
Data clear▶Allocating I/O address and type▶
Input conditions are read and stored into the input image area
before it starts processing.
Program is sequentially executed from the first step to
the last step Program operation processing.
The contents stored in the output image area is output to output
part when operation processing of a program is finished.
Stage for return processing after the CPU part has finish
ed 1 scan.
The END processing following processing is executed.
▶Self-diagnosis
▶Change present values of timer and counter, etc.
▶Processing data communications between computer
link module and communications module.
▶Checking the switch for mode setting.
2) Interrupt operation method
If a situation occurs which is requested to be urgently processed during execution of a PLC progra
m, this operation method processes immediately the operation, which corresponds to interrupt progr
am. The signal, which informs the CPU of those urgent conditions is called interrupt signal. The C
PU has two kinds of interrupt operation methods, which are internal and external interrupt signal me
thods.
Operation Start
Initialization
Input Image Area Refresh
Program operation processing
Program starts
Program ends
Output image area refresh
END processing

Chapter 4 CPU Function
4 - 3
4.2.2 Operation Processing at Momentary Power Failure Occurrence
The momentary power failure occurs when the input line voltage to the power supply falls down
below the rated voltage. When momentary power failure occurs within 10ms, the PLC option card
maintain operation processing. But if it exceeds 10ms, PLC option card stops processing and all
output turns off. And The re-start process is executed as the power is re-applied.
1) Momentary power failure within 10 ms
2) Momentary power failure exceeding 10 ms
Remark
1) Momentary power failure
The PLC option card defining power failure is a state that the voltage of power has been
lowered outside the allowable variation range of it. The momentary power failure is a power
failure of short interval (several to tens ms).
4.2.3 Scan Time
The processing time from a 0 step to the 0 step of next scan is called scan time.
1) Expression for scan time
Scan time is the sum of the processing time of scan program that the user has written, of the
task program processing time and the PLC option card internal processing time.
(1) Scan time = Scan program processing time + Interrupt program processing time +
PLC option card internal processing time
• Scan program processing time = The processing time used to process a user program
that is not specified to a task program.
• Interrupt program processing time = Total of the processing time of interrupt programs
executed during one scan.
• PLC option card internal processing time = Self-diagnosis time + I/O refresh time + Inte
rnal data processing time + Communications service proce
ssing time
Input
Power
Momentary power failure
within 1Oms
→The operation processing is maintained.
Input
Power Power failure exceeding
→The re-start process is executed as the power is
re-applied.