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Chapter 4 Troubleshooting 

 

 

 

4-4 

4.3 Cases                                                                            

 

It describes trouble types and measures for circuits.   

4.3.1 Trouble types and measures of input circuit 

The followings describe the examples and measures of troubles.   

 

Phenomena 

Causes 

Measures 

 

Input signal can 

not be off 

 

 

 

 

 

Leakage current of an external device(operation by 

a switch with LED mark) 

 

 Connect a proper resistance so that the voltage 

between input module terminal and common 

terminal is higher than off voltage as presented 

below.  

 

Input signal can 

not be off 

 

 

 

 

 Circulating current by using plural different power 

sources 

 

 

 

 

 

 

 

 If E1 > E2, it circulates. 

 Change plural to singular power 

  Connecting to a circulating current preventive 

diode(figure below) 

 

External device 

DC input 

R 

Leakage 

current 

DC Input 

R 

E1 

DC Input 

L 

E

 

DC Input 

 

L 

E

 

E

 

Summary of Contents for XGI-D21D

Page 1: ...g us for your partner Programmable Logic Controller Diagnostic Digital I O Module User s Manual Read this manual carefully before installing wiring operating servicing or inspecting this equipment Keep this manual within easy reach for quick reference XGI D21D XGQ RY1D XGT Series http www lsis com ...

Page 2: ...e applicable instruction is violated This symbol indicates the possibility of severe or slight injury and property damages if some applicable instruction is violated Moreover even classified events under its caution category may develop into serious accidents relying on situations Therefore we strongly advise users to observe all precautions properly just like warnings The marks displayed on the p...

Page 3: ...t signals are designed to be turned off and stopped for safety However there are cases when output signals remain active due to device failures in Relay and TR which can t be detected Thus you are recommended to install an addition circuit to monitor the output status for those critical outputs which may cause significant problems Never overload more than rated current of output module nor allow t...

Page 4: ...t electric shock or damage on the product may be caused Be sure that every module is securely attached after adding a module or an extension connector If the product is installed loosely or incorrectly abnormal operation error or dropping may be caused In addition contact failures under poor cable installation will be causing malfunctions as well Be sure that screws get tighten securely under vibr...

Page 5: ...ns Secure terminal screws tightly applying with specified torque If the screws get loose short circuit fire or abnormal operation may be caused Securing screws too tightly will cause damages to the module or malfunctions short circuit and dropping Be sure to earth to the ground using Class 3 wires for FG terminals which is exclusively used for PLC If the terminals not grounded correctly abnormal o...

Page 6: ...stalling or disassembling the module let all the external power off including PLC power If not electric shock or abnormal operation may occur Keep any wireless equipment such as walkie talkie or cell phones at least 30cm away from PLC If not abnormal operation may be caused When making a modification on programs or using run to modify functions under PLC operations read and comprehend all contents...

Page 7: ...Safety Instruction Safety Instructions for waste disposal Product or battery waste shall be processed as industrial waste The waste may discharge toxic materials or explode itself Caution ...

Page 8: ...Revision History Revision History Version Date Remark Page V 1 0 14 5 First Edition The number of User s manual is indicated right part of the back cover ⓒ 2014 LSIS Co Ltd All Rights Reserved ...

Page 9: ...ng User s Manual User s manual for programming to explain how to use instructions that are used PLC system with XGK XGB CPU XGI XGR XEC Instructions Programming User s Manual User s manual for programming to explain how to use instructions that are used PLC system with XGI XGR XEC CPU XGK CPU User s Manual XGK CPUA CPUE CPUH CPUS CPUU XGK CPUA CPUE CPUH CPUS CPUU user manual describing about XGK C...

Page 10: ...ns of parts of diagnostic digital Input module XGI D21D 2 4 2 3 2 Names and Functions of parts of diagnostic digital Output module XGQ RY1D 2 5 2 4 Functions of diagnostic digital I O module 2 6 2 4 1 Functions of diagnostic digital input module 2 6 2 4 2 Functions of diagnostic digital input module 2 10 3 1 Installation 3 1 3 1 1 Installation environment 3 1 3 1 2 Cautions for handling 3 2 3 2 At...

Page 11: ...ing Procedure 4 1 4 2 Troubleshooting 4 2 4 3 Cases 4 4 4 3 1 Trouble types and measures of input circuit 4 4 4 3 2 Trouble types and measures of output circuit 4 5 Appendix 1 Dimensions A1 1 Chapter 4 Troubleshooting 4 1 4 5 ...

Page 12: ...function of each input signal Input signal and wire break detection signal are displayed on the device of the CPU module it can be used in the PLC program Input PLC CPU I F I O Conn Broken Wire diagnosis Display LED R DC24V XGI D21D XGT CPU XG5000 Program XG5000 I F Diagnosis resistor Figure 1 1 Diagnostic digital input module system configuration In order to operate wire break detection function ...

Page 13: ...the PLC program XG5000 XGT CPU XG5000 I F Program PLC CPU I F Display LED Relay Drive Circuit SHUNT Broken Wire Detection Circuit LOAD Out COM XGQ RY1D Internal Signal Diagnosis Circuit Figure 1 2 Diagnostic digital output module system configuration Digital output module provides diagnostic functions of the following two 1 Interal output signal diagnosis Diagnosing whether internal output signal ...

Page 14: ... case of an application for highly frequent switching or inductive load switching the relay output module may have a shorter life so it needs a transistor module or triac output module instead of it 4 If an output module operates an inductive load L the max On Off frequency should be limited to On per 1 second and Off per 1 second each 5 In case a counter timer using DC DC converter is used as a l...

Page 15: ...re shows the relay life of relay output module It also shows the max life of relay used for relay output No of switching 10 thousands 100 50 30 20 10 100 10 5 3 2 1 0 5 Current A DC 30V resistance load AC 125V resistance load AC 250V resistance load ...

Page 16: ...erminal strip should be 0 3 0 75 stranded cable and 2 8 thick The cable may have different current allowance depending on the insulation thickness 9 The coupling torque available for fixation screw and terminal strip screw should follow the table below Coupling position Coupling torque range IO module terminal strip screw M3 screw 42 58 N IO module terminal strip fixation screw M3 screw 66 89 N 6 ...

Page 17: ...Contactdischarge IEC61131 2 IEC61000 4 2 Radiated electromagneticfield noise 80 1000MHz 10V m IEC61131 2 IEC61000 4 3 Fast transient Burst noise Classificat ion Power supply Digital AnalogInput Output CommunicationInterface IEC61131 2 IEC61000 4 4 Voltage 2kV 1kV 8 Operationmbience Freefromcorrosivegasesandexcessivedust 9 Altitude Lessthan2 000m 10 Pollutiondegree Lessthan2 11 Coolingmethod Air co...

Page 18: ... Response time Input filter Off On 1ms 3ms 5ms 10ms 20ms 70ms 100ms Initial value 3ms On Off 1ms 3ms 5ms 10ms 20ms 70ms 100ms Initial value 3ms Insulation withstand voltage DC 500V Insulation resistance 10 and higher by Insulation ohmmeter Diagnosis function Wire break detection Common method 8 point 1COM Suitable cable size Stranded cable between 0 3 0 75 2 8mm and smaller outer dia Suitable clam...

Page 19: ...rge killer None Life Mechanical 20 million and more times Electrical Rated load voltage current 100 thousand and more times AC200V 1 5A AC240V 1A COSΨ 0 7 100 thousand and more times AC200V 1A AC240V 0 5A COSΨ 0 35 100 thousand and more times DC24V 1A DC100V 0 1A L R 7ms 100 thousand and more times Response time Off On 10ms and lower On Off 12ms and lower Diagnosis function Wire break detection In...

Page 20: ...R 0 1 2 3 4 5 6 7 8 9 A B C D E F IN DIAG No Name Description LED Display 1 IN Input status 0 7 On Input On Off Input Off 2 DIAG Diagnosis status 8 F On broken wire occurs Off Normal state Input wiring connector Connector for input wiring Note RefertoChapter2 4Functions ofdiagnosticdigital I O moduleinthis manualfor InternalMemoryConfiguration and LED Display RefertoChapter3 3Wiring inthismanualfo...

Page 21: ...UT Output status 0 7 On Relay output On Off Relay output Off 2 DIAG Diagnosis status 1 Internal output signal diagnosis 0 7 On Internal output signal fail Off Normal state 2 Wire break detection 8 F On broken wire occurs Off Normal state Output wiring connector Connector for output wiring Note RefertoChapter2 4Chapter2 4Functionsofdiagnosticdigital I O module inthismanualforInternalMemoryConfigura...

Page 22: ...yed in the diagnosis device of the CPU module Diagnostic resistor In order to detect broken wire you need to connect a diagnostic resistor in parallel with the input signal device Please use 10KΩ 1 4W diagnostic resistance value Note RefertoChapter3 3Wiring inthismanualforWiringof diagnostic digital Inputmodule 3 Input filter function Digital input module is able to set input filter about input si...

Page 23: ...ng If Standard is selected it operates the value setting in Basic Parameter 4 Internal MemoryConfiguration Diagnostic digital input module can be accessed through Input device It provides Register Module Variable Comments function in XG5000 1 Aftersettingthemodule Click OK or Edit Register ModuleVariable Comments Thenclick Yes toregisterinthepop up windowas below ...

Page 24: ...0_IN5 P00005 Diagnostic DC Input Module Input 5 bit6 6 Input 6 _00_IN6 P00006 Diagnostic DC Input Module Input 6 bit7 7 Input 7 _00_IN7 P00007 Diagnostic DC Input Module Input 7 bit8 8 Diagnosis 0 _00_IN0_DIAG P00008 Diagnostic DC Input Module Input 0 Wire Break bit9 9 Diagnosis 1 _00_IN1_DIAG P00009 Diagnostic DC Input Module Input 1 Wire Break bit10 A Diagnosis 2 _00_IN2_DIAG P0000A Diagnostic D...

Page 25: ...Input 6 bit7 7 Input 7 _0000_IN7 IX0 0 7 Diagnostic DC Input Module Input 7 bit8 8 Diagnosis 0 _0000_IN0_DIAG IX0 0 8 Diagnostic DC Input Module Input 0 Wire Break bit9 9 Diagnosis 1 _0000_IN1_DIAG IX0 0 9 Diagnostic DC Input Module Input 1 Wire Break bit10 A Diagnosis 2 _0000_IN2_DIAG IX0 0 10 Diagnostic DC Input Module Input 2 Wire Break bit11 B Diagnosis 3 _0000_IN3_DIAG IX0 0 11 Diagnostic DC ...

Page 26: ...urrent LOAD load Ifa current of less than10mAflows it will be diagnosed withbroken wire RefertoChapter3 3Wiring inthismanualforWiringof diagnostic digital outputmodule The diagnosis result depending on the situation it is shown in the following table Diagnosis Normal state Relay failure Internal H W failure Broken wire Output signal 0 1 0 1 0 1 0 1 Internal output signal diagnosis 0 0 1 0 0 1 0 0 ...

Page 27: ...lterfunction Diagnosis digital output module is able to set input filter about diagnosis signal The range of values of the input filter user settable is 1ms 100ms The setting method is as follows 1 Double click I O Parameter in project window 25ms and higher Output signal Relay Output current Photo coupler output Broken wire check Off delay Wire break detection diagnosis Broken wire ...

Page 28: ... If Standard is selected it operates the value setting in Basic Parameter 4 Internal MemoryConfiguration Diagnostic digital output module can be accessed through output Input device It provides Register Module Variable Comments functioninXG5000 1 Aftersettingthemodule Click OK or Edit Register ModuleVariable Comments Thenclick Yes toregisterinthepop up windowas below ...

Page 29: ...Chapter 2 Specifications and Functions 2 13 2 Double click Variable Comment in project window variablesareregisteredinthe windowas below ...

Page 30: ...iagnostic Relay Output Module Output 0 Wire Break bit9 9 DIAG Wire break 2 _00_OUT1_LINE_DIAG P00009 Diagnostic Relay Output Module Output 1 Wire Break bit10 A DIAG Wire break 3 _00_OUT2_LINE_DIAG P0000A Diagnostic Relay Output Module Output 2 Wire Break bit11 B DIAG Wire break 4 _00_OUT3_LINE_DIAG P0000B Diagnostic Relay Output Module Output 3 Wire Break bit12 C DIAG Wire break 5 _00_OUT4_LINE_DI...

Page 31: ...re break 2 _0000_OUT1_LINE_DIAG IX0 0 9 Diagnostic Relay Output Module Output 1 Wire Break bit10 A DIAG Wire break 3 _0000_OUT2_LINE_DIAG IX0 0 10 Diagnostic Relay Output Module Output 2 Wire Break bit11 B DIAG Wire break 4 _0000_OUT3_LINE_DIAG IX0 0 11 Diagnostic Relay Output Module Output 3 Wire Break bit12 C DIAG Wire break 5 _0000_OUT4_LINE_DIAG IX0 0 12 Diagnostic Relay Output Module Output 4...

Page 32: ...een 5 95 7 Free of anycorrosive gas orflammablegas 2 Installationconstruction 1 When boringascrewholeorexecutingwiringconstruction anywiring impurities shouldnotbe insertedtothePLC 2 Thesystem should be installed ina placeeasilyaccessible 3 Do not installthesystem ona same panelof a high voltagedevice 4 Itshould be 50mm andmoreawayfrom wiring duct orproximatemodules 5 Grounding onapositionwherenoi...

Page 33: ...tlycontacted withoilsfora long time during wiring itmay causeshort circuit destruction ormalfunction 4 Polarities Pleasemakesure tocheck thepolarities ofmodules of whichterminalblock is polarized beforeallowing thepower 5 Wiring WhenI O wiring is executedwith high voltage orpowercable itmaycause inductivefault probablyleading tomalfunction ortrouble Nocableshould notbe arrangedfront of I Ooperatio...

Page 34: ...eaker 4 If necessary please install awiring duct However pleasekeep thefollowingcautions If installing on the top of PLC maintaintheheight of awiringduct50mmmorethanforbetter ventilation Inaddition maintainthe distancefrom thetopof PLCsothatthehook onthetopof thebasecan be pressed If installing on the bottom of it let optical orcoaxialcable beconnectedandconsider theminimum radius of thecable 5 Pl...

Page 35: ...tion and Wiring 3 4 7 Toavoid anyinfluenceof radiatingnoise orheat please install thePLCandotherdevices relay electroniccontact with aspacing securedas presentedbelow 50mmmorethan 50mmmorethan 100mmmorethan 100mmmorethan ...

Page 36: ...the hole ofmodule installationofthebase Pleasefix itonthebasebypushingthe top of amoduleandtight it byusingthemodulefixation screw Pleasetryto pullthetopof amoduletocheck whether itis tightlyfixed on it Note 1 A module should be installed by inserting the projection for module installation to the hole for module installation If applying an excessiveforce amodulemaybe broken Hole for module install...

Page 37: ...topwhile pressing thehook Lifting up themodule pleasedetachthe projectionformoduleinstallationfrom the holeformoduleinstallation Note 1 When detaching a module please press the hook to detach it from the base and then isolate the projection for module installation from the hole for module installation At the moment if trying to detach it forcibly the hook or projection may be damaged Hook for modu...

Page 38: ...rounded unless themaincircuitcableandpowercablecan not be isolated 5 When applying pipe wiring makesure tofirmlygroundthepiping 6 Theoutput line of DC24Vshould beisolatedfrom AC110Vcable or AC220Vcable For alongdistancewiringover 200m it is expectedthat accidentmayoccur due to leakagecurrent duetointer cablecapacity 3 3 2 Specifications of wiring cable Thespecifications ofcableusedfor wiring areas...

Page 39: ...1 4W Note In order to detect broken wire you need to connect a diagnostic resistor in parallel with the input signal device Please use 10KΩ 1 4W diagnostic resistance value Terminal block Contact XGI D21D 1 2 3 4 5 6 7 8 9 01 02 03 00 04 05 06 07 COM 24 Vd c 8mA R R 0 1 2 3 4 5 6 7 8 9 A B C D E F IN DIAG TB1 Input0 TB2 Input1 TB3 Input2 TB4 Input3 TB5 Input4 TB6 Input5 TB7 Input6 TB8 Input7 TB9 C...

Page 40: ...diagnosis Note In order to detect broken wire minimum 10mA or higher is required to be current LOAD load If a current of less than 10mA flows it will be diagnosed with broken wire Terminal block Contact XGQ RY1D 1 2 3 4 5 6 7 8 9 01 02 03 00 04 05 06 07 L COM 24 Vd c 220 Va c 2A L 0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7 8 9 A B C D E F DIAG OUT TB1 Output0 TB2 Output1 TB3 Output2 TB4 Output3 TB5 Output4 T...

Page 41: ...le and takecorrectivemeasures Totroubleshootthesystem correctly makesuretotakethefollowing cautions and procedures 1 Check byvisual inspection Pleasecheck thefollowings visually Operationstatus Stop Run PowerOn Offstatus I Odevicestatus Wiringstatus I Owiring extension andcommunicationcable Check the status of each display POWER LED RUN STOP LED I O LED and etc connect to peripherals and check the...

Page 42: ...us of SCL1 by XG5000 SOL1OutputLEDisOn No Replace the terminal strip connector Measure the terminal voltage of SOL1 by tester Correct the wiring Yes Isthemeasurementnormal Istheoutputwiringcorrect Isthecontactofterminal stripconnectorfine Isitnormal Separate the external wiring and check the electricity connection of module output Isitnormal Check the status of output device SOL1 Replace an output...

Page 43: ...ormal Check the status of input devices switch 1 2 Replace the input module Measure the terminal voltage of Switch 1 2 by atester Isthemeasurementnormal Isthetightnessof aterminalgood Istheinputwiringcorrect Is wiring correct Tighten the terminal screw Replace the terminal strip connector Replace the input module Check it from thefirst step Isthecontactofterminalstrip connectorcorrect Yes No No Ye...

Page 44: ...ernal device operation by a switchwith LEDmark Connect a proper resistance so that the voltage between input module terminal and common terminal is higher than off voltage as presented below Input signal can not beoff Circulating current by using plural different power sources If E1 E2 itcirculates Changepluraltosingular power Connecting to a circulating current preventive diode figurebelow Extern...

Page 45: ...bably causingatrouble Connect a dozens several hundreds kΩ resistor to a load inparallel Load can not be off Leakage current from surge absorbing circuit connectedtoan output elementin parallel Connect a dozens of kΩ resistor or CR of which impedanceis equal totheresistancetoloadin parallel Note If the length of wiring from output module to load is long it may have leakage current from capacity of...

Page 46: ...imensions of XGI D21D Unit mm 98 0 90 0 27 0 XGI D21D IN 24 Vd c 8 mA 01 06 COM 07 05 04 03 02 00 L L 1 2 3 4 5 6 7 8 9 DIAG 2 Dimensions of XGQ RY1D 98 0 113 0 27 0 XGQ RY1D OUT DIAG 24 Vd c 220 Va c 2 A 05 06 L 07 03 04 02 01 00 L COM 1 2 3 4 5 6 7 8 9 ...

Page 47: ...ing tothereasons unexpected atthelevelof thecontemporaryscienceandtechnologywhen delivered 6 Not attributabletothecompany forinstance naturaldisasters orfire 3 Since the above warranty is limited to PLC unit only make sure to use the product considering the safety for system configuration or applications Environmental Policy LSISCo Ltdsupports and observes the environmental policyas below LSIS con...

Page 48: ...l 86 20 8328 6754 Fax 86 20 8326 6287 e mail chenxs lsis com cn LSIS Chengdu Office _ Chengdu China Address 12FL Guodong Buiding No 52 Jindun Road Chengdu 610041 P R China Tel 86 28 8612 9151 9226 Fax 86 28 8612 9236 e mail comysb lsis biz LSIS Qingdao Office _ Qingdao China Address YinHe Bldg 402 Room No 2P Shandong Road Qingdao City Shandong province 266071 P R China Tel 86 532 8501 6068 Fax 86 ...

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