Kinco AX500 - User Manual

AX500 Intelligent Controller
Intelligent Controller User Guide
AX500 Intelligent Controller
AX500 intelligent controller is a medium-sized PLC developed based on CODESYS. It fully supports
IEC61131-3 programming system and multiple site real-time bus. It supports cam, CNC, and other
synchronous movement control providing various interfaces to meet the needs of projects.
This manual describes the specifications, characteristics and using methods of the AX500
controller. For the user program, hardware information and other information of this product,
please refer to the other manual.
Safety Instructions
Safety Precautions
1. Before installing, operating, and maintaining the product, please read and observe these safety
precautions.
2. To ensure personal and equipment safety, please follow all marks on the product and safety

Summary

Safety Instructions

Safety Precautions

Details essential safety measures before and during product operation.

Safety Level Definition

Control System Designing

Wiring

Maintenance & Inspection

Product Information

Product Naming Rules

Explains the structure and meaning of the product's model name.

Product Nameplate

General Specifications

Components Information

Status Indicators

Explains the function and status of the PWR, RUN, ERR, and BUS indicator lights.

Network Ports

Details the three available network ports: EtherNET, EtherCAT A, and EtherCAT B.

Power Supply Terminals

Control Functions

Power Terminal Arrangement

IO Coupler Power Supply

Details the 24V and 5V power indicators for IO couplers and modules.

Communication and Error Indicators

Explains the LINK and ERR indicators for module communication and errors.

DI Terminal Instructions

NPN Wiring Configuration

Illustrates the NPN wiring method for digital input expansion modules.

PNP Wiring Configuration

Illustrates the PNP wiring method for digital input expansion modules.

Function Description

Status Indicator Function

Provides a detailed explanation of the status indicators (PWR, RUN, ERR, BUS).

User Program Download by USB

Firmware Upgrade

Multi-node Connection

RS485 Bus Wiring

RS232 Bus Wiring Description

Ethernet Connection

Programming Tool Downloading

Programming Environment and Software Installation

Outlines hardware and software setup requirements for the programming environment.

Mechanical Design

Dimensions

Displays the physical dimensions of the AX500 controller in millimeters.

Mounting

Mounting Guide

Provides instructions and considerations for the snap-fit installation of the AX500 controller.

Add Device Packages to CODESYS

Explains the process of installing the AX500 device package into the CODESYS software.

Standard Project

Warranty Agreement

Product Warranty Card

Form for recording customer, product, and repair information for warranty claims.

Overview

1. Function Description
2. Usage Features
3. Maintenance Features

The AX500 Intelligent Controller is a sophisticated, medium-sized Programmable Logic Controller (PLC) designed by Kinco, built upon the CODESYS platform. It fully adheres to the IEC611131-3 programming standard and supports multiple real-time bus systems, making it a versatile solution for various industrial automation needs. This controller is particularly adept at synchronous movement control, including cam and CNC applications, and offers a wide array of interfaces to accommodate diverse project requirements.

Function Description

The AX500 Intelligent Controller serves as the central processing unit for automation systems, executing user-defined programs to manage and coordinate industrial processes. Its core functionality revolves around real-time control, enabling precise and synchronized operation of connected devices. The controller's robust design supports complex programming logic, allowing for intricate automation sequences and responsive system behavior.

Key functions include:

• Program Execution: The controller runs user programs developed using the IEC611131-3 standard, which encompasses various programming languages like Ladder Diagram (LD), Function Block Diagram (FBD), Structured Text (ST), and Sequential Function Chart (SFC). This flexibility allows engineers to choose the most suitable language for their application.
• Real-time Bus Communication: With support for multiple real-time bus systems, the AX500 facilitates high-speed and deterministic data exchange with distributed I/O modules, drives, and other intelligent devices. This ensures synchronized operation and quick response times critical for motion control and other time-sensitive applications.
• Synchronous Movement Control: A standout feature of the AX500 is its capability for advanced motion control. It can handle complex synchronous movements, such as those required for cam profiles and multi-axis CNC operations. This enables precise coordination of multiple motors and actuators, crucial for robotics, packaging, and machine tool applications.
• Data Processing and Storage: The controller is equipped with sufficient memory and storage capacity to handle application programs, user data, and non-volatile storage for critical parameters, ensuring data integrity and operational continuity even after power cycles.
• Communication Interfaces: The AX500 provides a rich set of communication interfaces, including Ethernet, RS485, and RS232. These interfaces allow for seamless integration with Human-Machine Interfaces (HMIs), Supervisory Control and Data Acquisition (SCADA) systems, other PLCs, and various field devices, supporting a wide range of industrial communication protocols like Modbus TCP and EtherCAT.
• Diagnostic and Status Indication: The front panel features LED indicators for Power (PWR), Run (RUN), Error (ERR), and Bus (BUS) status. These indicators provide immediate visual feedback on the controller's operational state, program execution status, and any communication or system faults.

Usage Features

The AX500 Intelligent Controller is designed for ease of use and robust performance in industrial environments.

• Programming and Debugging: User programs can be downloaded and debugged via Ethernet or USB. The Ethernet port supports Modbus TCP and Socket (TCP, UDP) for flexible communication. EtherCAT A and B ports function as EtherCAT Masters, supporting auto-scan and independent configuration of axes/I/O, which simplifies system setup. EtherCAT B also offers Ethernet functionality for additional programming and debugging options.
• Power Supply: The controller operates on a DC 24V power supply, with a 3-pin European terminal for power input. This terminal uses a spring-clip crimping method, facilitating convenient and secure wiring, replacement, and maintenance.
• Communication Terminals: The RS485 and RS232 communication terminals are clearly defined, supporting various serial communication needs. For RS485, daisy-chain topology is recommended for multi-node connections, with branch lengths ideally not exceeding 3 meters to maintain signal integrity. Star-type connections are prohibited. Shielded twisted pair cables are advised for RS485 to minimize electromagnetic interference and improve signal quality.
• Status Indicators: The PWR indicator shows if the device is powered on (green). The RUN indicator shows program execution status: green when running, off when stopped, rapidly flashing during download, and flashing when the Wink button is pressed for device identification. The ERR indicator turns red for user program faults, and the BUS indicator turns red for communication faults, providing clear diagnostic information. An alternating flash between RUN and ERR indicates no user program is found.
• Reset Functionality: A dedicated Reset Button allows for resetting the controller to default IP settings (long press until RUN light blinks) or clearing the user program and restarting (continued holding).
• Firmware Upgrade and Program Transfer: Firmware upgrades can be performed by placing the firmware package in the root directory of a FAT32 formatted USB drive and restarting the controller. User programs can also be transferred via USB by copying application files to the root directory of a USB drive and restarting the controller. Alternatively, firmware can be upgraded through CODESYS software by placing the package in the controller's root directory and restarting.
• Mounting: The AX500 features a snap-fit installation design, allowing for easy snap-in mounting in various cabinet sizes. This design simplifies installation and ensures a secure fit.

Maintenance Features

Proper maintenance is crucial for the longevity and reliable operation of the AX500 Intelligent Controller.

• Safety Precautions: All maintenance and inspection tasks must be performed by electrically trained personnel. It is imperative to disconnect all external power supplies before cleaning, tightening screws, or removing/connecting communication wirings to prevent electric shock or damage. Terminals should not be touched while power is on.
• Wiring Integrity: During wiring, care must be taken to prevent metal filings or wire ends from entering ventilation holes, which could lead to fire or malfunction. Good insulation on terminals is essential to maintain adequate insulation distance between cables. Bolts on terminal blocks should be tightened within the specified torque range to prevent short-circuits or damage.
• Environmental Considerations: The controller is designed for indoor electrical environments (overvoltage category II). The power supply must include system-level lightning protection to prevent damage from overvoltage.
• Cable Management: Control wires, communication wires, and power cables should not be bundled together; a minimum distance of 100 mm should be maintained to prevent noise interference and malfunction. Shielded cables are recommended for high-frequency signal I/O in environments with significant interference to enhance anti-interference ability.
• Disposal: Scrapped modules should be treated as industrial waste. Batteries must be disposed of according to local laws and regulations to ensure environmental safety.
• Firmware and Software Updates: Kinco continuously improves its products and materials. Users are encouraged to timely update their software and refer to the latest published materials for optimal performance and security.
• Online Modification Safety: Before performing online modifications, forcible output, or RUN/STOP operations, users must be thoroughly acquainted with the guide and ensure safety to prevent unintended system behavior.
• Extension Card Handling: The power supply must be disconnected before installing or removing any extension cards to prevent damage to the module or electric shock.

The AX500 Intelligent Controller provides a comprehensive solution for industrial automation, combining powerful control capabilities with user-friendly features and robust design for reliable operation and straightforward maintenance.

Kinco AX500 Specifications