ELECTRICAL & CONTROLLER

(B200 & TC200)

DC 500 CL-T

TOSHIBA MACHINE CO., LTD 1

 PREFACE
Electricity is essentially invisible. When the electricity flows in electric wires, it turns on electric lights,
drives, motor, and warms up nichrome wires. We know the great energy of electricity but have little knowledge
about electricity. Unfortunately, most people are apt to give up getting to know electricity. However, change your
mind about electricity, which you have believed to be difficult, and make positive maintenance management. A
little knowledge about electricity enables you to maintain machines increasing the operation rate.
The following explains the fundamentals of electricity for die casting machine :

1. THEORY OF ELECTRICITY

(1) Current
If you connect a dry cell and a light bulb using a copper wire as shown below, electricity flows in the direction
from the positive terminal (+) to the negative (-). To take water as an example for the glowing from the positive
terminal (+) to the negative terminal (-), water flowing from high level to a low level is called a water flow.
Similarly, electricity flows from high electric charge level to a low level. This is called a current, which expressed
with the symbol A (ampere).

Dry cell
1.5 V

(2) Voltage
The potential difference between the positive (+) and negative (-) terminals before they are connected by an
electric wire is called a voltage, which is expressed with the symbol V (volt).

(3) Resistance
While the current is flowing from the positive terminal (+) to the negative terminal (-), it encounters the light bulb
which is an obstacle between them. The obstacle is called resistance, which is expressed with the symbol Ω
(ohm). When a voltage of 1V is applied for flowing a current of 1A, the value of resistance is 1Ω.

(4) Ohm’s law

A ---------- Ampere V ---------- Volt R --------- Ohm
A = V / R ------ Formula 1 V = A X R ----- Formula 2 R = V / A ----- Formula 3
The above are the fundamental electricity.
Example 1: When a voltage of 100V is applied to a resistance of 20Ω, the current is obtained from formula 1 as
follows:
A = 100 / 20 = 5 (A)
Example 2: When a current of 2A is flowing into a resistance of 30Ω, the voltage is obtained from formula 2 as
follows:
V = 30 x 2 = 60 (V)

(5) Power and quantity of power

Electricity generates heat when being used with a heater, and works as mechanical power when being used with
a motor. The amount of work per unit hour is called “power”, which is expressed with the symbol W (watt). In
other words, the work of 1W is the amount per unit time of work done by a current of 1A when a voltage of 1V is
applied.
W = VA --------- Formula 4 W = V²/ R -------- Formula 5 W = A²R -------- Formula 6
Example 3: If the voltage is 200V and the current is 5A, W is obtained from formula 4 as follows:
W = 200 X 5 = 1000 (W) = 1 (kW)

2
If the resistance is 20Ω and the current is 5A, W is obtained from formula 6 as follows:
W = 5 X 20 = 500 (W)
One hour work done by a power of 1W is counted as one unit, and the amount of work is measured in the units,
which is expressed with the symbol WH (watt-hour). Horsepower (hp) can be explained just like power. The
work of lifting up a weight of 1 pound by 33 000 feet for 1 minute is expressed as 1 hp. Conversion from 1hp into
W is 0.746 kW. (A unit of power equal to 746 watts)

(6) Grounding ( Earth)

The earth is considered as a huge conductor of which potential is zero. If we connect a charged object and the
earth using an electric wire, electricity flows into the earth through the wire. This connection is called ground
connection, which expressed with the symbol E or .
See the grounding specifications below.
A) Ground the machine through the iron base or iron core of the machine / apparatus, the control unit.
B) A steel frame of the factory may be used as a grounding electrode. However never use a gas pipe or air pipe
for grounding the machine.
C) The sizes of ground wires are defined depending on the main switch and the fuse capacity.
Up to 50A : 3.5 mm² Up to 100A : 5.5 mm² Up to 200A : 14 mm²
Up to 400A : 30 mm² Above 400A : 38 mm²

(7) Series and parallel connections

A) Series connection of resistors R1 R2 R3
R = R1 + R2 +R3 ------ Formula 7
Example 1: If R1, R2, and R3 are 10Ω, 15Ω, and 30Ω, respectively, the total resistance is obtained as follows :
R = 10 + 15 + 30 = 55 (Ω)

B) Parallel connection R1
1
R2
R= 1 1 1 ------ Formula 8
+ + R3
R1 R2 R3

Example 1: If R1, R2, and R3 are 10Ω, 15Ω, and 30Ω, respectively, the total resistance is obtained as follows :
1
R= = 5 (Ω)
1 1 1
+ +
10 15 30
(8) Frequencies of direct current and alternating current
Electricity flowing from the positive terminal (+) to the negative terminal (-) of a battery is constant free from any
change. This called current, which expressed with the symbol DC.
In comparison with the direct current, electricity sent to households and factory is called alternating current
which expressed with the symbol AC. Positive (+) voltage and negative (-) voltage are applied alternately as
shown below. This waveform is called frequency, which is expressed with the symbol Hz (hertz).

Positive (+) potential

Negative (-) potential
1 hertz
For alternating current, a voltage of up to 600V is called low voltage, a voltage of 601 to 700V is called high
voltage, a voltage higher than 700V is called extra high voltage. For direct current, a voltage of up to 750V is
called low voltage, and a voltage higher than 750V is called high voltage. The method of electric work is
specified according to the type of voltage. However, the specification does not cover information about
maintenance work for the control circuits of the machine. 3
 2.How to read sequencer circuits
Electric control circuits are necessary for running a die casting machine.
There are various electric circuits, of which main ones are relay circuits and PC (Sequencer) circuits. This
chapter explain how to read the two types of electric circuits.

2.1 Comparison between Relay circuits and Sequencer circuits

(1) What is a relay circuits.
Below Figure is an extended connection diagram of a relay circuit (Ejector circuit). Each selector switch and the
relay contact are connected through the electric wiring, and the coil of the relay or the coil of the solenoid valve
is energized for getting the die casting machine to run.

6 155 7 4
EJECTOR
BACK 0 EJECT

DOR SHFR 1CBR EFR EFSOL

180 181 182 183 186
Ejector Forward

IR

EBSOL
DOR 187 188
Ejector Backward

EBR
189 Counter
CUT

EFR 190 191

ET Ejector Time

ET

(1) What is a PC circuits.

Below Figure is an extended connection diagram of a PC circuit. Figure 1 to 3 are hardware circuit diagrams,
and figure 4 is a software circuit diagram. (Ejector circuit).
The signals of the selector switches (fig. 1) and the limit switches (fig. 2) are all input into the program by the
input module in order to make up the electric circuit (fig. 4). When all the conditions are satisfied, (Y04C) in the
program is turned ON. When (Y04C) is turned on, the signals are output externally by the output module (Fig. 3)
which energizes the solenoid valve or the like to get the die casting machine to operation.

Fig. 1 Input Module

EJECTOR Input module

PC-0 4
X008 BACK 0 EJECT X10
X100 Ejector Forward
0
CEF

X101 Ejector Backward

1
CEB

Fig. 2 Input Module

Input module
PC-0
7 X01 4
EFLS
X01A Ejector Forward LS
A
EFL
EBLS 4
X01B Ejector Backward LS
B
EBL
Fig. 3 Output Module

10 Output module
PC-0
4
C EFSOL
Y04 Y04C
Ejector Forward SOL

D EBSOL
Y04D
Ejector Backward SOL

Fig. 4 Software Circuit

R012 T141 R038 R13A
AR DT DOCB TEFX
T012 Ejector Delay Time
EST
T012 X012 X01C X111 00010
EST DOL SHFL 1CBL
R039 Ejector Auxiliary
EFY
R010 X100 X101
MR CEF CEB

R039 X01A Y04D

EFY EFL EBS
Y04C Ejector Forward SOL
EFS

2-2 How to read Basic Circuits

(1) Relay Circuits
Series Connection

PB1 PB 2 SL-1 PB 1

W PB 2

SL-1

The lamp (SL-1) goes on only when you pressed the push buttons (PB1) and (PB2) concurrently. The lamp
Goes off when you release either one of the push button.

Parallel connection

PB 1 SL-1
PB 1

W
PB 2
PB 2
SL-1

5
The lamp (SL-1) goes on when you pressed either one of the push button (PB1) or (PB2)
 Self –holding circuit.
PB 1
PB1 PB 2

R1
R1
PB2
R1

Self-holding contact after coil R1 ON

The relay (R1) is turned on when you press the push button (PB1). In series connection, (R1) is turned off when
You release (PB1). By connecting the push button (PB1) in parallel with contact A of (R1), (R1) remains on even
If you release (PB1).

Interlock circuit.
When the circuit of higher priority is turned ON, other circuit are opened and cannot be operated on.

PB 1 R2
PB 1
R1
R1
R1

PB 2 PB2
R2
R2 R2

When you turn on a high priority circuit, the other circuit opens and is unable to work. The relay (R1) is turned on
when you press the push button (PB1) and (PB2) remains on through the self holding feature. However when you
press the push button (PB2), the relay (R2) is turned on, and the contact B of (R2) on the circuit of (R1) opens.
As a result (R1) is turn off. (R2) remains through the self holding feature. Even if you press the push button (PB1)
Again, (R1) is not turned on because the contact B of (R2) id open.

Priority Circuit
PB 1
PB 1
R1

R1 R2
R1

PB2
PB 2

R2 R2

R2 R1

The latest input always has priority over the previous input. The relay (R1) is turned on when you press the push
button (PB1), and (R1) remains on through the self holding feature because (R2) is off. However , the relay (R2)
is turned on when you press the push button (PB2) next, and the contact B of (R2) on the circuit of (R1) opens.6
As a result, (R1) is turned off. (R2) remains on through the self holding feature. However, (R2) is turned off when
you press (PB1) again, and (R1) is turn on.
Timer circuit.

A. Delayed operation circuit.

PB 1

R1 PB 1

R1
R1
T
T
T
SL-1

Certain time operation circuit.

Actuated simultaneously when the switch is turned ON and stops when the timer set time is up.

PB 1 T

R1 PB 1

R1 R1

T
T

Repeated operation circuit.

Two timers are used and the circuits are repeatedly turned ON and OFF according to their set times.

SS R1

T1 SS

T1
L
T1
T2 R1
R1
T2
R1

T2 L

T1 T2 T1 T2 7
 (2) Sequencer Circuit.
Applied circuit using a basic circuit in a PC circuit.
•Clamping start non-repeat circuit (safety interlock).

Common to manual and automatic operations

Input module
1 PC-0
7 PBS1 4
X10
X10C Cycle Start
C
Figure 1
2 PBS1
PBS2
X10D Cycle Start
D
PBS2

R000 X10C T007

00205 HPDR PBS1 PBT2
R004 Start Pushbutton 1
PBR1 00206
4
R004
00206 PBR1
T006 Start Pushbutton interval 1
PBT1 /00207
Figure 2 6
X10D T006
5
R000
00207 HPDR PBS2 PBT1
R005 Start Pushbutton 2
PBR2 00208
R005
00208 PBR2
T007 Start Pushbutton interval 2
PBT2 /00205

1) Figure 1
Clamping starts only when you press the start push button PBS1 (1)(X10C) and PBS2 (2)(X10D) concurrently
or within 1 second (4)(5) (1 second set to T006 and T007 by the manufacturer

2) Figure 2
Clamping does not start when you press the two push buttons separately at an interval of 1 second or more.
When 1 second or more has passed after you press PBS1 (3)(X10C), the timer of start pushbutton interval 1 (4)
(T006) has reached the specified time, and (6)(T006, contact B) opens. As a result, the start push button 2 can
not longer be turned on and clamping does not start.
(Similarly, a non-repeat circuit is also incorporated in relay circuit.

8
2-3 How to read extended connection diagram of electric circuit.

(1) Relay circuit

The numbers below (1) in the below figure are addresses on the diagram. For example, the numbers above (2)
indicates that the contacts of (ET) are at addresses 34 and 63.
The underlined number (34) indicates contact B, and the non-underline number indicates contact A.

The number (181) indicated by (3) is the wire number (marked on the wire).

181
wire

Wire number
(marked on the wire)
1 6 155 7 4
EJECTOR
BACK 0 EJECT
56 3
DOR SHFR 1CBR EFR EFSOL
186
58 180 181 182 183 Ejector Forward

IR
59
EBSOL
DOR 187 188
60 Ejector Backward

61 EBR
189 Counter
CUT

62 EFR 190 191

ET Ejector Time
34 63
63 ET

2 Contact B

(2) PC circuit
As is the case with the relay circuit, the numbers below (1) in the below figure are addresses, and the numbers
above (2) are the addresses being used.

Difference from the relay circuit is that slash (/) is prefixed to the address of contact B (/00801). The number with
no slash being prefixed indicates contact A.

1
R012 T141 R038 R13A
AR DT DOCB TEFX
00718 T012 Ejector Delay Time
EST 00719
T012 X012 X01C X111 00010
EST DOL SHFL 1CBL
00719 R039 Ejector Auxiliary
EFY 00722 /00800
R010 X100 X101 00804
MR CEF CEB
00721

R039 X01A Y04D

EFY EFL EBS
00722 Ejector Forward SOL
Y04C
EFS /00801
9
2 Contact B
2-4 How to read extended connection diagram of relay circuit.

Example : The ejector cylinder does not move forward (Manual)

(1) Using a multi-meter, check if a voltage is applied to the ejector (forward) solenoid valve.
[Measure the voltage of the wires 186 and 4 at the terminal of the ejector (forward) solenoid valve whether there
is 100V. If voltage OK, then mechanical failure may cause the problem.]
(2) Conditions for turning on the ejector (forward) solenoid valve.
(A) EFR (ejector forward limit switch) OFF figure 2
(B) 1CBR (core 1 return limit) ON figure 2
(C) SHFR (safety hook on limit) ON figure 2
(D) DOR (die open limit) ON figure 2
(E) Ejector selector switch “Forward” figure 2
(F) Cycle selector switch “Manual” figure 1
For conditions (A) to (D) above, determined by the movement of the iron core if each relay is ON/OFF.
For condition (E), check if the ejector selector switch is set to “Forward”.
For condition (F), check if the cycle selector switch is set to “Manual”.
Example : SHFR (safety hook on limit) is OFF due to a contact failure of the relay.
(1) Using a multi-meter, check if the voltage of wires 4 and 7 are 100V.
(2) Using a multi-meter, check the voltage of each terminal on the circuit of wire 4 to find out where is shut down.
(3) If a multi-meter reads that the voltages of wires 4 and 181 are 100V but the voltage of wires 4 and 182 are 0V, it
is clear that electricity is shut down at the contact A of SHFR.
(4) If there is a free terminal at the contact A of SHFR, move it to another contact. If the check result is still NG,
replace the relay.

Cycle
5 COS1
Manual Automatic 4
7 EBR

Figure 1
COR IBR Automatic
AR

AR

Figure 2
6 155 7 4
EJECTOR
BACK 0 EJECT
56
DOR SHFR 1CBR EFR EFSOL
186
58 180 181 182 183 Ejector Forward

IR
59
EBSOL
DOR 187 188
60 Ejector Backward

61 EBR
189 Counter
CUT

62 EFR 190 191

ET Ejector Time
34 63
63 ET

10
2-4 How to read extended connection diagram of PC circuit.

Example : The ejector cylinder does not forward.

This section explains how to trouble shoot (read) the circuit when the ejector cylinder does not move forward.
There are two trouble shooting procedures:
> Trouble shooting through the LED of the input and output modules.
> Trouble shooting using the handy programmer to check for the software circuit.

The following explains the trouble shooting procedure through the LED of the input and output modules.
(1) Check the output module LED whether Y04C (ejector forward solenoid) is ON. When the check is OK : Using
multi meter, measure the voltage at the terminal block of the ejector forward solenoid valve.
If the voltage is 100V. Then mechanical failure may causes the problem.
If the voltage is less than 100V. Check for the wiring from the control unit to the solenoid valve.
If the check is NG. according to the software diagram, check the conditions in which Y04C is turned ON, and
identify the cause the problem by the LED of the input and output modules.
(2) Conditions for turning ON Y04C.
(A) X01A (ejector forward limit switch) OFF figure 2
(B) Y04D (ejector backward solenoid) OFF figure 3
(C) R039 (ejector forward auxiliary) ON figure 4
[Check the conditions for R039 according to (3) If both X01A and Y04D are OFF]

R039 X01A Y04D •See the section explaining B200

Figure 1 EFY EFL EBS Ejector Forward for how to view the LED of the
Y04C
EFS input and output modules.

Ejector Ejector
Backward Forward Input module
Limit sw Limit sw 7 PC-0
X01 4
EFLS
X01A Ejector Forward LS
EBLS EFLS A
EFL
Figure 2
EBLS
X01B Ejector Backward LS
B
EBL

10 Output module
PC-0
4
C EFSOL
Y04 Y04C
Ejector Forward SOL
Figure 3
D EBSOL
Y04D
Ejector Backward SOL

R012 T141 R038 R13A

AR DT DOCB TEFX
T012 Ejector Delay Time
EST 00719
T012 X012 X01C X111 00010
Figure 4 EST DOL SHFL 1CBL
R039 Ejector Auxiliary
EFY 00722 /00800
00804
R010 X100 X101
MR CEF CEB
11
 (3) Conditions for turning ON R039 (ejector forward auxiliary)
The conditions for manual ejector forward auxiliary are enclosed in broken line in the circuit in figure 1.
(A) X111 (core 1 return limit) ON figure 2
(B) X01C (safety hook in limit) ON figure 3
(C) X012 (die open limit) ON figure 4
(D) X101 (ejector selector switch: ejector backward) OFF figure 5
(E) X100 (ejector selector switch: ejector forward) ON figure 5
As the case with the previous item, check the input module LED whether the conditions above are satisfied.
(F) R010 (manual operation) is ON when another operation (e.g., clamping or injection) is manually performed.
If the cylinder does not move in manual mode when you attempt to perform operation such as injection, check
the conditions for R010.
If the check result show that any of the conditions is not satisfied, check for the hardware (e.g., LS or wiring) in
the conditions.

R012 T141 R038 R13A

AR DT DOCB TEFX
T012 Ejector Delay Time
EST 00719
T012 X012 X01C X111 00010
Figure 1 EST DOL SHFL 1CBL
R039 Ejector Auxiliary
EFY 00722 /00800
00804
R010 X100 X101
MR CEF CEB

7 Input Module 4
Figure 2
Safety hook cylinder
MC 1 X11
X111 Core 1 return limit
X111
1CBL

7 Input Module 4
Figure 3
SHFL X01
SHFL SHBL X01C Safety hook in limit
S (a) S (a) X01C

SHFLS
Link Housing

7 Input Module 4
Figure 4
DOL X01
DCLS DHILS SHSL DOLS X012 Die open limit
X012
(b) (b) S (a) (a)
DOLS

Manual
X008 Ejector 4
COS 4 Input Module
Figure 5 Backward 0 Forward X10
X100
X100 Ejector forward
Ejector
0
Backward Forward X101
X101 Ejector backward

12
 (4) Conditions for turning ON R010 (manual operation) in figure 1. to check the manual operation conditions, set all
the selector switches to neutral, turn ON X002, and then set cycle selector switch to “Manual” whether “X008” is
turn ON.
Conditions for turning on R010 (manual operation)
(A) X002 (selector switches neutral) ON figure 2
(B) X008 (manual) ON figure 3
(C) X009 (automatic) OFF figure 4
(D) X00A (full automatic) OFF figure 5
(E) X012 (automatic operation) OFF figure 5
(R012 is OFF when both X009 and X00A are OFF)
After conforming that the conditions above are satisfied, set the ejector selector switch to “Forward” again to get
the machine to run
If the cylinder does not move, probably causes are follows:
(A) A terminal of the electric wiring is loose or the wiring is about to break, and the input is unstable switching back
and forth between ON and OFF.
(B) The PC is in abnormal state. (e.g., module defective)

X008 X009 X00A X002 R012

KSM KSA KSFA COR AR
Figure 1 R010 Manual operation
MR
R010
MR

7 4
Input Module

COR X00
Figure 2 X002 Selector switches neutral
X002
COR

3 DIE INJECTION EJECTOR CORE 1 4

COS2 COS3 COS4 COS5
Open 0 Close Inject 0 Return Eject 0 Return In 0 Out
Figure 2 20 21 22 27 Selector switches
COR neutral

7 CYCLE 4
KS 2 Input Module
Man Off Auto Full Auto X00
X008
X008 Cycle manual

KSM
Figure 3 X009
X009 Cycle auto
KSA
X00A
X00A Cycle full auto

KSFA

R041 X002 X009 X008

MRBR COR KSA KSM
R011
Automatic operation auxiliary
AR1
X00A
KSFA

Figure 4 R011 R00C R010

AR1 MHPR MR
R012
AR
Automatic operation 13
R012
AR2
2-6 Lubrication pump circuit (Relay circuit).
(1) Figures 1 and 2
When hydraulic pump ON is completed, the relay (MLR)(1) is turned on and the lubricant pump run (LBL)(3) is
turned on through (LBX contact B)(2) at the same time. Consequently, the lubricant pump starts running.
(2) Figure 3
When the lubricant pump starts running and the pressure increases to 17 kg/cm², the pressure switch (LBPS)(4)
is turned ON, the lubricant pump stop (LBX)(5) is turned ON, and (LBX contact B)(2) is opens to stop.
Consequently, the lubricant pump stop.
(3) Figure 3
The lubricant pump stop relay (LBX)(5) remains on through the self holding feature. The timer of lubricant pump
stop time (LBT)(6) starts at the same time (LBX) is turned ON.
(4) Figure 4
When the timer of lubricant pump stop time (LBT) has reached the specified time, (LBT contact B)(7) opens to
turns OFF the lubricant pump stop relay (LBX). Consequently, the lubricant pump starts running again.

Fig. 1
1
5
MLR LBPS LBT
Lubricant pump stop
LBX
LBX
Lubricant pump stop time
LBT
2 3
LBOL Lubricant pump run
LBL

LB Lubricant pressure detect

PT

Fig. 2
R S T
NFB 1 LBL LBOL
U3
V3
LBM Motor for lubricant pump
W3

Fig. 3
4
5
MLR LBPS LBT
Lubricant pump stop
LBX
6
LBX
Lubricant pump stop time
LBT

LBOL Lubricant pump run

LBL

LB Lubricant pressure detect

PT

Fig. 4
7
MLR LBPS LBT
Lubricant pump stop
LBX
LBX
Lubricant pump stop time
LBT

LBOL Lubricant pump run

LBL

LB 14
Lubricant pressure detect
PT
2-7 Lubrication pump circuit (PC circuit).
(1) Figures 1, 2 and 3
When hydraulic pump ON is completed, the relay (R000)(1) is turned on and the output relay (Y038)(2) is turned
ON at the same time. Consequently, the external relay (LBL)(3) is energized through the output module, and the
lubricant pump starts running. The internal timer of lubricant pump run time (T001)(4) starts at the same time.
(2) Figure 4
When the timer of lubricant pump run time (T001) has reached the specified time, (T001contact B)(5) opens,
and the lubricant pump run relay (Y038) is turned OFF. Consequently, the lubricant pump stop.
(3) Figure 5 and 6
When the timer (T001)(6) has reached the specified time, (T001contact A)(7) is turned ON, and the timer of
lubricant pump stop time (T002)(8) starts.
When the timer (T002) has reached the specified time, (T002 contact B)(9) of the circuit of (Y038) opens.
Consequently, (T001 contact B)(10) is reset. When the timer (T002)(8) has reached the specified time, the
lubricant pump starts running.

1 2
R000 T002 T001
HPDR LBST LBMT
Y038 Lubricant pump run
LBL
4
Fig. 1 T001 Lubricant pump run time
R000 T001 LBMT
HPDR LBMT
T002 Lubricant pump stop time
LBST

10 Output module 4
Y03 Y038
3
LBOL
Fig. 2 Y038
LBL Lubricant pump on
LBL

R0 S0 T0
NFB 2 LBL LBOL
U3

Fig. 3 V3
LBM Motor for lubricant pump
W3

R000 T002 T001 5

HPDR LBST LBMT
Fig. 4 Y038 Lubricant pump run
LBL
6
T001 Lubricant pump run time
LBMT

R000 T001 7
HPDR LBMT 8
Fig. 5 Lubricant pump stop time
T002
LBST

9
10
R000 T002 T001
HPDR LBST LBMT
Fig. 6 Y038 Lubricant pump run
LBL

T001
LBMT
Lubricant pump run time 15
 Programmable Logic Control
B200

1. Specification

Item Description

Voltage 100AC only

Regulation Between 85 and 132 VAC 50 Hz
Power supply

Primary side 5V 10A 135 VAC or less

power
consumption 5V 5A 80 VAC or less
Ambient temperature used 0 to 55 ºC
Storage temperature -20ºC to 65ºC
Earthing Earthing in Class 3
Cooling system Natural cooling
Control system Stored program system
Program system Indicated program system
(11 rows x 11 columns + 11 output)
Word length 16 bits/word, 1 to 4 word instruction
Instruction executing time Basic input instruction : 0.42µ
Basic output instruction : 0.58µ (Y, L, SD & MC)

Basic instruction 16 types

Instruction

Applied Standard FS 00 ~ FS 63 MOVE,1,2,3,4,V,BIN, & BCD

Instruction FUN instruction

User Defined User define FU 00 through FU 63 with the
FUN instruction mnemonic basic language
Program capacity 4kw, 11kw, 18kw, CMOS.RAM, EPROM
Note : The EPROM board is required to use the
EPROM
Number of points of external 2048 points between X000 to XF7F or Y000 to
input / output relay YF7F (Every 16 input/output points available)
16
Programmable Logic Control
B200

Item Description
Internal relay 1024 points, R000 to R77F
Timer counter T000 to T17F 0.1 to 3276.7 sec
(Totals 512 points) T200 to T37F 0.01 to 327,67
T000 to T37F
C000 to C37F C000 to C37F 1 to 32767
Latch 128 points L000 to L07F
Shift register 128 points S000 to S07F
Edge register 128 points E000 to E07F
Data register 1024 words D000 to D77F
(General purpose register)
Timer Set value 512 words V000 to V37F
counter Preset value 512 words P000 to P37F
Alarm flag A011 : To be turned ON when the battery voltage
of the CPU module is unusual.
A012 : To be turned ON when the PC link
transmission is unusual.
Temporary storage

A013 : To be turned ON when the user program

execution times exceeds 100ms.
Special auxiliary relay

A014 : To be turned ON when an instantaneous

power failure occurs.
A015 : To be turned ON when the undefined
FUN instruction is executed.
A016 : To be turned ON when the out put module
fuse is blown out.
A017 : To be turned On when the coil output
instruction is used for the 16 point input in
the user program.
Dead fuse alarm for A020 : To be turned ON when the output module
each rack fuse of the rack No. 0 is blown out.
to
A02F : To be turned ON when the output module
fuse of the rack No. F is blown out.

17
Programmable Logic Control
B200

Item Description

Special PC operation Dry contact input, shorting .. PC operates,

input / input Disconnecting .. PC stops.
output Abnormal PC Contact output : 24 VDC, 250 VAC, 2A;
output contact close .. When the PC stops due to the
trouble of the PC
Indicating Power supply Power On … turned ON
function indicator (green) Power OFF … turned OFF
In operation During operation … turned ON,
indicator (green) stop … turned OFF
Alarm indicator When a controllable trouble occurs … turned ON,
(yellow) Normal … turned OFF
Trouble indicator When an uncontrollable trouble occurs … turned
(red) ON, Normal … turned OFF
Battery 25 ºC 5 years or longer
life 55 ºC 2 years or longer

Status holding function

during The counter, latch and shift register hold the status
interruption before power failure. To hold the status of the
internal auxiliary relay, assign the storage area with
the programmer.
Battery Lithium battery brand name :
ER 6 (AA) 3.6 V 1.9 Ah
Battery replacement Within 5 minutes
Duration

18
Programmable Logic Control
B200

Item Description
Trouble Operation / Trouble of CPU :
detecting monitor It is detected that the CPU is uncontrollable
function mode
Trouble of ROM :
It is detected that the system program ROM
controlling the PC or the usersequence program
EPROM is abnormal

Trouble of RAM :
It is detected that the system RAM controlling the
PC is abnormal

Back up data error :

It is detected that the content of the user sequence
program CMOSRAM or the data held in service
interruption is changed

Instantaneous power failure detection :

An intantaneous power failure of the PC power
supply for 10ms or longer is detected. (When the
Instantaneous operation stop mode is set)

Trouble of the battery :

It is detected that the voltage of the memory back
up battery is dropped to approx. 2.8 V or lower

Dead fuse detection :

It is detected that the fuse inside the output module
is blow out

Trouble of I/O bus :

Abnormal input/output data of the input/output
module are detected

19
Programmable Logic Control
B200

Item Description
Trouble Operation / Trouble of I/O mismatch :
detecting monitor It is detected that the output instruction is used for
function mode the input module in the user program

Trouble of PC Link :
The trouble of PC Link transmission is detected

Abnormal cycle time :

It is detected that an undefined function instruction
is processed

Function over :
The memory capacity for function instruction is
insufficient

Program Circuit element error

mode Memory full
MT PC playback error
Peripheral circuits
Pair coil error

Searchec data error

Memory PC < MT
PC = MT checking error
Number of coil circuits error
discompiling error

Monitored data error

Memory ROM
Uncompleted circuit
Duplicate coil error

20
 Programmable Logic Control
B200

2.1. Programmable Logic Control

Connector for
connecting extended
Input/ Output rack

Basic base board

Rack number setting switch
Input/ Output module

7 6 5 4 3 2 1 0
Module slot number

CU module

Maximum 8 pieces of input and out module

Input module indicates -- X
Power module
Output module indicates -- Y   
Connector for peripheral equipment
(Programmer PGM 355)
1 2 3
1 indicates Rack number
2 indicates Module slot number
3 indicates Terminal number
21
 Programmable Logic Control
B200

2.2. Programmable Logic Control

From Basic Board

Extension base board Mode switch

To another
Extension base

7 6 5 4 3 2 1 0
Module slot number
Power module

Maximum 8 pieces of input and out module

Input module indicates -- X
Output module indicates -- Y   

1 indicates Rack number

1 2 3 2 indicates Module slot number
3 indicates Terminal number

*Mode switch setting :

1. When basic Rack number used only ‘0’ (all I/O module), the extension power module set at ‘1’
2. When basic Rack number used ‘0’ & ‘1’ (all I/O module), the extension power module set at ‘2’
3. When basic Rack number used ‘0’, ‘1’, ‘2’ & ‘3’ (all I/O module), the extension power module set at ‘4’ 22
 Programmable Logic Control
B200

3. Configuration and function of module

A. Basic Power Module – Used for the basic and remote I/O rack

Model : B200PW110A – 100 VAC

Rack Number setting switch (Set 0 at shipping)

Power lamp When 5VDC is supplied… turned ON

(Green) Turned OFF if voltage is dropped to less than 5 VDC

PC operation input terminal :

When the terminal is turned on, the PC executes the sequence program

PC emergency stop output terminal :

When uncontrollable trouble occurs in the PC, turns off the terminal.
They are normally on. Use them for emergency stop circuit, when the
trouble occurs.

Power terminal : Used to connected from power supply (external)

Common ground terminal and frame ground terminal :
Used to make the ground in the shortest route.

Fuse (glass tube fuse 250V, 4A)

B. Extension Power Module – Used for the extension and remote I/O rack

Model : B200PW110B – 100 VAC

Rack Number setting switch (From 0 to F)

Power lamp (Green)

Power terminal :

Common ground terminal and frame ground terminal :

Fuse (glass tube fuse 250V, 4A)

23
 Programmable Logic Control
B200

C. Cu module Model : B200 CU, B200 CURM

In operation lamp --- During normal operation .. Turned on
(Green) ---During stops .. Turned off

Alarm lamp --- When a controllable trouble occurs .. Turned on

(Yellow) ---During normal operation .. Turned off

Emergency --- When a controllable trouble occurs .. Turned on

(Red) ---During normal operation .. Turned off

Peripheral equipment interfacing connector :

To be interfaced with peripheral equipment including CRT programmer

CU Cover :
Battery and memory card inside

When the front cover is removed

CU board :
Used to executes / operates sequence program

Battery connector : Connect the lithium battery to the CPU board

Lithium battery (Model K21141G 3.6 VDC):

Used for the power supply to hold the memory during service
Interruption. For the EPROM memory, it is used to back up the
data.

Battery replacement :
When the alarm lamp on the PC is turned on and the message
“Battery Alarm” is output to peripheral equipment or used up to 5 yrs
(base on the date at the Battery replace name plate inside the
CB box).
Notes : Through the battery replacement can be change during the
power on, replace it carefully while the PC is in operated in
particular.
When changing the battery at power off, replacement time
within 5 min after remove the battery connector.

24
The EPROM memory board
 Programmable Logic Control
B200

When dismantle and view from the back

PC mode setting switch :

Used to set the working mode of the PC and set as

3 4
follow when shipping :-

1 2
ON No. PC mode OFF ON
4 Test mode OFF ON
3 Instantaneous Operation Operation
power failure stop continuing
detection and
cycle time over
2 Timer counter Unchangeable Changeable
set value
1 Intial clear Unexecuted Executed
Shipping status : All OFF position

Initial clear : Used to set the status on whether to clear the battery back-up area of the
CMOS RAM when the power is turned on.

Back up area Address While data While data is

is memor- memorized by
ized by the the EPROM
CMOS Timer counter
RAM set value SW
Unchan Chang
geable eable
Holding area in the R000 - R37F Cleared Cleared Cleared
temporary storage
during interruption
Latch relay L000 - L07F Cleared Cleared Cleared
Shift relay S000 - S07F Cleared Cleared Cleared
General purpose D000 - D77F Cleared Cleared Cleared
register
Timer counter V000 - V37F Cleared ----- Cleared
set value
Preset value of P000 - P37F Cleared ----- Cleared 25
counter
Program ----- Cleared ----- Cleared
 Programmable Logic Control
B200

D. 16 points Input Module Model : B200 16 AI – 100 VAC

B200 16 DI -- 24 VDC

Input ON/OFF indicator lamp (red)

ON – turned on
OFF– turned off

Terminal block

E. 16 points Output Module Model : B200 16AO – 100 VAC

B200 16 DON – 24 VDC
B200 16 DOP – 24 VDC

Built in blow-fuse indicator lamp (red)

Blown out – turned on
Normal – turned off

Output ON/OFF indicator lamp (red)

ON – turned on
OFF– turned off

Terminal block

26
 Programmable Logic Control
B200

F. 32 points Input Module Model : B200 32 AI – 100 VAC

B200 32 DI -- 24 VDC

Input ON/OFF indicator lamp (red)

ON – turned on
OFF– turned off

Terminal block

G. 32 points Output Module Model : B200 32AO – 100 VAC

B200 32 DON – 24 VDC
B200 32 DOP – 24 VDC

Note : The 32 points output module has no built in blow out fuse
Install the 1 common 5A fuse outside the module. Through this fuse
Prevent the module pattern from burning, it’s protects no internal element.

Output ON/OFF indicator lamp (red)

ON – turned on
OFF– turned off

Terminal block

27
Programmable Logic Control
B200

3. Replace fuse on output module (B200 16AO)

Fuse
blowout
indicator

Screw
2

Fuse

Rear Output Screw 1 Case Terminal

cover board block

Fuse

Fuse : 125 V 7.5A

Model : MP 7.5

Fuse : Ordinary blowout type

Model : MF-51 250V 6A Note : Used recommended fuse28or
Size :  5.2 X 20 mm same ampere fuse only.
 Programmable Logic Control
B200

4. LED display on I/O module (16 points)

AC100V AC100V
OUTPUT INPUT
Fuse blown
Output module (1)
0 8
only
1 9
2 A
0
3 B 1
(3)
4 C 2
5 D 3
6 E 4
7 F 5
(a) 6
7
COM
8
(b) 9
0 Y070 A
1 Y071 B
2 Y072 C
Left 3 Y073 D
4 E
side Y074 F
5 Y075 COM
6
Y076
7
Y077
Y078
8
Y709
9
A
Y07A
Y07B Right
B Side
C Y07C
D Y07D
E Y07E
F Y07F

Note : For input, the display in the programmer

will indicating ‘X’

The part (3) in figure is the close-up of the part (1) of the LED indicator.
The LED indicator of a 16 point output module has a structure of 2 columns listing 8 points in vertical.
The points are re-listed in a single column consisting of (a) and (b) as shown.
When they are re-listed in a single column , they are easy to understand because they are in the same list as for the
terminal block. Each of 2 COM indicates power supply.
29
 Programmable Logic Control
B200

5. LED display on I/O module (32 points)

AC 100V
INPUT

0 1 2 3
0 1 2 3
0 0 0 0
1 1 1 1
2 2 2 2
3 3 3 3
4 4 4 4
5 5 5 5
6 6 6 6
7 7 7 7

AC 100V
INPUT
0 1 23
0 0
X000 X008 1 1
X100 X108
2 2
To To 3 3 To To
X007 X00F 4 4
X107 X10F
5 5
6 6
7 7

0 X100
X000 0 1 X101
X001 1 2 X102
X002 2 3 X103
X003 3 4 X104
X004 4 5 X105
X005 5 6 X106
X006 6 7 X107
X007 7 COM COM
COM COM 8 X108
X008 8 9 X109
X009 9 A X10A
X00A A B X10B
X00B B C X10C
X00C C D X10D
X00D D E X10E
X00E E F X10F
X00F F COM COM
COM COM

Note : For output, the display in the programmer

will indicating ‘Y’

Figure 1 is the close-up of the part (1) of the LED indicator (fig. 6) of the input module. The indicator is a structure of 4
columns containing 8 points in vertical appears to be complicated, but it can be simplified by dividing as shown.
30
 Programmable Logic Control
TC200

1. Specification

Item Description

Voltage AC 100 V 50 Hz
Regulation Between 85 and 132 VAC
Power supply

Primary side 5V 10A 120 VAC or less

power
consumption 5V 5A 80 VAC or less
Ambient temperature used 0 to 55 ºC
Storage temperature -20ºC to 70ºC
Grounding Grounding resistance of 100 ohm or less.
Cooling system Natural cooling (SEA)
Control system Stored program system
Program system Indicated program system
(11 rows x 11 columns + 11 output)
Word length 16 bits/word, 1 to 5 words instruction
Processing time Basic instruction : 0.09µ to 0.18µ
Application instruction : 0.57µ

Basic instruction 16 types

Instruction

Applied Application 127 kinds (Arbitrary setting of argument and

Instruction instruction Selection of operating conditions are possible)

User defined 127 kinds

A. instruction
Program capacity Sequence area : 32 kW
User area : 12 kW

Number of points of external 2048 points between X000 to XF7F or Y000 to

input / output relay YF7F.
31
Programmable Logic Control
TC200

Item Description

Internal relay 1024 points, R000 to R77F

Extension Internal relay 1 2048 points, G000 to GF7F

Extension Internal relay 2 2048 points, H000 to HF7F

Latch relay 128 points, L000 to L07F

Shift register 128 points, S000 to S07F

Edge relay 1024 points, E000 to E77F

General-purpose register 1 2048 points, D000 to DF7F

General-purpose register 2 2048 points, B000 to BF7F

Timer / counter 1024 points, T/C000 to T/C77F

Set value 1024 points, V000 to V77F

Current value 1024 points, P000 to P77F

Alarm flag A011 - Battery fault

A012 - PC link error

A013 - Cycle time over

A014 - Instantaneous power failure

A015 - Undefined function execution

A016 - Fuse blow-out detection

A017 - Input / output module mismatch

Fuse blow-out alarm A020 - Rack No. 0 fuse blow-out

to

A02F - Rack No. F fuse blow-out

32
 Programmable Logic Control
TC200

2.1. Programmable Logic Control

7 6 5 4 3 2 1

1 – Power module
2 – CU module
3 – Communication module ( For “J” type machine only)
4 – Remote module ( For “J-S” type machine only)
5 – Input module
6 – Output module
7 – Output module
8 – Output module (For “J” type machine only)
9 – Input module (For “J” type machine only)
10- Input/output module (For “J” type machine only)

8 10

9 33
 Programmable Logic Control
TC200

3. Configuration and function of module

A. Basic Power Module – Used for the basic and remote I/O rack
Model : TCPW 110A – AC 100V (For standard machine)
TCPW 110AL – AC 100V (For Toscast machine)

I/O connector (TCPW 110AL model only)

Power indicator LED (Green)
Illuminated when DC 5V power supply normal
Rack No. setting switch
Power wiring terminal block :
▪INPUT AC 100V terminal
▪FG (frame ground) terminal
▪STOP relay out put terminal.
If an uncontrollable trouble occurs, turn off this terminal.
Note : Contact capacity : DC 24V / AC 220 V 2A
▪OUTPUT DC 5V terminal. Power of 5 VDC is supplied to TCPW5B
EXT. I/O (OUT) connector :
Connector for extension I/O connection. Connect it with the EXT. I/O
IN connector of the next extension I/O power supply module.

B. Extension Power Module – Used for the extension I/O rack

Model : TCPW 110B – AC 100V
EXT. I/O (IN) connector :
Connector for extension I/O connection. Connect it with the EXT. I/O
(OUT) connector of the preceding extension I/O power module.

Rack No. setting switch

Power wiring terminal block :

▪INPUT AC 100V terminal
▪FG (frame ground) terminal
▪OUTPUT DC 5V terminal: Power of DC 5V is supplied to TCPW5B

EXT. I/O (OUT) connector :

Connector for extension I/O connection. Connect it with the EXT. I/O
IN connector of the next extension I/O power supply module. 34
 Programmable Logic Control
TC200

C. Cu module Model : TCCUH (Control module with high speed sequence function)

1. RUN lamp

2. ALARM lamp

3. STOP lamp

4. Maintenance Code display

5. RUN / STOP key switch

6. Peripheral equipment interfacing connector

7. RS232 connector

8. Maintenance Code reset push button

9. Lithium battery

10.Battery connector

11. Memory card and connector

12. Memory card ejector

13. PC mode setting switch

35
Programmable Logic Control
TC200

1. RUN lamp :
Illuminated during normal PC operation and goes out during stop.
2. ALARM lamp :
Illuminated if a controllable trouble occurs.
3. STOP lamp :
Illuminated if an uncontrollable trouble occurs.
4. Maintenance Code display :
An error message is display by the 3 digit 7 segment LED. It is also possible to display
a user message. (This code cannot be cleared at trouble causing PC stop)
5. RUN switch :
Used to change over the PC start and stop. When this switch is set to “RUN” the PC start.
6. Peripheral equipment interfacing connector :
To be interfaced with peripheral equipment including the programmer. (PGM 559)
7. RS232 connector :
To be connector with the personal computer or equipment having an RS232 interface.
8. Maintenance Code reset push button :
Press this switch when clearing a maintenance code display.
9. Lithium battery :
RAM backup battery.
10.Battery connector :
Used to connect the lithium battery with the CU module.
11.Memory card and connector :
EEPROM type memory card storing the sequence program. The memory capacity is
128 KB. And connector for inserting the memory card.
12.Memory card ejector :
Eject push button for removing the memory card.
13.PC mode setting switch :
Used to set the PC operation mode. In all the following 8 modes are available.

No. PC mode
9 9
8 8 MC BOOT
7 7 MC WRITE
6
5 6 SEQ. PROTECT
4 5 DATA REG. PROTECT
3
2
4 I/O CHANGE
1 3 OUT HOLD
2 CONTINUE
ON 1 INITIAL
36
 Programmable Logic Control TC200

No. 8. MC BOOT When set to ON from OFF, the sequence program is booted
(memory card boot) from the memory card. (Also booted when the switch set to
ON at power ON)
No. 7. MC WRITE When set to ON from OFF, the sequence program is written
(Memory card write) into the memory card. (Memory card write protect “WP” must
switch to ON) See fig. below

WP

No. 6. SEQ. PROTECT When set to ON, writing of sequence program is prohibited.
(Sequence protect)
No. 5. DATA REG. PROTECT Writing of data register is banned.
(Data register protect)
No. 4. I/O CHANGE When set to ON, the I/O module can be changed during PC
(input / output change) operation. In this condition, I/O processing is not executed.
After replacement, be sure to set the switch to OFF.
No. 3. OUT HOLD When set to ON, output is held even if the PC stops. When
(Output hold) set OFF, all number of output are turned off.
No. 2. CONTINUE When set to ON, the PC operation continues even if
(Resumption of operation) instantaneous power failure or cycle time over is detected.
No. 1. INITIAL When set to ON from OFF, all contents of sequence program
(Initial clear) and data register are cleared. (They are also cleared when
the switch is set to ON at power ON)
Note : All dip switches of the PC mode setting switch are set to OFF for spare parts.
As for installed on the machine, usually dip switch No. 5 and 6 are set to ON.

D. Replacement of battery

1. Replace the memory backup and clock battery within the term of
validity. The battery can be replace while the PRIVISOR power is on or
off. When the power off, replace the battery within 5 minutes.
2. Model : ER3V-C

Battery connector

37
 Programmable Logic Control TC200

D. Input module Model : TC 32DI – DC 24V

TC 32AI – AC 100V

Input signal indicator lamp

When the input signal is ON, LED light in red

Terminal block

E. Output module Model : TC 32DON – DC 24V COM - NEGATIVE

TC 32 DOP – DC 24V COM - POSITIVE
TC 32AO – AC 100V

Fuse blow out indicator lamp

Illuminated in red if the output wiring protection has blown out

Input signal indicator lamp

When the input signal is ON, LED light in red

Terminal block

38
 Programmable Logic Control
TC200

4. Fuse replacement on Output module

Only the fuse of the output module is changeable by customer. If the fuse has blown out,
identify and remove the case, then replace it with a new fuse.
Through the fuse is also in the Power Module, it is blown out even by an abnormal generated
In the internal circuit and must not be replaced by customer.

Rear
PCB Case
cover

Terminal block

Fuse

Spare
fuse

Note :
Type of fuse used : Normal blow out fuse 5.2 X 20 mm
TC 32 DON : MF – 51, 250V 8A
TC 32 DOP : MF – 51, 250V 8A
TC 32 AO : MF – 51, 250V 6A

Before replacing the fuse, be sure to turn off the PROVISOR and I/O power supply.

Note : Used recommended fuse or

same ampere fuse only.

39
 Programmable Logic Control TC200

5. 32 points input module LED display and terminal connection

TC 32DI TC 32AI

0 1 2 3
0 1 2 3
0 0 0 0
1 1 1 1
2 2 2 2
3 3 3 3
4 4 4 4
5 5 5 5
6 6 6 6
7 7 7 7

TC 32DI TC 32AI

0 1 23
0 0
X000 X008 1 1
X100 X108
2 2
To To 3 3 To To
X007 X00F 4 4
X107 X10F
5 5
6 6
7 7

0 X000
X001 1 2 X002
X003 3 4 X004
X005 5 6 X006
X007 7 C1 COM
X008 8 9 X009
X00A A B X00B
X00C C D X00D
X00E E F X00F
COM C2 0 X100
X101 1 2 X102
X103 3 4 X104
X105 5 6 X106
X107 7 C3 COM
X108 8 9 X109
X10A A B X10B
X10C C D X10D
X10E E F X00F
COM C4

40
 Programmable Logic Control TC200

6. 32 points Output module LED display and terminal connection

TC 32DON
Fuse blown out indicator
FUSE
0 1 2 3
0 1 2 3
0 0 0 0
1 1 1 1
2 2 2 2
3 3 3 3
4 4 4 4
5 5 5 5
6 6 6 6
7 7 7 7

TC 32DON

0 1 23
0 0
Y000 Y008 1 1
Y100 Y108
2 2
To To 3 3 To To
Y007 Y00F 4 4
Y107 Y10F
5 5
6 6
7 7

0 Y000
Y001 1 2 Y002
Y003 3 4 Y004
Y005 5 6 Y006
Y007 7 8 Y008
Y009 9 A Y00A
Y00B B C Y00C
Y00D D E Y00E
X00E F C1 COM
N - 0 Y100
Y101 1 2 Y102
Y103 3 4 Y104
Y105 5 6 Y106
Y107 7 8 Y108
Y109 9 A Y10A
Y10B B C Y10C
Y10D D E Y10E
Y10F F C2 COM
N -

41
 Programmable Logic Control TC200

7. 16/4 points input module. Model : TR 16DIC, TR 16DIE, TR 04DI

Mode switch
Operation monitor LED display

1 2

0
1
LINE
END
CH NO

Input LED display

Main I/O
Terminal connector
Unit supply
DC24V DC24V X**0 COM X**1 X**2 COM1 X**3 X**4 COM2 X**5 X**6 COM3 X**7

A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16

B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16

A+ B- FG FG X**8 COM4 X**9 X**A COM5 X**B X**C COM6 X**D X**E COM7 X**F

42
 Programmable Logic Control TC200

8. 16/4 points output module. Model : TR 16AOECE, TR 16AOE, TR 04AO

Fuse
250 VAC 3A
5.2 X 20mm

Input LED display

I/O
Terminal connector
supply
AC100V Y**0 COM Y**1 Y**2 COM1 Y**3 Y**4 COM2 Y**5 Y**6 COM3 Y**7

A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16

B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16

FG Y**8 COM4 Y**9 Y**A COM5 Y**B Y**C COM6 Y**D Y**E COM7 Y**F

43
 Programmable Logic Control TC200

9. Input / output module. Model : TR 80DIDOPT (64 points input & 16 points output)

X+0 TB2
X+2
TB1
0 0
1 1 1
2 2 2
3 3 3
4
4 DC 24V Input 4
5 5 5
6 6 6
7 7 7
C1 8 C5
8 9 8
9 10 9
A 11 A
B 12 B
C 13 C
D 14 D
E 15 E
F 16 F
C2 17 C6
18
0 19 0
1 20 1
2 21 2
3 22 3
4 23 4
5 24 5
6 25 6
7 26 I/O LED 7
C3 27 display Power LED C7
8 28 Led 1 - 16 Run LED 8
9 29 Error LED 9
A 30 A
B 31 B
C 32 C
D 33 D
E 34 E
F 35 F
SW2 O O SW3
C4 36 C8
37
38 Channel I/O LED indicator
OV 39 OV
OV 40 OV
24V 24V
24V 24V
SW1

2 1
Fuse for output 2 – Line End F3 Power Supply Control
Y**0 to Y**7 1 – Channel change

F1
F2 TB3
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Fuse for output
Y**8 to Y**F
Y**C
Y**D
Y**A
Y**B

Y**E
Y**F
Y**0
Y**1
Y**2
Y**3
Y**4
Y**5
Y**6
Y**7

Y**8
Y**9

A(+)
C10

24V

B(-)
SG
FG

FG
C9

0V
(-)

44
Fuse type: for F1 and F2 normal blown out fuse 250V / 1A 5.2 X 20mm
for F3 normal blown out fuse 250v / 3A 5.2 X 20mm
 Programmable Logic Control TC200

9-1. Terminal connector TB 1 and TB 2 (DC24V input)

Common connector C1 to C8 (0V) for 8 points input
C1at TB 1-1-9 pin
Example : Input contact X000, X00F and X020
X000 to connect at TB 1-1 pin
X00F to connect at TB 1-9 pin
X020 to connect at TB 2-1 pin
Power supply : OV to connect at TB 1-37, TB 1-38, TB 2-37 & TB 2-38.
DC 24V to connect at TB 1-39, TB 1-40, TB 2-39 & TB 2-40.

9-2. Terminal connector TB3

(Included output, communication and control power supply ports)
Example : Output contact Y000 and Y00f
Y000 to connect at TB 3-1 pin
Y00F to connect at TB 3-18 pin
Common connector C9 and C10 (24V) for 8 points output
C9 at TB 3-9 and TB 3-19.
RS485 I/F connection (A+ and B-) Split I/O communication
A+ to connect at TB 3-24 and B- to connect at TB 3-25
For shield FG to connect at TB 3-27
Power supply connection (0V, 24V and FG)
0V to connect at TB 3-21
24V to connect at TB 3-22
FG to connect at TB 3-23

9-3. LED 1-16 (I/O display LED) / SW3 (indicator I/O)

LED 16 F
LED 15 E
LED 14 D SW3
LED 13 C 0 OFF
LED 12 B 1 LED display for input signal TB 1-1 to 8 & 10 to 17 connection ports
LED 11 A 2 LED display for input signal TB 1-19 t0 26 & 28 to35 connection ports
LED 10 9 2 3
3 LED display for input signal TB 2-1 to 8 & 10 to17 connection ports
1 4 4 LED display for input signal TB 2-19 to 26 & 28 to35 connection ports
LED 9 8
LED 8 7 0 5 5 LED display for output signal TB 3-1 to 8 & 11 to 18 connection ports
LED 7 6 9 6 6~8 Unused
8 7
LED 6 5 9 LED test mode
LED 5 4
LED 4 3
LED 3 2
LED 2 1
LED 1 0

45
 Programmable Logic Control TC200

10. Communication module. Model : TCRMT

TCRMT

RUN Operation LED display

ALARM Run : ON when CU module switch to run
STOP Alarm : On when RS485 wire trouble
Stop : Module trouble

A R
S
B 4 Terminal connector
8 Connect the blocks according. These 2 terminal blocks
FG 5 are connected internally by connecting the same signals.

A R
S
B 4
8
FG 5
Open the cover on the module front lower side, and you can see
switches SW1 and SW2 there.
The function of each switch is as follows. Set these switches according
to the intended use.
● SW1 TERMINATING RESISTANCE
Used to turn on and off the 100 Ω terminator. Only when the
module is located on the final end of the transmission line, set
this switch ON.
● SW2 MASTER/SLAVE MODE SWITCH
Used to select the master station or slave station for the module.
When the module is used as the master station, set the switch to
“MASTER”.
When its serve as the slave station, set it to “SLAVE”.
In the same remote system, only 1 master station is available.
NEVER set 2 or more modules for the master station.

46
 Programmable Logic Control TC200

LED ON / OFF State of Power supply and CU module

O : LED ON, ? : LED OFF
LED indication
Power Peripheral Alarm content
supply CU module equipment & reference
module error message for remedy
Power RUN ALARM STOP MAINTENA-
NCE CODE
Normal condition
O ? ? ?
Abnormal condition, operation continues.
O O O ? C.7.0 F Table error The undefined function
instruction is used.
C.7.1 I/O mismatch The output instruction is
used for the input module.
C.7.2 Link table error The link table data is
abnormal.
C.6.0 Cycle time over The processing time of
one cycle exceeds the
predetermined time.
C.4.0 Battery fail The battery voltage drops
to 2.8 V or less.
C.4.1 EEPROM Data writing to or reading
from the memory card is
abnormal.
F.0.0 to Fuse down The fuse of the output
F.0.7 module has blown out.
L.0.0 to PC link error Abnormal data
L.3.F transmission by PC link.
Abnormal condition, operation stop.
O ? ? O C.0.0 PC CPU error The main PC CPU has
malfunction.
C.0.1 PC RAM error The operating system
RAM is abnormal.
C.0.2 PC ROM error The operating system
ROM is abnormal.
P.0.0 EXT. power fail The DC 5V power voltage
abnormal.
C.3.0 Back up data The sequence memory
error data is abnormal.
L6.0 Link master Two or more link master
master are preset.
C.6.1 INT. Prog. over The interruptive program
has not been processed
within the predetermined
time.
 Programmable Logic Control TC200

Notes :
▪If the cycle time over or instantaneous power failure is detected, the PC operating condition
and LED status change with the internal setting of the CU module.

Maintenance code display content

. . .

Signifies the related module. Signifies the alarm breakdown.

C : CU Module 0 ~ 2 : Replacement of module is needed
P : Power Module 3 ~ 5 : If the same alarm is repeated, replacement
U : I/O Module module, etc. is needed.
E : Intelligent Module 6 ~ 8 : Illegal programming or setting.

. . .

0 ~ F : Rack number 0 ~ 7 : Card number (If the remote I/O is

F : Fuse down
generated, the card number is “0”)
H : Remote I/O error
U : I/O error

L. . .

0 ~ 3 : PC number 0 ~ F : PC number
L : PC link error
(Upper) (Lower)

Maintenance code display

48
 SYMBOL (1)

ELECTRICAL SYMBOL

Name Symbol Symbol Name Description

EE Melts down to protect the circuit when
Fuse
FUSE electric current larger than the flows.
Therefore, do not use fuse greater than
the rated capacity.

This is a 3-phase motor and a symbol for

MOTOR 3-phase
the location it is used is entered in this part.
induction
M The supply voltage must be ±10% of the
motor
Rated voltage.

Generates heat when a current larger than

OVERLOAD RELAY
MOL Bimetal the rated current flows, becoming warped
to break the contact. This action turns off
current in the magnet switch coil to protect
MOL
the motor.
Contact
MOL

When current flows in the coil, its activates

MAGNETIC Coil the motor that has contacts connected.
SWITCH L Normally open contacts operated by above.

Contact

When current flows in the coil, it connects

FORWARD / DF contact DF or DB.
Coil to move die
REVERSE
height unit
SWITCH
forward and
DB backward.

DF

Contacts of DF Contacts connected by DF or DB.

and DB.

DB

When current flows in the power section, it

Shot counter
SHOT COUNTER rotates the gear a ½ turn and when current
CUT stops, it simultaneously rotates the gear ½
turn further to change the indicator number.
 SYMBOL (2)

ELECTRICAL SYMBOL

Name Symbol Symbol Name Description

COS & KS Vertical line = Locations where broken line intersect as
SELECTOR a switch position marked by • are connected from left to
SWITCH & 1 0 2
,the horizontal right.
KEY SWITCH A B line = When switch to 0 connection is from C to D
C D combination, & And G to H.
E F
G H the • mark = When switch to 1 connection is from A to B
connection. When switch to 2 connection is from E to F

PRS Contact A Connected when pressure rises above the

PRESSURE
(normally open set pressure. Disconnected when pressure
SWITCH
contact) is below the set pressure.
PRS Contact B Disconnected when pressure rises above
(normally close she set pressure. Connected when
contact) pressure is below the set pressure.

PS When switched over, a to c and d to e are

SELECT SWITCH a → b Contact B
b connected, a to b are disconnected.
a a → c Contact A
If is not switch over, the connection as
c d → e Contact A
shown in the diagram.
d e

FS Contact A Connection when the pedal is stepped on.

FOOT SWITCH

When the current flows, it is energized to

SOLENOID COIL Solenoid coil
Switch over the valve.

Shorted for Discounted in the terminal block section

SHORTING WIRE Standard Close
Standard when using automatic device or safety
Machine. equipment.

Contact A Connected when switch lever push to ON

SNAP SWITCH SS
position. And disconnected when push to
OFF position.

Earth One side of the transformer secondary

GROUND E
circuit is grounded to earth with green wire.
(EARTH)
(wire directly connected to the coil)

180 200 220 Voltage varies in proportion to the number

TRANSFORMER Primary side
Of coil windings. The voltage on the
Tr secondary side varies as the tap on the
Secondary side
primary side is changed.
100
INDICATOR LAMP SL Indicator lamp Also called signal lamp.
Symbol W is white, G is green, R is red &
W Y is yellow.
 SYMBOL (3)

ELECTRICAL SYMBOL

Name Symbol Symbol Name Description

PB Contact A Connected when pushed & disconnected
PUSH BUTTON
when release.
SWITCH
Contact B Disconnected when pushed & connected
(mushroom type) when release.
Contact B (use at emergency stop)

Connected when lever was pressed and

LIMIT SWITCH
Contact A disconnected when release.

Contact B Disconnected when lever was pressed and

connected when release.

Coil When current flows, it is energized to

AUXILIARY RELAY R switch over the contact.

Contact A Connected when coil energized.

Disconnected when coil is not energized.
Contact B Disconnected when coil is energized.
Connected when coil is not energized.

When current flows, it time lag operation

TIMER Coil
T start.
(TIMER LAG
Connected when the set time elapses after
RELAY) T
flows in the coil. Disconnected when
Contact A
current stops.
T Disconnected when the set time elapses
Contact B
After current flows in the coil. Connected
when current stops.

This switch cannot be operated unless the

KEY SWITCH Key switch key was inserted. When the key inserted &
Off On
KS turn to ON position, a and b are connected.

a b

Metal connector Core in/out limit switch is connected when

METAL CONSENT MC
using a core. And a & b are connected
a b through the limit switch.

The lamp lights when the push button is

PUSH BUTTON pressed.
WITH W is white.
LAMP R is red.
Contact A

W Lamp

When current flows in the coil, it’s creates

BUZZER Buzzer a sound.
BZ