38 1 15MB
HOLLiAS MACS
K Series Hardware Manual
V1.7 2017.06
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 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 HollySys 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, HollySys 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 HollySys Group, 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 HOLLiAS MACS, HollySys, and the logos are registered trademarks of HollySys Group. All other trademarks are the property of their respective holders. Copyright © HollySys Group. All rights reserved. Hangzhou HollySys Automation CO., Ltd. North No.1, No.19 Road, Xiasha Economic-Technological Development Zone, Hangzhou, Zhejiang 310018, China Hotline: 400-881-0808 Eamil: [email protected] Website: http://www.hollysys.com
Contents Chapter 1
About This Book.............................................................................................................1
1.1
What’s New .............................................................................................................................1
1.2
Purpose...................................................................................................................................1
1.3
Intended Audience.................................................................................................................1
1.4 Document Conventions ........................................................................................................2 1.4.1 Menu.................................................................................................................................2 1.4.2 Mouse ...............................................................................................................................2 1.4.3 Keyboard ..........................................................................................................................2 1.4.4 Online Help .......................................................................................................................2 1.4.5 Important Information .......................................................................................................2 1.5
Abbreviations .........................................................................................................................3
Chapter 2
Overview..........................................................................................................................5
2.1
Basic Specifications ..............................................................................................................7
2.2
Certifications ..........................................................................................................................7
Chapter 3
Power Devices ................................................................................................................9
3.1 K-PW01 ................................................................................................................................. 11 3.1.1 Hardware ........................................................................................................................11 3.1.1.1 Dimensions ...........................................................................................................13 3.1.2 Technical Specifications.................................................................................................13 3.2 K-PW11..................................................................................................................................14 3.2.1 Hardware ........................................................................................................................14 3.2.1.1 Dimensions ...........................................................................................................16 3.2.2 Technical Specifications.................................................................................................16 3.3 K-PW21 .................................................................................................................................17 3.3.1 Hardware ........................................................................................................................17 3.3.1.1 Dimensions ...........................................................................................................19 3.3.2 Technical Specifications.................................................................................................19 3.4 HPW2405G............................................................................................................................20 3.4.1 Hardware ........................................................................................................................20 3.4.2 Protections .....................................................................................................................21 3.4.2.1 Overload Protection ..............................................................................................21 3.4.2.2 Overvoltage Protection .........................................................................................21 3.4.2.3 Short Circuit Protection ........................................................................................21 3.4.2.4 Over Temperature Protection ...............................................................................21 3.4.3 Redundancy ...................................................................................................................21 3.4.4 Mounting & Wiring ..........................................................................................................21 3.4.4.1 Rail Mounting........................................................................................................22 3.4.4.2 Panel mounting.....................................................................................................22 3.4.4.3 Cables...................................................................................................................24
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3.4.5
Technical Specifications.................................................................................................24
3.5 HPW2410G............................................................................................................................27 3.5.1 Hardware ........................................................................................................................27 3.5.2 Protections .....................................................................................................................28 3.5.2.1 Overload Protection ..............................................................................................28 3.5.2.2 Overvoltage Protection .........................................................................................28 3.5.2.3 Short Circuit Protection ........................................................................................28 3.5.2.4 Over Temperature Protection ...............................................................................28 3.5.3 Redundancy ...................................................................................................................28 3.5.4 Mounting & Wiring ..........................................................................................................28 3.5.4.1 Rail Mounting........................................................................................................29 3.5.4.2 Panel mounting.....................................................................................................29 3.5.4.3 Cables...................................................................................................................31 3.5.5 Technical Specifications.................................................................................................31 3.6 HPW2420G............................................................................................................................34 3.6.1 Hardware ........................................................................................................................34 3.6.2 Protections .....................................................................................................................35 3.6.2.1 Overload Protection ..............................................................................................35 3.6.2.2 Overvoltage Protection .........................................................................................35 3.6.2.3 Short Circuit Protection ........................................................................................35 3.6.2.4 Over Temperature Protection ...............................................................................35 3.6.3 Redundancy ...................................................................................................................35 3.6.4 Mounting & Wiring ..........................................................................................................35 3.6.4.1 Rail Mounting........................................................................................................36 3.6.4.2 Panel mounting.....................................................................................................36 3.6.4.3 Cables...................................................................................................................38 3.6.5 Technical Specifications.................................................................................................38 3.7 HPW4803G............................................................................................................................41 3.7.1 Hardware ........................................................................................................................41 3.7.2 Protections .....................................................................................................................42 3.7.2.1 Overload Protection ..............................................................................................42 3.7.2.2 Overvoltage Protection .........................................................................................42 3.7.2.3 Short Circuit Protection ........................................................................................42 3.7.2.4 Over Temperature Protection ...............................................................................42 3.7.3 Redundancy ...................................................................................................................42 3.7.4 Mounting & Wiring ..........................................................................................................42 3.7.4.1 Rail Mounting........................................................................................................43 3.7.4.2 Panel mounting.....................................................................................................43 3.7.4.3 Cables...................................................................................................................45 3.7.5 Technical Specifications.................................................................................................45 3.8 HPWR01G .............................................................................................................................48 3.8.1 Hardware ........................................................................................................................48 3.8.2 Redundancy ...................................................................................................................49 3.8.3 Mounting & Wiring ..........................................................................................................50 3.8.3.1 Mounting ...............................................................................................................51 3.8.3.2 Dismounting..........................................................................................................51 3.8.3.3 Cables...................................................................................................................51 3.8.4 Technical Specifications.................................................................................................51 Chapter 4 4.1
II
Main Controller Units ...................................................................................................53
K-CU01 ..................................................................................................................................54
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4.1.1 Hardware ........................................................................................................................54 4.1.1.1 Status Indicators ...................................................................................................54 4.1.1.2 Dimensions ...........................................................................................................55 4.1.2 Redundancy ...................................................................................................................56 4.1.3 Diagnosis ........................................................................................................................57 4.1.4 Reset ..............................................................................................................................57 4.1.5 Power Failure Protection ................................................................................................57 4.1.6 Configuration ..................................................................................................................58 4.1.6.1 Baudrate ...............................................................................................................59 4.1.6.2 Using the default value for DP parameter ............................................................59 4.1.7 Technical Specifications.................................................................................................59 4.1.7.1 Basic Technical Specifications .............................................................................59 4.1.7.2 Load Capacity.......................................................................................................60 4.2
K-CU02 ..................................................................................................................................61
4.3 K-CUT01 ................................................................................................................................62 4.3.1 Hardware ........................................................................................................................62 4.3.1.1 DC Input................................................................................................................63 4.3.1.2 DC Status Input ....................................................................................................64 4.3.1.3 IO-BUS Terminal (8-pin) .......................................................................................64 4.3.1.4 IO-BUS Extended Terminal ..................................................................................65 4.3.1.5 Time Sync .............................................................................................................65 4.3.1.6 Grounding .............................................................................................................66 4.3.1.7 Dimensions ...........................................................................................................66 4.3.2 Domain Address Setting ................................................................................................66 4.3.3 Station Address Setting..................................................................................................67 4.3.4 IO-BUS Address Setting ................................................................................................69 4.3.5 Short Circuit Protection ..................................................................................................70 4.3.6 Technical Specifications.................................................................................................71 Chapter 5
I/O Devices ....................................................................................................................73
5.1 I/O Modules ..........................................................................................................................74 5.1.1 K-AI01.............................................................................................................................75 5.1.1.1 Hardware ..............................................................................................................75 5.1.1.2 Redundancy .........................................................................................................77 5.1.1.3 Diagnosis ..............................................................................................................78 5.1.1.4 Electrical Schematic .............................................................................................79 5.1.1.5 Application Instructions ........................................................................................79 5.1.1.6 Configuration (for K-CU01/K-CU02 control station) .............................................80 5.1.1.7 Configuration (for K-CU03 control station) ...........................................................81 5.1.1.8 Technical Specifications .......................................................................................81 5.1.2 K-AIH01 ..........................................................................................................................83 5.1.3 K-AI02.............................................................................................................................84 5.1.3.1 Hardware ..............................................................................................................84 5.1.3.2 Redundancy .........................................................................................................85 5.1.3.3 Diagnosis ..............................................................................................................85 5.1.3.4 Electrical Schematic .............................................................................................87 5.1.3.5 Application Instructions ........................................................................................87 5.1.3.6 Configuration ........................................................................................................88 5.1.3.7 Technical Specifications .......................................................................................88 5.1.4 K-AIH02 ..........................................................................................................................90 5.1.5 K-AI03.............................................................................................................................91 5.1.5.1 Hardware ..............................................................................................................91
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5.1.5.2 Redundancy .........................................................................................................92 5.1.5.3 Diagnosis ..............................................................................................................92 5.1.5.4 Electrical Schematic .............................................................................................93 5.1.5.5 Application Instructions ........................................................................................93 5.1.5.6 Configuration ........................................................................................................94 5.1.5.7 Technical Specifications .......................................................................................94 5.1.6 K-AIH03 ..........................................................................................................................95 5.1.7 K-AO01 ...........................................................................................................................96 5.1.7.1 Hardware ..............................................................................................................96 5.1.7.2 Redundancy .........................................................................................................97 5.1.7.3 Diagnosis ..............................................................................................................98 5.1.7.4 Electrical Schematic .............................................................................................98 5.1.7.5 Application Instructions ........................................................................................98 5.1.7.6 Configuration (for K-CU01/K-CU02 control station) .............................................99 5.1.7.7 Configuration (for K-CU03 control station) .........................................................100 5.1.7.8 Technical Specifications .....................................................................................101 5.1.8 K-AOH01 ......................................................................................................................102 5.1.9 K-RTD01 ......................................................................................................................103 5.1.9.1 Hardware ............................................................................................................103 5.1.9.2 Redundancy .......................................................................................................105 5.1.9.3 Diagnosis ............................................................................................................105 5.1.9.4 Electrical Schematic ...........................................................................................106 5.1.9.5 Application Instructions ......................................................................................106 5.1.9.6 Configuration (for K-CU01/K-CU02 control station) ...........................................107 5.1.9.7 Configuration (for K-CU03 control station) .........................................................108 5.1.9.8 Technical Specifications .....................................................................................109 5.1.10 K-TC01 .........................................................................................................................111 5.1.10.1 Hardware ............................................................................................................ 111 5.1.10.2 Redundancy ....................................................................................................... 113 5.1.10.3 Diagnosis ............................................................................................................ 113 5.1.10.4 Cold-junction Compensation .............................................................................. 114 5.1.10.5 Electrical Schematic ........................................................................................... 114 5.1.10.6 Application Instructions ...................................................................................... 114 5.1.10.7 Configuration (for K-CU01/K-CU02 control station) ........................................... 115 5.1.10.8 Configuration (for K-CU03 control station) ......................................................... 116 5.1.10.9 Technical Specifications ..................................................................................... 117 5.1.11 K-DI01 ..........................................................................................................................119 5.1.11.1 Hardware ............................................................................................................ 119 5.1.11.2 Redundancy .......................................................................................................120 5.1.11.3 Diagnosis ............................................................................................................120 5.1.11.4 Electrical Schematic ...........................................................................................121 5.1.11.5 Application Instructions ......................................................................................121 5.1.11.6 Configuration (for K-CU01/K-CU02 control station) ...........................................122 5.1.11.7 Configuration (for K-CU03 control station) .........................................................123 5.1.11.8 Technical Specifications .....................................................................................124 5.1.12 K-DI11 ..........................................................................................................................126 5.1.13 K-DI03 ..........................................................................................................................127 5.1.13.1 Hardware ............................................................................................................127 5.1.13.2 Diagnosis ............................................................................................................128 5.1.13.3 Electrical Schematic ...........................................................................................128 5.1.13.4 Application Instructions ......................................................................................129 5.1.13.5 Configuration (for K-CU01/K-CU02 control station) ...........................................129 5.1.13.6 Configuration (for K-CU03 control station) .........................................................130 5.1.13.7 Technical Specifications .....................................................................................130
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5.1.14 K-DI13 ......................................................................................................................... 132 5.1.15 K-DO01........................................................................................................................ 133 5.1.15.1 Hardware ........................................................................................................... 133 5.1.15.2 Diagnosis ........................................................................................................... 134 5.1.15.3 Electrical Schematic .......................................................................................... 135 5.1.15.4 Application Instructions ..................................................................................... 135 5.1.15.5 Configuration (for K-CU01/K-CU02 control station) .......................................... 135 5.1.15.6 Configuration (for K-CU03 control station) ........................................................ 136 5.1.15.7 Technical Specifications .................................................................................... 137 5.1.16 K-SOE01 ..................................................................................................................... 139 5.1.16.1 Hardware ........................................................................................................... 139 5.1.16.2 Diagnosis ........................................................................................................... 140 5.1.16.3 Timing Function ................................................................................................. 141 5.1.16.4 Electrical Schematic .......................................................................................... 143 5.1.16.5 Application Instructions ..................................................................................... 143 5.1.16.6 Configuration (for K-CU01/K-CU02 control station) .......................................... 144 5.1.16.7 Configuration (for K-CU03 control station) ........................................................ 146 5.1.16.8 Technical Specifications .................................................................................... 148 5.1.17 K-SOE11 ..................................................................................................................... 150 5.1.18 K-PI01.......................................................................................................................... 151 5.1.18.1 Hardware ........................................................................................................... 151 5.1.18.2 Diagnosis ........................................................................................................... 152 5.1.18.3 Electrical Schematic .......................................................................................... 153 5.1.18.4 Application Instructions ..................................................................................... 153 5.1.18.5 Configuration (for K-CU01/K-CU02 control station) .......................................... 154 5.1.18.6 Configuration (for K-CU03 control station) ........................................................ 155 5.1.18.7 Application Example .......................................................................................... 156 5.1.18.8 Technical Specifications .................................................................................... 156 5.1.19 K-FC01 ........................................................................................................................ 158 5.1.19.1 Hardware ........................................................................................................... 158 5.1.19.2 Configuration ..................................................................................................... 168 5.1.19.3 Function Description .......................................................................................... 172 5.1.19.4 Installation ......................................................................................................... 176 5.1.19.5 Technical Specifications .................................................................................... 176 5.1.20 K-SV01 ........................................................................................................................ 179 5.1.20.1 Hardware ........................................................................................................... 179 5.1.20.2 Configuration ..................................................................................................... 193 5.1.20.3 Function Description .......................................................................................... 200 5.1.20.4 Typical Application ............................................................................................. 202 5.1.20.5 Installation ......................................................................................................... 208 5.1.20.6 Technical Specifications .................................................................................... 208 5.2 I/O Bases ........................................................................................................................... 212 5.2.1 K-AT01 ........................................................................................................................ 214 5.2.1.1 Hardware ........................................................................................................... 214 5.2.1.2 I/O Module Address ........................................................................................... 216 5.2.1.3 Application Instructions ..................................................................................... 217 5.2.1.4 Technical Specifications .................................................................................... 219 5.2.2 K-AT02 ........................................................................................................................ 220 5.2.2.1 Hardware ........................................................................................................... 220 5.2.2.2 I/O Module Address ........................................................................................... 221 5.2.2.3 Anti 220 VAC ..................................................................................................... 221 5.2.2.4 Application Instructions ..................................................................................... 222 5.2.2.5 Technical Specifications .................................................................................... 222
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5.2.3 K-AT11 .........................................................................................................................223 5.2.4 K-AT21 .........................................................................................................................224 5.2.4.1 Hardware ............................................................................................................224 5.2.4.2 I/O Module Address ............................................................................................226 5.2.4.3 Anti 220 VAC ......................................................................................................226 5.2.4.4 Application Instructions ......................................................................................226 5.2.4.5 Technical Specifications .....................................................................................227 5.2.5 K-AT12 .........................................................................................................................228 5.2.5.1 Hardware ............................................................................................................228 5.2.5.2 I/O Module Address ............................................................................................229 5.2.5.3 Application Instructions ......................................................................................229 5.2.5.4 Technical Specifications .....................................................................................231 5.2.6 K-AT13 .........................................................................................................................232 5.2.6.1 Hardware ............................................................................................................232 5.2.6.2 I/O Module Address ............................................................................................233 5.2.6.3 Application Instructions ......................................................................................233 5.2.6.4 Technical Specifications .....................................................................................233 5.2.7 K-AT22 .........................................................................................................................235 5.2.7.1 Hardware ............................................................................................................235 5.2.7.2 I/O Module Address ............................................................................................237 5.2.7.3 Application Instructions ......................................................................................237 5.2.7.4 Technical Specifications .....................................................................................237 5.2.8 K-AT03 .........................................................................................................................239 5.2.8.1 Hardware ............................................................................................................239 5.2.8.2 I/O Module Address ............................................................................................240 5.2.8.3 Application Instructions ......................................................................................240 5.2.8.4 Technical Specifications .....................................................................................241 5.2.9 K-AT23 .........................................................................................................................242 5.2.9.1 Hardware ............................................................................................................242 5.2.9.2 I/O Module Address ............................................................................................244 5.2.9.3 Application Instructions ......................................................................................244 5.2.9.4 Technical Specifications .....................................................................................245 5.2.10 K-TT01..........................................................................................................................246 5.2.10.1 Hardware ............................................................................................................246 5.2.10.2 I/O Module Address ............................................................................................247 5.2.10.3 Application Instructions ......................................................................................247 5.2.10.4 Technical Specifications .....................................................................................248 5.2.11 K-TT21..........................................................................................................................249 5.2.11.1 Hardware ............................................................................................................249 5.2.11.2 I/O Module Address ............................................................................................251 5.2.11.3 Application Instructions ......................................................................................251 5.2.11.4 Technical Specifications .....................................................................................252 5.2.12 K-DIT01 ........................................................................................................................253 5.2.12.1 Hardware ............................................................................................................253 5.2.12.2 I/O Module Address ............................................................................................254 5.2.12.3 Application Instructions ......................................................................................254 5.2.12.4 Technical Specifications .....................................................................................256 5.2.13 K-DIT02 ........................................................................................................................257 5.2.13.1 Hardware ............................................................................................................257 5.2.13.2 I/O Module Address ............................................................................................258 5.2.13.3 Anti 220 VAC ......................................................................................................258 5.2.13.4 Application Instructions ......................................................................................259 5.2.13.5 Technical Specifications .....................................................................................259 5.2.14 K-DIT11 ........................................................................................................................260
VI
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5.2.15 K-DIT21 ....................................................................................................................... 261 5.2.15.1 Hardware ........................................................................................................... 261 5.2.15.2 I/O Module Address ........................................................................................... 263 5.2.15.3 Anti 220 VAC ..................................................................................................... 263 5.2.15.4 Application Instructions ..................................................................................... 263 5.2.15.5 Technical Specifications .................................................................................... 264 5.2.16 K-DIT23 ....................................................................................................................... 265 5.2.16.1 Hardware ........................................................................................................... 265 5.2.16.2 I/O Module Address ........................................................................................... 267 5.2.16.3 Application Instructions ..................................................................................... 267 5.2.16.4 Technical Specifications .................................................................................... 269 5.2.17 K-DOT01 ..................................................................................................................... 270 5.2.17.1 Hardware ........................................................................................................... 270 5.2.17.2 I/O Module Address ........................................................................................... 272 5.2.17.3 Application Instructions ..................................................................................... 272 5.2.17.4 Technical Specifications .................................................................................... 275 5.2.18 K-PIT01 ....................................................................................................................... 276 5.2.18.1 Hardware ........................................................................................................... 276 5.2.18.2 I/O Module Address ........................................................................................... 277 5.2.18.3 Application Instructions ..................................................................................... 277 5.2.18.4 Technical Specifications .................................................................................... 284 5.3 Terminal Boards................................................................................................................ 285 5.3.1 K-AIR01 ....................................................................................................................... 285 5.3.1.1 Hardware ........................................................................................................... 285 5.3.1.2 Application Instructions ..................................................................................... 286 5.3.1.3 Technical Specifications .................................................................................... 287 5.3.2 K-AIR02 ....................................................................................................................... 288 5.3.2.1 Hardware ........................................................................................................... 288 5.3.2.2 Application Instructions ..................................................................................... 288 5.3.2.3 Technical Specifications .................................................................................... 290 5.3.3 K-DIR01 ....................................................................................................................... 292 5.3.3.1 Hardware ........................................................................................................... 292 5.3.3.2 Electrical Schematic .......................................................................................... 294 5.3.3.3 Application Instructions ..................................................................................... 294 5.3.3.4 Technical Specifications .................................................................................... 296 5.3.4 K-DIR03 ....................................................................................................................... 298 5.3.4.1 Hardware ........................................................................................................... 298 5.3.4.2 Jumper Setting .................................................................................................. 300 5.3.4.3 Electrical Schematic .......................................................................................... 301 5.3.4.4 Application Instructions ..................................................................................... 301 5.3.4.5 Technical Specifications .................................................................................... 303 5.3.5 K-DIR04 ....................................................................................................................... 305 5.3.5.1 Hardware ........................................................................................................... 305 5.3.5.2 Application Instructions ..................................................................................... 305 5.3.5.3 Technical Specifications .................................................................................... 307 5.3.6 K-DOR01 ..................................................................................................................... 308 5.3.6.1 Hardware ........................................................................................................... 308 5.3.6.2 Jumper & Fuse .................................................................................................. 310 5.3.6.3 Electrical Schematic ........................................................................................... 311 5.3.6.4 Application Instructions ...................................................................................... 311 5.3.6.5 Technical Specifications .................................................................................... 313 5.3.7 K-DOR02 ..................................................................................................................... 315 5.3.7.1 Technical Specifications .................................................................................... 315
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5.3.8 K-DOR03 ......................................................................................................................317 5.3.8.1 Hardware ............................................................................................................317 5.3.8.2 Electrical Schematic ...........................................................................................319 5.3.8.3 Application Instructions ......................................................................................320 5.3.8.4 Technical Specifications .....................................................................................321 5.3.9 K-UR01 .........................................................................................................................323 5.3.9.1 Hardware ............................................................................................................323 5.3.9.2 Application Instructions ......................................................................................324 5.3.9.3 Technical Specifications .....................................................................................339 Chapter 6
Communication Devices ...........................................................................................341
6.1 IO-BUS Devices..................................................................................................................341 6.1.1 K-BUS02 ......................................................................................................................344 6.1.1.1 Hardware ............................................................................................................344 6.1.1.2 Detection Function .............................................................................................345 6.1.1.3 Application Instructions ......................................................................................346 6.1.1.4 Configuration (for K-CU01/K-CU02 control station) ...........................................346 6.1.1.5 Configuration (for K-CU03 control station) .........................................................347 6.1.1.6 Technical Specifications .....................................................................................348 6.1.2 K-BUS03 ......................................................................................................................349 6.1.2.1 Hardware ............................................................................................................349 6.1.2.2 Detection Function .............................................................................................350 6.1.2.3 Application Instructions ......................................................................................350 6.1.2.4 Configuration ......................................................................................................350 6.1.2.5 Technical Specifications .....................................................................................350 6.1.3 K-BUST01 ....................................................................................................................352 6.1.3.1 Hardware ............................................................................................................352 6.1.3.2 Short Circuit Protection ......................................................................................353 6.1.3.3 Technical Specifications .....................................................................................354 6.1.4 K-BUST02 ....................................................................................................................355 6.1.4.1 Hardware ............................................................................................................355 6.1.4.2 Technical Specifications .....................................................................................356 6.1.5 K-BUST03 ....................................................................................................................357 6.1.5.1 Hardware ............................................................................................................357 6.1.5.2 Technical Specifications .....................................................................................359 6.2 Gateway Devices ...............................................................................................................360 6.2.1 K-DP02 .........................................................................................................................361 6.2.1.1 Hardware ............................................................................................................361 6.2.1.2 Redundancy .......................................................................................................362 6.2.1.3 Diagnosis ............................................................................................................362 6.2.1.4 Electrical Schematic ...........................................................................................363 6.2.1.5 Application Instructions ......................................................................................363 6.2.1.6 Configuration ......................................................................................................364 6.2.1.7 DCS Data Calculation ........................................................................................373 6.2.1.8 Technical Specifications .....................................................................................374 6.2.2 K-DP03 .........................................................................................................................375 6.2.2.1 Hardware ............................................................................................................375 6.2.2.2 Redundancy .......................................................................................................376 6.2.2.3 Diagnosis ............................................................................................................376 6.2.2.4 Electrical Schematic ...........................................................................................377 6.2.2.5 Application Instructions ......................................................................................377 6.2.2.6 Configuration ......................................................................................................378 6.2.2.7 DCS Data Calculation ........................................................................................385
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6.2.2.8 Technical Specifications .................................................................................... 385 6.2.3 K-PA01 ........................................................................................................................ 387 6.2.3.1 Hardware ........................................................................................................... 387 6.2.3.2 Redundancy ...................................................................................................... 388 6.2.3.3 Diagnosis ........................................................................................................... 388 6.2.3.4 Electrical Schematic .......................................................................................... 389 6.2.3.5 Application Instructions ..................................................................................... 389 6.2.3.6 Configuration ..................................................................................................... 390 6.2.3.7 DCS Data Calculation ....................................................................................... 392 6.2.3.8 Technical Specifications .................................................................................... 393 6.2.4 K-PA02 ........................................................................................................................ 394 6.2.4.1 Hardware ........................................................................................................... 394 6.2.4.2 Redundancy ...................................................................................................... 395 6.2.4.3 Diagnosis ........................................................................................................... 396 6.2.4.4 Electrical Schematic .......................................................................................... 396 6.2.4.5 Application Instructions ..................................................................................... 396 6.2.4.6 Configuration ..................................................................................................... 397 6.2.4.7 DCS Data Calculation ....................................................................................... 400 6.2.4.8 Technical Specifications .................................................................................... 400 6.2.5 K-MOD01..................................................................................................................... 401 6.2.5.1 Hardware ........................................................................................................... 401 6.2.5.2 Redundancy ...................................................................................................... 403 6.2.5.3 Diagnosis ........................................................................................................... 403 6.2.5.4 Electrical Schematic .......................................................................................... 403 6.2.5.5 Application Instructions ..................................................................................... 403 6.2.5.6 Configuration ..................................................................................................... 404 6.2.5.7 Configuration Procedure ................................................................................... 415 6.2.5.8 DCS Data Calculation ....................................................................................... 416 6.2.5.9 Technical Specifications .................................................................................... 416 6.2.6 K-PAT01 ...................................................................................................................... 417 6.2.6.1 Hardware ........................................................................................................... 417 6.2.6.2 I/O Module Address ........................................................................................... 419 6.2.6.3 Application Instructions ..................................................................................... 419 6.2.6.4 Technical Specifications .................................................................................... 423 6.2.7 K-PAT21 ...................................................................................................................... 424 6.2.7.1 Hardware ........................................................................................................... 424 6.2.7.2 I/O Module Address ........................................................................................... 426 6.2.7.3 Application Instructions ..................................................................................... 426 6.2.7.4 Technical Specifications .................................................................................... 429 6.2.8 K-DPR01 ..................................................................................................................... 430 6.2.8.1 Hardware ........................................................................................................... 430 6.2.8.2 Electrical Schematic .......................................................................................... 433 6.2.8.3 Application Instructions ..................................................................................... 433 6.2.8.4 Application Example .......................................................................................... 435 6.2.8.5 Technical Specifications .................................................................................... 437 6.2.9 K-HUB01 ..................................................................................................................... 438 6.2.9.1 Hardware ........................................................................................................... 438 6.2.9.2 Fault Isolation .................................................................................................... 440 6.2.9.3 Electrical Schematic .......................................................................................... 441 6.2.9.4 Application Instructions ..................................................................................... 441 6.2.9.5 Technical Specifications .................................................................................... 444 6.2.10 K-DPT01 ...................................................................................................................... 446 6.2.10.1 Hardware ........................................................................................................... 446 6.2.10.2 Electrical Schematic .......................................................................................... 448
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Contents
6.2.10.3 Application Instructions ......................................................................................448 6.2.10.4 Technical Specifications .....................................................................................448 6.2.11 K-JNCT01 .....................................................................................................................450 6.2.11.1 Hardware ............................................................................................................450 6.2.11.2 Technical Specifications .....................................................................................452 Chapter 7
Cables ..........................................................................................................................453
7.1 Wiring Cable .......................................................................................................................453 7.1.1 Signal Cable .................................................................................................................453 7.1.2 Grounding Cable ..........................................................................................................454 7.2
DB37 Cable .........................................................................................................................455
7.3 Communication Cable.......................................................................................................456 7.3.1 K-DP02/DP03 ...............................................................................................................456 7.3.2 K-PA01/PA02 ...............................................................................................................456 7.3.3 K-MOD01 .....................................................................................................................456 7.4
Specialized Cable ..............................................................................................................458
Chapter 8
DCS Current Calculation ...........................................................................................461
8.1
Module Voltage and Current .............................................................................................461
8.2
Example ..............................................................................................................................462
Chapter 9
DCS Data Calculation ................................................................................................463
9.1
DCS module buffer address assignment principles......................................................463
9.2
Buffer size for each module .............................................................................................464
9.3
Example 1: module buffer address assignment ............................................................465
9.4
Example 2: module quantity calculation.........................................................................465
Chapter 10 How to Contact HollySys...........................................................................................467 APPENDIX 1
I/O Module, Base and Terminal Board Matching Table ..........................................469
APPENDIX 2
Fuse .............................................................................................................................473
APPENDIX 3
RTD Indexing Table ....................................................................................................475
APPENDIX 4
TC Indexing Table.......................................................................................................477
APPENDIX 5
Modbus Abnormal Function Codes .........................................................................483
Glossary
......................................................................................................................................485
Index
......................................................................................................................................487
X
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Chapter 1 About This Book 1.1 What’s New Version
Date
Description
1.0
2015.12.30
New.
1.1
2016.01
Change manual name from HOLLiAS MACS-K User’s Manual Hardware to HOLLiAS MACS K Series Hardware Manual. Adding contents of K-AI02, K-AIH02, K-AT12, K-AT13 and K-AT22.
1.2
2016.06
K-PW01 appearance modification and switch replacement. Adding contents of FM138-SSRR wiring. Adding contents of K-FC01 and K-SV01. Adding contents of K-PA02. Adding contents of Device Standard Diagnosis. Adding contents of Device data calculation. Modification of K-PI01 wiring.
1.3
2016.06
Adding contents of K-DOR03.
1.4
2016.08
Adding HPW2405G/2410G/2420G/4803G/R01G. Adding Chapter 8 of DCS current calculation. Adding Chapter 9 of DCS data calculation. Technical specifications revision.
1.5
2016.10
Modification of HPWR01G redundancy schematic figure. Modification of wiring figures of K-PI01+K-DOT01+K-UR01.
1.6
2017.01
Adding K-HUB01.
2017.06
Adding K-DIT23. Adding specialized cable KX-DOR-25. Adding specialized cable KX-BUSEX08-1.4m. Adding information about battery K-BAT01.
1.7
1.2 Purpose This document mainly introduces HollySys HOLLiAS MACS K series DCS hardware, including functions, applications, wiring, configuration, technical specifications etc.
1.3 Intended Audience This document is intended for engineers, installers and electricians that have a basic knowledge of automation.
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Chapter 1 About This Book
1.4 Document Conventions 1.4.1 Menu Menu commands, the sub commands in the menu, the tag page name in this manual with the note said, such as [file], [Edit] menu.
1.4.2 Mouse Press: press the left mouse button once and keep. 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 Write keyboard keys in bold style, such as Enter.
1.4.4 Online Help The online help that is integrated into the software is a supplement to this manual. The purpose of providing online help is to provide detailed support when using the software. The help system is integrated into the software through a number of interfaces.
Context help provides information about the current context. For example, open the dialog box or shortcut menu, you can through the menu command [what’s this?] Or press the F1 key or help in the dialog box to accurately locate the relevant help instructions.
You can also use the menu bar [help] - [content] call the help of the current software
As the manual and online help some of the contents of the scheduling order is different, so the use of online help, you can use the search function to find the full text.
1.4.5 Important Information The following marks are used in this manual for identifying appropriate information:
2
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. Indicates a potentially hazardous situation that could result in damage to equipment.
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Chapter 1 About This Book
Note icon. Provides important helpful information for the understanding of an operation or a function.
Operation icon. Indicates the operation method of an object.
Interpretation of the contents of the operation Icon. The location of the operation: Mouse command + Operation sequence.
Menu bar: click [Insert]-[Input element],
Tool bar:
Shortcut: Ctrl + I,
POU: right click the empty area, click [input element].
,
As shown in the first operation method above, in the menu bar, click [Insert] menu and the sub menu [Input element] command.
Reference icon. Provides additional source of information.
1.5 Abbreviations Abbreviation
Full name
AC
Alternating Current
AI
Analog Input
AO
Analog Output
AWG
American Wire Gauge
DC
Direct Current
DCS
Distributed Control System
DI
Digital Input
DO
Digital Output
GPS
Global Positioning System
I/O
Input/Output
NTP
Network Time Protocol
PI
Pulse Input
Profibus
Process Field Bus
RTD
Resistance Temperature Detector
SOE
Sequence of Event
SR
System Redundancy
SSR
Solid State Relay
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Chapter 1 About This Book
4
Abbreviation
Full name
STP
Shielded Twisted Pair
TC
Thermocouple assembly
UPS
Uninterruptible Power System/Uninterruptible Power Supply
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Chapter 2 Overview HOLLiAS MACS-K system is based on international standards and industry specifications. It consists of K series hardware and MACS V6.5 software. It integrates advanced control algorithm platforms and could provide professional and comprehensive solutions for the automation control requirements of different industries. K series hardware is the 5th generation high reliability DCS system officially launched by HollySys in 2013. With full redundancy, multiple isolations, thermal analysis, fault tolerance and other reliability technologies, it ensures the system run safely and stably for long term in complex and harsh industrial environments. K series hardware consists of the followings:
Power devices
Main controller units
I/O devices
Communication devices
Cables
Cabinets
The main cabinet is shown in Figure 2-1.
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Chapter 2 Overview
1
2
3
4
5
6
7
8
9
Front
Rear
Figure 2-1 Table 2-1
6
Main Cabinet Diagram Main Cabinet List
No.
Name
Description
1
Main controller units
-
2
IO-BUS Devices
-
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Chapter 2 Overview
No.
Name
Description
3
Auxiliary power distribution board
K-PW21
4
Air switch
Two 220 VAC inputs: the mains and the UPS
5
AC/DC conversion modules
-
6
AC distribution board
K-PW01
7
DC distribution board
K-PW11
8
I/O devices
-
9
IO-BUS connector or terminal
-
-
Cabinet
Also includes fans, lighting, etc.
2.1 Basic Specifications System Basic Technical Specifications Operation temperature
-20℃~60℃
Operation relative humidity
5%~95%, no freezing or condensing
Storage temperature
-40℃~70℃
Storage relative humidity
5%~95%, no freezing or condensing
Insulation voltage between ≥1500 VAC@1 min@5 mA (Factory test, no earthing) channel and system Insulation between system
Normal environments (temperature: 25 ℃ ±2 ℃ , humidity: resistance 30%±5% RH, no freezing or condensing): >100 MΩ channel and Hot or humid environments (temperature: 45℃±2℃, humidity: 95%±3% RH, no freezing or condensing): >10 MΩ
Protection degree
IP20
2.2 Certifications HOLLiAS MACS K series hardware conforms to the following standards:
CE
G3
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Chapter 3 Power Devices K system uses the system power supply, the field power supply and the auxiliary power supply.
I/O module CPU Communication
Auxiliary Power
Analog circuits A/D conversion
Isolation
Digital circuits
Field Power Isolation
System Power
Digital bases Relays
Wiring diagnosis
Safety barrier
Figure 3-1 Power Supply Schematic AC
Mains
UPS 220 VAC
Air Air switch switch 220 VAC
AC distribution
K-PW01 220 VAC
AC/DC
AC/DC AC/DC (24/48 V, (24/48 V, 120 W) 120 W)
AC/DC (24 V, 120 W)
AC/DC (24 V, 120 W)
AC/DC (24 V, 240 W)
AC/DC (24 V, 240 W)
AC/DC (24 V, 120 W)
AC/DC (24 V, 120 W) 24/48 VDC
DC distribution
Auxiliary
Field 2
System
Field 1
K-PW11
Auxiliary
System & Field 24/48 VDC
Auxiliary distribution
K-PW21
Digital bases, relays, safety barriers
K-CUT01, K-BUST01
Figure 3-2 Typical Power Supply Diagram Table 3-1 Power Devices List Name
Model
Description
AC distribution
K-PW01
AC power supply distribution board
AC/DC
AC/DC(24 V, 120 W)
Convert to system power, field power 2, 24 VDC
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Chapter 3 Power Devices
Name
Model
Description auxiliary power (SM910 or HPW2405G)
AC/DC(24 V, 240 W)
Convert to field power 1 (SM913 or HPW2410G)
AC/DC(48 V, 120 W)
Convert to 48 VDC auxiliary power (SM920 or HPW4803G)
AC/DC(24 V, 480 W)
HPW2420G
DC distribution
K-PW11
DC power supply distribution board
Auxiliary distribution
K-PW21
Auxiliary power supply distribution board
HPWR01G
-
power
DC redundancy
10
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Chapter 3 Power Devices
3.1 K-PW01 K-PW01 is a K series AC power supply distribution board. It provides AC power supply for AC/DC conversion modules.
Features
Support 110/220 VAC input.
Independent switch and indicator for every channel.
Integrate redundant high-performance filters to prevent grid disturbance and frequency interference.
3.1.1 Hardware 1
2
3
Figure 3-3 K-PW01 Diagram 1.
AC input (AC IN)
The two AC inputs are redundant. Input A comes from the mains and input B comes from the UPS. Input A and input B have similar terminals. One terminal is described as follows: L N E
L: live line N: null line E: earth
Figure 3-4 AC Power Supply Input Terminal Diagram 2.
AC output (AC OUT)
The ten AC outputs are divided into two groups, group A and group B. Table 3-2 AC Output List
Group A
Group B
Name
Description
SYS_A
System power A
FLD1_A
Field power 1_A
FLD2_A
Field power 2_A
AUX_A
Auxiliary power A (not filtered by high-performance filters)
BAK_A
Backup power A (not filtered by high-performance filters)
SYS_B
System power B
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Chapter 3 Power Devices
Name
Description
FLD1_B
Field power 1_B
FLD2_B
Field power 2_B
AUX_B
Auxiliary power B (not filtered by high-performance filters)
BAK_B
Backup power B (not filtered by high-performance filters)
Ten outputs have similar terminals. One terminal is described as follows: L N E
L: live line N: null line E: earth
Indicator
I Switch
O
Figure 3-5 AC Power Supply Output Terminal Diagram There's a switch and an indicator for every output.
3.
12
When the "I" end is pressed down, the switch closes and the indicator turns on.
When the "O" end is pressed down, the switch opens and the indicator turns off.
Grounding
Connect the ground terminal to the cabinet.
Ground resistance < 4 Ω.
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3.1.1.1 Dimensions
Figure 3-6 Dimensions of K-PW01 (mm)
3.1.2 Technical Specifications K-PW01 AC Power Supply Distribution Board Input
110/220 VAC (2 channels)
Output
110/220 VAC (2 groups, 5 channels per group)
Rated maximum continuous 3 A (For each group, the total current of system power, current per terminal field power 1 and field power 2 should not exceed 3 A.) Installation
DIN35 rail mounting
Weight
Approx. 1000 g
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Chapter 3 Power Devices
3.2 K-PW11 K-PW11 is a K series DC power supply distribution board. It distributes the DC power from AC/DC modules in redundancy.
System & field power: to K-CUT01, K-BUST01.
DC status: to K-CUT01, K-BUST01.
Auxiliary power: to K-PW21.
3.2.1 Hardware 1
2
3
4
5
Figure 3-7 K-PW11 Diagram 1.
DC Input (DC IN)
The eight DC inputs are divided into four groups. Two inputs are redundant in each group. Table 3-3 DC Input List Name
Description
SYS(24 VDC)
System power
FLD1(24 VDC)
Field power 1
FLD2(24 VDC)
Field power 2
AUX(24/48 VDC)
Auxiliary power
Eight inputs have similar terminals. One terminal is described as follows: A
+ B -
Figure 3-8 DC Power Supply Input Terminal Diagram 2.
Auxiliary Power Output (AUX OUT)
Auxiliary power is connected to the power input terminal of K-PW21 by cable KX-PW03. The four outputs have similar terminals. One terminal is described as follows:
14
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Chapter 3 Power Devices
+ -
Figure 3-9 Auxiliary Power Output Terminal Diagram 3.
DC Status Output (DC STATUS OUT)
The status of system power, field power and auxiliary power are detected by the IO-BUS module through the DC status output terminal. This function can be enabled or disabled. See details in Chapter 6.1.1.4 Configuration. Wiring: connect to the DC status input terminal of K-CUT01 or K-BUST01 by cable KX-PW02. 12
11
10
9
8
7
6
5
4
3
2
1
Figure 3-10 DC Status Output Terminal Diagram Table 3-4 DC Status Output Terminal List
4.
Pin
Description
Pin
Description
1
48 VDC auxiliary power A alarm
7
24 VDC auxiliary power A alarm
2
48 VDC auxiliary power B alarm
8
24 VDC auxiliary power B alarm
3
24 VDC field power A (120 W) alarm
9
24 VDC field power B (120 W) alarm
4
24 VDC field power A (240 W) alarm
10
24 VDC field power B (240 W) alarm
5
24 VDC system power A alarm
11
24 VDC system power B alarm
6
Current return (signal reference ground)
12
Current return (signal reference ground)
System and Field Power Output (SYS & FLD OUT)
The two outputs are redundant. They are connected to the DC input terminals of K-CUT01 or K-BUST01 by cable KX-PW01. Two outputs have similar terminals. One terminal is described as follows:
Figure 3-11
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4
1
5
2
6
3
System and Field Power Output Terminal Diagram
15
Chapter 3 Power Devices
Table 3-5 System and Field Power Output Terminal List
5.
Pin
Description
Pin
Description
1
System power output -
4
System power output +
2
Field power 1 output -
5
Field power 1 output +
3
Field power 2 output -
6
Field power 2 output +
Grounding
Connect the ground terminal to the cabinet.
Ground resistance < 4 Ω.
3.2.1.1 Dimensions
Figure 3-12 Dimensions of K-PW11 (mm)
3.2.2 Technical Specifications K-PW11 DC Power Supply Distribution Board
16
Load capacity
10 A@24 VDC 5 A@48 VDC
Voltage drop
21.6 V, open when at 0~5 V. For 48 VDC: Close when >43.2 V, open when at 0~10 V.
Installation
DIN35 rail mounting
Weight
Approx. 1000 g
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Chapter 3 Power Devices
3.3 K-PW21 K-PW21 is a K series auxiliary power supply distribution board. It provides auxiliary power for digital bases, relays and safety barriers.
Features
16 outputs
Support 24/48 VDC
Short circuit protection (self-recovery fuse)
Fault LED indicators
3.3.1 Hardware
1
2
3
4
5
Figure 3-13 K-PW21 Diagram
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Chapter 3 Power Devices
1.
Power Input (AUX 24/48 VDC Input)
Wiring: connect to the auxiliary output terminal of K-PW11 with cable KX-PW03. Two inputs have similar terminals. One terminal is described as follows: + -
Figure 3-14 Power Input Terminal Diagram 2.
Power Output (AUX 24/48 VDC Distribution Output)
16 outputs have similar terminals. One terminal is described as follows: + -
Figure 3-15 Power Output Terminal Diagram 3.
Power Protection Cover
4.
LED Indicators
There is a self-recovery fuse (750 mA) and a short-circuit LED indicator for every output. The LED turns on in case of short circuit. 5.
18
Grounding
Connect the ground terminal to the cabinet working ground bar.
Ground resistance < 4 Ω.
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Chapter 3 Power Devices
3.3.1.1 Dimensions
Figure 3-16 Dimensions of K-PW21 (mm)
3.3.2 Technical Specifications K-PW21 Auxiliary Power Supply Distribution Board Input/output
24/48 VDC
Input channels
2
Output channels
16
Output short-circuit indicators
Red LED turns on
Rated output current
≤750 mA per channel
Voltage drop
≤1 V
Weight
Approx. 500 g
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Chapter 3 Power Devices
3.4 HPW2405G HPW2405G is a 24 VDC (120 W) power module for conversion from 220 VAC to 24 VDC.
Features
Input voltage range: 85~264 VAC
Output voltage: 24 VDC@5 A
Output power: 120 W
Support redundancy (with HPWR01G)
Protections: short circuit/ overvoltage/ overcurrent/ overload/ over temperature/ failure alarm
DC OK indicator
3.4.1 Hardware 3
2
4 5
1
Figure 3-17Figure 3-18 HPW2405G Diagram 1.
220 VAC Input
L: live line
N: null line
2.
20
: earth
24 VDC Output
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Chapter 3 Power Devices
3.
+: positive
-: negative
DC OK Relay Contact
Dry contact output, 30 V@1 A. The relay is normally on when the output > 90% of Vout. 4.
DC Voltage Adjustment Potentiometer
Voltage regulation range is 22~28 VDC.
5.
Non-redundancy mode: recommend 23.5~24.5 VDC
Redundancy mode: please refer to the voltage requirement of Chapter 3.8.2 Redundancy.
DC OK Indicator
On: output normally
Off: output failure
3.4.2 Protections 3.4.2.1 Overload Protection When the output current is 105%~150% of the rated load current, the output voltage will start to droop. The power supply will recover once the cause of overload protection is removed.
3.4.2.2 Overvoltage Protection When the output voltage is 28.8~35.2 VDC, the overvoltage circuit will be activated and the power supply will latch off. Restart the power manually after the overvoltage is removed.
3.4.2.3 Short Circuit Protection When a short circuit occurs, the short circuit protection function will be activated and the output current will operate in Hiccup mode. The power supply will return to normal operation after the short circuit is removed.
3.4.2.4 Over Temperature Protection When the operating temperature of the module exceeds, the over temperature protection function will be activated and the power supply will latch off. Restart the power manually after the over temperature is removed.
3.4.3 Redundancy Please refer to Chapter 3.8.2 Redundancy.
3.4.4 Mounting & Wiring HPW2405G supports the following mounting methods:
DIN35 standard rail (35*7.5*1 mm or 35*15*1 mm) mounting
Panel mounting
Mounting clearance:
Above clearance: 50 mm
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Chapter 3 Power Devices
Bottom clearance: 180 mm
Lateral clearance: 10 mm
3.4.4.1 Rail Mounting 1.
Mounting
Step 1. Tilt the module upwards and insert it onto the DIN rail Step 2. Push downwards until the bottom is locked Step 3. Shake the module slightly to ensure that it is secured
Figure 3-19 2.
Mounting Diagram
Dismounting
Step 1. Pull the latch to release the bottom of the module Step 2. Release the latch and pull out the module from the rail
Figure 3-20 Dismounting Diagram
3.4.4.2 Panel mounting Step 1. Unscrew the 4 screws (M4) to remove Part A
22
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Chapter 3 Power Devices
A
Figure 3-21 Remove Part A Diagram Step 2. Install Part B (KC194) with these 4 screws
B
Figure 3-22
Install Part B Diagram
Step 3. Fix the module in a proper location by screws (M4)
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Chapter 3 Power Devices
Figure 3-23
Mounting Module Diagram
3.4.4.3 Cables
Input wire: AWG 18~8
Output wire: AWG 24~12
Prohibit input wires and output wires in the same slot.
The spacing between input wire slot and output wire slot should be 30 mm at minimum.
When two wires come out of a pin, make sure the wire diameters are the same.
3.4.5 Technical Specifications HPW2405G 24 VDC (120 W) Power Module Input Characteristics
24
Input voltage range
85~264 VAC
Input frequency range
47~63 Hz
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Chapter 3 Power Devices
HPW2405G 24 VDC (120 W) Power Module Efficiency at 100% load
85%@115 VAC 88%@230 VAC
Leakage current
40°C, de-rate power by 1.67% / °C @ 115VAC > 50°C, de-rate power by 2.5% / °C @ 230VAC < 100VAC, de-rate power by 1% / VAC
Minimum current range
0A
Output power
120 W
Ripple (including noise)
-10~+60°C: