Kinco-K5

User’s Manual

Contents

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CONTENTS………………………………………………………………………………………………………1

PART I GENERAL INTRODUCTION..................................................................................................................... 6

CHAPTER I SYSTEM OVERVIEW..........................................................................................................................7

1.1 APPLICATION SCOPE OF THE PRODUCT................................................................................................................ 7

1.2 GENERAL DESIGNATION IN THE MANUAL........................................................................................................... 7

1.2.1 Vocabulary of Terms...................................................................................................................................... 7

1.3 NAME RULES FOR THE PRODUCT..........................................................................................................................9

1.3.1 Description of the Product Name..................................................................................................................9

1.3.2 Description of Order Number..................................................................................................................... 12

1.4 PRODUCT LIST OF KINCO-K5..............................................................................................................................13

PART II HARDWARE MANUAL..........................................................................................................................15

CHAPTER I APPLICATION OF KINCO-K5 SERIES MICRO PLC...................................................................16

1.1 ARCHITECTURE OF KINCO-K5.......................................................................................................................... 16

1.1.1 Overview...................................................................................................................................................... 16

1.1.2 Allowable System Scales............................................................................................................................. 16

1.1.3 Communicating over a Network................................................................................................................. 17

1.2 POWER SUPPLY DESIGN........................................................................................................................................18

1.2.1 DC24V Power Supply calculation.............................................................................................................. 18

1.2.2Expansion power supply calculation........................................................................................................... 19

1.2.3Input power of the CPU................................................................................................................................20

1.3 OPERATION ENVIRONMENTAL CONDITION......................................................................................................... 20

CHAPTER II CPU PRINCIPLE AND APPLICATION......................................................................................... 22

2.1 OVERVIEW............................................................................................................................................................22

2.1.1 Front view.................................................................................................................................................... 22

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2.1.2CPU Types.................................................................................................................................................... 22

2.2FUNCTIONS........................................................................................................................................................... 24

2.2.1OperationMode.............................................................................................................................................24

2.2.2Communication Port.................................................................................................................................... 25
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2.2.3Data Keep-in and Back Up.......................................................................................................................... 25

2.2.4Real-time Clock (RTC)................................................................................................................................. 26

2.2.5High-speed counter and High-speed pulse output...................................................................................... 26

2.2.6 Trigger interrupt.......................................................................................................................................... 26

2.3 WIRING DIAGRAM............................................................................................................................................... 27

2.4SPECIFICATIONS....................................................................................................................................................35

2.4.1CPU Specifications.......................................................................................................................................35

2.4.2 CPU DI Specifications................................................................................................................................ 36

2.4.3 CPU DO Specifications(Transistor)........................................................................................................... 37

2.4.4 CPU Output Specifications(Relay)............................................................................................................. 37

2.4.5 AI channel parameters on CPU.................................................................................................................. 38

2.4.6 AO Channel Parameters on CPU............................................................................................................... 38

CHAPTER III DI (DIGITAL INPUT) MODULES.................................................................................................39

3.1 DI 8*DC24V.......................................................................................................................................................39

3.1.1 Wiring Diagram...........................................................................................................................................39

3.1.2 Technical Data.............................................................................................................................................40

3.2 DI 16*DC24V.....................................................................................................................................................41

3.2.1 Wiring Diagram...........................................................................................................................................41

3.2.2 Technical Data.............................................................................................................................................42

CHAPTER IV DO (DIGITAL OUTPUT) MODULES...........................................................................................43

4.1 DO 8*DC24V..................................................................................................................................................... 43

4.1.1 Wiring Diagram...........................................................................................................................................43

4.1.2 Technical Data.............................................................................................................................................44

4.2 DO 8*RELAY....................................................................................................................................................... 45

4.2.1 Wiring Diagram...........................................................................................................................................45

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4.2.2 Technical Data.............................................................................................................................................46

4.3 DO 16*DC24V................................................................................................................................................... 47

4.3.1 Wiring Diagram...........................................................................................................................................47

4.3.2 Technical Data.............................................................................................................................................48

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4.4 DO 16*RELAY.................................................................................................................................................... 49

4.4.1 Wiring Diagram...........................................................................................................................................49

4.4.2Technical Data..............................................................................................................................................50

CHAPTER V DI/O MODULES...............................................................................................................................51

5.1 DI/O, DI4*DC24V DO4*DC24V......................................................................................................................51

5.1.1Wiring Diagram............................................................................................................................................51

5.1.2Technical Data..............................................................................................................................................52

5.2 DI/O,DI 4*DC24VDO 4*RELAY.......................................................................................................................54

5.2.1Wiring Diagram............................................................................................................................................54

5.2.2Technical Data..............................................................................................................................................54

5.3 DI/O, DI 8*DC24VDO 8*DC24V.....................................................................................................................56

5.3.1Wiring Diagram............................................................................................................................................56

5.3.2Technical Data..............................................................................................................................................56

5.4 DI/O, DI 8*DC24V DO 8*RELAY.....................................................................................................................58

5.4.1Wiring Diagram............................................................................................................................................58

5.4.2Technical Data..............................................................................................................................................58

CHAPTER VI AI (ANALOGINPUT) MODULES.................................................................................................60

6.1 AI 4*IV, MULTI-SIGNAL INPUT..........................................................................................................................60

6.1.1Wiring Diagram............................................................................................................................................60

6.1.2Measurement Ranges and The measured value Representation................................................................. 61

6.1.3Technical Data..............................................................................................................................................61

6.2 AI 4*RD, RTD INPUT.........................................................................................................................................62

6.2.1Wiring Diagram............................................................................................................................................62

6.2.2Measurement Ranges and The measured value Representation................................................................. 62

6.2.3Technical Data..............................................................................................................................................63

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6.3 AI 4*TC, THERMOCOUPLE INPUT.......................................................................................................................64

6.3.1Wiring Diagram............................................................................................................................................64

6.3.2Measurement Ranges and The measured value Representation................................................................. 65

6.3.3 Technical Data.............................................................................................................................................65

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CHAPTER VII AO (ANALOG OUTPUT) MODULES.........................................................................................66

7.1 AO 2*IV, MULTI-SIGNAL OUTPUT.....................................................................................................................66

7.1.1Wiring Diagram............................................................................................................................................66

7.1.2Output Ranges and the Output Value Representation................................................................................. 66

7.1.3Technical Data..............................................................................................................................................67

CHAPTER VIII AI/O (ANALOG INPUT/OUTPUT) MODULES........................................................................68

8.1 AI/O, AI 2×IVAO 2×IV, MULTI-SIGNAL OUTPUT..........................................................................................68

8.1.1Wiring Diagram............................................................................................................................................69

8.1.2Measurement Ranges and The measured value Representation................................................................. 69

8.1.3 Output Ranges and the Output Value Representation................................................................................ 69

8.1.4Technical Data..............................................................................................................................................70

CHAPTER IX EXPANSION FUNCTION MODULES......................................................................................... 71

9.1 K541, CAN BUS MODULE.................................................................................................................................. 71

9.1.1 Main Features..............................................................................................................................................71

9.1.2Terminals and Status LEDs.......................................................................................................................... 72

9.1.3Wiring and Arranging...................................................................................................................................73

9.1.4Technical data...............................................................................................................................................74

9.2 EXPANSION POWER MODULE............................................................................................................................. 75

9.2.1 Main Specifications..................................................................................................................................... 75

9.2.2 PS580 used in the actual application..........................................................................................................76

9.2.3 CPU selection and PS580 Calculation.......................................................................................................76

9.2.4 Technical Data.............................................................................................................................................78

CHAPTER X INSTALLATION&WIRING GUIDELINES................................................................................... 79

10.1 PLASTIC CASE DIMENSION............................................................................................................................... 79

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10.2 INSTALLATION GUIDELINES.............................................................................................................................. 80

10.2.1 Module Connection................................................................................................................................... 80

10.2.2 Installing the KINCO-K5 modules............................................................................................................81

10.3 INSTALLATION AND REMOVING THE WIRING TERMINAL ROW.......................................................................... 83

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10.3.1 Remove wiring terminal row..................................................................................................................... 83

10.3.2 Install the terminal row............................................................................................................................. 83

10.4 PROTECTION CIRCUIT AND GROUND CONNECTION........................................................................................... 84

10.4.1 Protection function of transistor digital Output....................................................................................... 84

10.4.2 Protection function of Relay output.......................................................................................................... 84

10.4.3 Grounding...............................................................................................................................................85

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Part I

General Introduction

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Chapter I System Overview

This chapter will briefly introduce the Kinco-K5 series micro PLC (Programmable Logic Controller) and
7 focuses on the explanation of the terms related to Kinco-K5 with a purpose of facilitating you to understand the

contents in the following part of this manual. The main content of this chapter covers: application scope of the

product, explanations on relevant terms, rules for nomenclature, etc.

1.1 Application Scope of the Product

According to the accepted classification rules for PLC, Kinco-K5 series PLC falls into the range of micro PLC.

Therefore, it can be used to control machines and small-scale process. Kinco-K5 series PLC can well satisfy the

demands in the following application areas (including but not limited to these applications):

Packing machinery textile machinery building material machinery

Food machinery plastic machinery numerical control machine

Printing mechanism central air conditioner

Environmental Machinery individual process control device

1.2 General Designation in the Manual

1.2.1 Vocabulary of Terms

▪Micro PLC (Programmable Logic Controller)

According to the general classification rules, micro PLC generally refers to the type of PLC with the IO number

less than 128. This type of PLC usually adopts compact structure, that is, a certain number of I/O channels,

output power supply; high-speed output/input and other accessories are integrated on the CPU module.

▪ CPU body

Namely, the CPU module, it’s the core of the control system. The user program is stored in the internal storage of

the CPU module after being downloaded through the programming software, and will be executed by the CPU.

Meanwhile, it also executes the CPU self diagnostics: check each modules’ operation status and operation error of

user program

▪ Expansion module & expansion bus

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The expansion module is used to extend the functions of the CPU body and it contains expansion I/O module

(to extend the input/output channels of the system) and expansion functional module (to expend the functions of

CPU).

The expansion bus connects the CPU and expansion modules, and the 16-core flat cable is adopted as the
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physical media. The data bus, address bus and the expansion module’s working power supply are integrated into

the expansion bus cable.

▪ KincoBuilder

The programming software for Kinco-K5 series PLC, accords with IEC61131-3 standard. KincoBuilder presently

provides LD and IL languages for convenience and efficiency in developing the control programs for your

applications. KincoBuilder provides a user-friendly environment to develop and debug the programs .

▪CPU firmware

It is the “operating system” of the CPU module and it is stored in the Flash memory. When powered on, it starts

to manage and arrange all the tasks of the CPU module.

▪ User program

It’s also called user project or application program, the program written by the user to execute some specific

control functions. After the user program is downloaded to the CPU module, it is stored in the FRAM. When

powered on, the CPU module shall read it from FRAM into RAM to execute it.

▪ Main program and scanning cycle

The CPU module executes a series of tasks continuously and cyclically, and we call this cyclical execution of

tasks as scanning.

The main program is the entry of application program. In the CPU, the main program is executed once per

scanning cycle and there is only one main program in application program, user can call multiple sub-routines in

from main program.

▪ Free-protocol communication

The CPU body provides serial communication ports that support the special programming protocol Modbus RTU

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protocol (as a slave) and free protocols. Free-protocol communication mode allows your program to fully control

the communication ports of the CPU. You can use free-protocol communication mode to implement user-defined

communication protocols to communicate with all kinds of intelligent devices. ASCII and binary protocols are

both supported.
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▪I/O Mapping Area

The memory area of physical I/O terminals, which is including input mapping area and output mapping area. In

order to ensure data consistency in one scanning cycle and to improve the program execution speed, CPU will

read the status of physical inputs to input mapping area at the beginning of a scanning cycle and send the output

mapping area data to physical output channels at the ending of scanning cycle. The IO address in this manual,

like I0.0, Q1.0, AIW0, AQW0 and so on , they are all I/O mapping area address.

▪ Retentive Area Range and Data backup

In “Hardware” configuration of KincoBuilder, you can define four retentive ranges to select the areas of the

RAM which you want to retain on power loss. In the event that the CPU loses power, the instantaneous data in

the RAM will be maintained by the lithium cell, and the data in retentive ranges will be retentive at next power

on. The retaining duration is 3 years at normal temperature.

Data backup is hat PLC has a particular memory area in FRAM. The data in this area will be permanent storage

automatically. Note: Every type of permanent memory has its own expected life, for example, E2PROM allows

100 thousand of times of writing and FRAM provides unlimited read/write endurance.

1.3 Name Rules for the product

1.3.1 Description of the Product Name

The “product name” of Kinco-K5 PLC is used to indicate the main functions and applications of the product.

The “product name” is not for any individual product but the general name for a type of products. The “product

name” is defined according to the following principle:

Product name: module type + 5 + subtype + serial number + function identification

Module type is indicated by the following English letters

CPU CPU module

PM expansion I/O module

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SM expansion function module

PS power supply module

SW Software

AS Accessory
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▪ 5 means Kinco-K5 series micro PLC

▪ Subtype: use a number (0~9) to indicate the subtype of the module.

0 CPU modules

1 Reserved

2 Digital Input/output module

3 Analog Input/output module

4 Communication module

5 Specific function module

6 Software

7 Accessory

8 Power Module

9 Reserved

▪ Serial number:: use a number (0~9) to indicate the sequence number of a subtype. The serial numbers of

subtypes have the following meanings.

▪ CPU module

4 CPU which provides 14 I/O channels on the CPU body;

6 CPU which provides 24 I/O channels on the CPU body;

8 CPU which provides 40 I/O channels on the CPU body;

Other serial numbers are reserved.

▪ Digital Input/Output module

1 DI (digital input) module;

2 DO (digital output) module;

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3 DI / DO mixed module;

Other serial numbers are reserved.

▪ Analog Input/Output module

1 AI (analog input) module;

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2 AO (analog output) module;

3 AI/AO mixed module;

Other serial numbers are reserved.

▪ Communication Module

0 RS485 communication module;

1 CAN Protocol Interface module;

Other serial numbers are reserved.

▪ Special Function Module

These numbers are reserved.

▪ Software

0 Programming software;

Other serial numbers are reserved.

▪ Accessories

0 Programming cable;

Other serial numbers are reserved.

▪ Power Module

0 Expansion power supply module;

Other serial numbers are reserved.

▪ Function Identifier (optional)

EC Communication Enhanced CPU Module;

EA Analog Enhanced CPU Module;

EM Motion Control Enhanced CPU Module;

EX Other functions Enhanced CPU Module.

According to the above principles, CPU506 indicates a CPU module with 24 I/O channels; PM521 indicates DI

expansion module; AS360 stands for KincoBuilder programming software, etc.

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1.3.2 Description of Order Number

The difference from “product name” is that each product has a unique “order No.”, users just need to inform us

the order number of the demanded product when making an order. The “order number” is in accordance with

12 the following rules:

Order Number :Kinco-K + module code + feature code

CPU and PM must have this option,

Fixed prefix But other module may omit it.

Kinco-K -
Optional:
Sub-item of function identifier,
Number Represented with the letters X,Y,Z
Same with the or numbers 0~9
product name
The 1st digit indicates:
Power supply voltage
D: DC 24V
A: AC 85-265V

CPU extended function Identifier (optional) The 2nddigit indicates:

EC Communication Enhanced CPU Module; Type of the output channel
Number of CPU and T: Transistor
EA Analog Enhanced CPU Module; I/O channels
EM Motion Control Enhanced CPU Module; Digital module R: Relay
EX Other Enhanced CPU Module.
Fill in X where not
Other serial numbers are reserved
applicable
Function identifier

IV: current/voltage
TC: thermal couple
Analog module
RD: RTD
NT: NTC thermistor

Diagram 1-2 Description of the Order Number

According to the above principle,KINCO-K506-24DT stands for the CPU module with 24 I/O channels (the

output channel is of transistor type) and DC24V power supply; KINCO-K521-08DXstands for the DI expansion

module with 8 transistor-type input channels.

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1.4 Product list of Kinco-K5

Type Name Order no. Description

AC85~265V power supply, with 14 I/O, DI 8*DC24V, DO

Kinco-K504-14AT
6*DC24V,1*RS232, non-reconnected extension module
13 AC85~265V power supply, with 14 I/O, DI 8*DC24V, DO
Kinco-K504-14AR
6*Relay, 1*RS232, non-reconnected extension module
CPU504
DC20.4~28.8V power supply, with 14 I/O, DI 8*DC24V, DO 6*
Kinco-K504-14DT
DC24V, 1*RS232, non-reconnected extension module

DC20.4~28.8Vpower supply,with 14 I/O,DI 8*DC24V,DO

Kinco-K504-14DR
6*Relay, 1*RS232, non-reconnected extension module

AC85~265V power supply, with 14 I/O, DI 8*DC24V, DO

Kinco-K504EX-14AT
6*DC24V, 1*RS232,1*RS485

AC85~265V power supply, with 14 I/O, DI 8*DC24V, DO

Kinco-K504EX-14AR
6*Relay, 1*RS232, 1*RS485
CPU504EX
DC20.4~28.8V power supply, with 14 I/O, DI 8*DC24V, DO 6*
Kinco-K504EX-14DT
DC24V, 1*RS232, 1*RS485

DC20.4~28.8V power supply, with 14 I/O, DI 8*DC24V, DO

Kinco-K504EX-14DR
6*Relay, 1*RS232, 1*RS485

DC24V power supply, with 24 I/O, DI 14*DC24V, DO

CPU module Kinco-K506-24DT
10*DC24V, 1*RS232, 2*RS485

DC24V power supply, with 24 channels, DI 14*DC24V, DO

Kinco-K506-24DR
10*Relay, 1*RS232, 2*RS485
CPU506
AC85~265V power supply, with 24 I/O, DI 14*DC24V, DO
Kinco-K506-24AR
10*24V, 1*RS232, 2*RS485

AC85~265V power supply, with 24 I/O, DI 14*DC24V, DO

Kinco-K506-24AT
10*Relay, 1*RS232, 2*RS485

AC85~265V power supply, with 30 I/O, DI 14*DC24V, DO

Kinco-K506EA-30AT
10*24V, AI 4*IV, AO 2*IV, 1*RS232, 2*RS485
CPU506EA
DC20.4~28.8V power supply, with 30 I/O, DI 14*DC24V, DO
Kinco-K506EA-30DT
10*24V, AI 4*IV, AO 2*IV, 1*RS232, 2*RS485

AC85~265V power supply, with 40 I/O, DI 24*DC24V, DO

Kinco-K508-40AT
16*DC24V, max output current per channel 0.75A

AC85~265V power supply, with 40 I/O, DI 24*DC24V, DO

CPU508 Kinco-K508-40AR
16*Relay, max output current per channel 3A

AC85~265V power supply, with 40 I/O, DI 24*DC24V, DO

Kinco-K508-40AX
4*DC24V/12*Relay, max output current per channel 0.75A/3A

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DC20.4~28.8V power supply, with 40 I/O, DI 24*DC24V, DO

Kinco-K508-40DT
16*24V, 1*RS232, 2*RS485

DC20.4~28.8V power supply, with 40 I/O, DI 24*DC24V, DO

Kinco-K508-40DR
16*Relay, 1*RS232, 2*RS485

Kinco-K521-08DX DI 8*DC24V
14 PM521
Kinco-K521-16DX DI 16*DC24V

Kinco-K522-08DT DO 8*DC24V

Kinco-K522-16DT DO 16*DC24V
PM522
Kinco-K522-08XR DO 8*Relay

Kinco-K522-16XR DO 16*Relay

Kinco-K523-08DT DI 4*DC24V, DO 4*DC24V,

Kinco-K523-08DR DI 4*DC24V, DO 4*Relay

PM523
Kinco-K523-16DT DI 8*DC24V, DO 8*DC24V
Expansion I/O Kinco-K523-16DR DI 8*DC24V, DO 8*Relay
module 4analog input channels,
Kinco-K531-04IV
0-20mA/4-20mA/±10V/1-5V optional for each channel

4Thermocouple input channels,

PM531 Kinco-K531-04TC
Type J/K/E/S optional for each channel

4RTD input channels,

Kinco-K531-04RD
Pt100/Pt1000/Cu50/R, 2/3 wire optional for each channel

2 analog output channels,

PM532 Kinco-K532-02IV
0-20mA/4-20mA/0-10V/1-5V optional for each channel

2analog input channels, 2 analog output channel,

PM533 Kinco-K533-04IV
4-20mA/1-5V/0-10V optional for each channel

Expansion
CAN communication expansion module, supports CANopen
functions SM541 Kinco-K541
master and CAN free protocol.
module

Expansion Power supply for expansionmodules.

Power supply PM580 Kinco-K580 Rated supply voltage AC85~265V, Max. output current: DC5V
module 1A and DC24V 250mA.

Table 1-1 Product list

Note: the relay output type of CPU module (the last number is “R”, for example K506-24AR), which doesn’t

support high-speed pulse output function!

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Part II

Hardware Manual

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Chapter I Application of Kinco-K5 Series Micro PLC

16 This chapter will briefly describe the architecture, expansion connection, network interface, etc and the

introduction will help to you understand the basics of KINCO-K5 series PLC to use them correctly.

1.1 Architecture of KINCO-K5

1.1.1 Overview

The Kinco-K5 is a kind of high-performance micro PLC (Programmable Logic Controller), and it provides a
wide variety of CPU modules and expansion modules. The compact design, flexible configuration and powerful
instruction set make Kinco-K5 a perfect solution for a wide variety of applications.
CPU module is the core of Kinco-K5, and it can monitor input channels and change output channels as controlled
by the user program, which can include Boolean logic, counting, timing, complex math operations, and
communications with other devices. 24VDC sensor supply, communication ports and a certain number of I/O
channels are integrated on the CPU body.
Expansion module can add additional functionality to the CPU.The CPU module controls the operation modes of
connected expansion modules and exchanges data through the expansion bus with them. Kinco-K5 provides all
kinds of expansion modules for you, such as DI, DO, DI/DO, AI, AO, AI/AO, RTD, TC modules, etc.
KincoBuilder is the programming software for Kinco-K5. KincoBuilder accords with IEC61131-3 standard, and
presently provides LD and IL languages. KincoBuilder provides you with a variety of useful functions such as
programming, hardware configuration, reading diagnostic message, monitoring and forcing output, etc.

1.1.2 Allowable System Scales

The max numbers of expansion modules and IO that supported by each CPU are listed in the following table.
Besides, the number of relay-output is restricted because of the limited power supply of the expansion bus.
Notie: All the data in the table refer to the maximum limitations, and each restrictive condition must be
satisfied simultaneously!

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Max. number of
DI DO AI AO
expansion modules
CPU504 8 6 - - -

CPU504EX 8 6 - - 4

17 CPU506 14 10 - - 10

CPU506EA 14 10 4 2 10

CPU508 24 16 - - 10

Table 1-1 Allowable system scales

1.1.3 Communicating over a Network

Kinco-K5 provides serial communication (RS232 and RS485) and CAN bus to conveniently communicate with
other equipments and systems. Kinco-K5 can not only meet the requirement of monitoring single equipment but

also build up a complex network to satisfy all kinds of demands.

Figure 1-1 Communication Network

▪ Serial communication

The CPU module provides one RS232 port and one or two RS485 ports, these ports support the standard

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Modbus RTU protocol and free-protocol mode. User can connect 32 (max) devices through RS485 port.

In default, all ports support Modbus RTU slave. RS485 ports supports Modbus RTU master functions too.

▪ CAN bus
18 K541 is a CAN bus expansion module, and it supports CANOpen mater and CAN free-protocol mode.
When working as a CANOpen master, K541 supports CAN2.0A, and accords with DS301 V4.2.0.
When working as a CAN free-protocol device, K541 supports CAN2.0A and CAN2.0B, and Kinco-K5 provides
various CAN communication instructions for your application.

1.2 Power supply design

The Kinco-K5 CPU has an internal integrated power supply that provides power for the CPU itself, for all
connected expansion modules and for other DC24V (VO+, VO-) power requirements.
The integrated power supply of the CPU module, supplies both DC5V power and DC24V power to the connected
expansion modules, therefore, the DC5V power supply serves the internal circuit of each expansion module as
working power supply, and the DC24V power supply is specially designed as the drive supply (DC24V) for the
relay coil in the relay-type DO modules.
K5 CPU also have DC24V (VO+, VO-) power supply output for its own outputs or other devices. The terminal

labels are VO+ and VO-.

1.2.1 DC24V Power Supply calculation

The DC24V power supply can supply DC24V for input channels or other requirements. If the power requirement
exceeds the capacity of the sensor supply, you can add an external DC24V power supply. Note: Do not connect
an external DC24V power supply in parallel with the CPU DC24V Power Supply because this can result in
a conflict between the two power supplies.

The capacity of the DC24V sensor supply is shown in the following table.

CPU504/CPU504EX 300 mA

CPU506/CPU506EA/CPU508 AC：500mA; DC：300 mA

Table 1-2 Capacity of the 24VDC power supply on CPU

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KDN-K306-24DR

1.2 1.3 1.4 1.5 VO- VO+

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Diagram 1-1 Wiring of the DC24V Sensor Supply

1.2.2Expansion power supply calculation

The expansion supply provides both DC5V power and DC24V power for the connected expansion modules
through expansion bus. In a PLC system, the power requirements for all the expansion modules must not exceed
the capacity of the CPU’s expansion power supply, otherwise you have to add a PS580 module to provide extra
expansion power supply, or select a CPU with higher capacity of the expansion power supply.
The following tables list the expansion supply capacity of each CPU and the power requirements of each
expansion module.
DC5V DC24V
CPU504EX 600mA 300mA
CPU506、CPU506EA、CPU508 1500mA 360mA
PS580 1000mA 250mA
Table 1-3 Capacity of expansion power supply

Typical requirements of Max. requirement of expansion supply

external DC24V supply
(L+ and L-) DC5V DC24V

K521-08DX - 180mA -
K521-16DX - 210mA -
K522-08DT - 200mA -
K522-08XR - 180mA 60mA
K522-16DT - 240mA -
K522-16XR - 210mA 120mA
K523-08DT - 200mA -
K523-08DR - 180mA 30mA
K523-16DT - 240mA -

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K523-16DR - 210mA 60mA

K531-04IV 10mA 172mA -
K531-04RD 10mA 172mA -
K531-04TC 10mA 172mA -
K532-02IV 10mA 160mA -
20
K533-04IV 10mA 166mA -
K541 30mA 170mA -
Table 1-4 Power requirements of expansion modules

1.2.3Input power of the CPU

The input power requirements of the CPU in three different situations are described below:
 Maximum power: This is the required maximum input power while the CPU is in the full load working
condition, including the DC24V power supply working full load, and the expansion supply working full
load, etc.

 Maximum power of a single CPU: This is the required maximum input power while a single CPU (without
expansion modules) is in the full load working condition.

 Typical power of a single CPU: This is the required typical input power while a single CPU (without
expansion modules) is in the normal working condition.
The following table lists the power values, unit: W.
Max. power Max. power of a single CPU Typical power of a single CPU
AC 15.0 15.0 3.0
CPU504
DC 15.0 10.0 2.5
AC 22.5 15.0 3.0
CPU504EX
DC 22.5 10.0 2.5
AC 40.0 22.5 3.9
CPU506
DC 24.0 10.5 3.0
AC 40.0 22.8 4.0
CPU506EA
DC 24.0 12 3.5
AC 40.0 23.2 4.2
CPU508
DC 24.0 11.2 3.0
Table 1-5 Input power values of the CPU

1.3 Operation Environmental Condition

Kinco-K5 accords with GB/T 15969.3-2007（idt IEC61131-2：2007）standard and test specifications.

The following table lists the conditions and requirements for Kinco-K5 to work properly. Please do not use the

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PLC in the bad condition which exceeds the following conditions.

Transport and storage

temperature -40 --- +70 °C

Ambient
relative humidity 10%~95%, no condensation
21 conditions
Altitude Up to 3000 m
Mechanical With manufacturer's original package, 5 times falling from 1m height to
Free falls
conditions concrete ground.

Normal Operation

air temperature Open equipment : -10 --- +55°C; Enclosed equipment: -10 --- +40°C

Ambient relative humidity 10%~95%, no condensation

conditions Altitude Up to 2000 m
Pollution degree Suitable pollution degree 2.
Sinusoidal 5<f<8.4Hz, Occasional: 3.5mmamplitude; Continuous: 1.75mmmplitude.
Mechanical
vibrations 8.4<f<150, Occasional: 1.0gacceleration; Continuous: 0.5gacceleration.
conditions
Shock half-sine , 15g, 11 ms, half-sine, ach axes 6 times

Electrostatic
±4kV Contact, ±8kV Air. Performance Level: B
discharge
a.c. main power:2KV CM, 1KV DM;
d.c. main power:0.5KV CM, 0.5KV DM;
High energy surge
Electromagnetic I/Os and Communication port:1KVCM.
compatibility Performance Level: B
(EMC) Fast transient main power: 2KV, 5KHz. I/Os and Communication port: 1KV, 5KHz.
bursts Performance Level: B
a.c. power supply: at 50Hz, 0% voltage for 1 period; 40% voltage for 10
Voltage drops and
periods; 75% voltage for 20 periods.
interruptions
Performance criteria A.
Protection
IP20
Level

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Chapter II CPU Principle and Application

This chapter will describe the CPU module of Kinco-K5.

22
2.1 Overview

2.1.1 Front view

The following diagram is the front view of a CPU.

Operation Switch
CPU Status LED I/O Status LED (RUN/STOP)

Expansion Bus
Port

Communication Removable 35mm DIN Rail Clip M4 Mounting Hole

Port Connectors

Diagram 2-1 Main components

2.1.2CPU Types

Kinco-K5 provides different CPU models with a diversity of features and capabilities that help you create

effective solutions for your varied applications.

According to the voltage of main power supply, there are two kinds of CPU: one requires DC24V power supply

and another requires AC85V~265V.

According the number of the built-in I/O channels, there are 5 type of CPU models, including CPU504,

CPU504EX, CPU506, CPU506EA and CPU508, and the larger the serial number is, the more integrated I/O

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channels and the higher the performance is. The following table describes main technical data of each CPU

model.

CPU504 CPU504EX CPU506 CPU506EA CPU508

Built-in I/O and Communication

23
Digital channel 8*DI/6*DO 8*DI/6*DO 14*DI/10*DO 14*DI/10*DO 24*DI/16*DO
Analog channel -- -- -- 4*AI / 2*AO --
Max. expansion modules -- 4 10
1 (PORT0) 2 (PORT0, PORT1) 3(PORT0, PORT1, PORT2)

PORT0 is RS232,PORT1 andPORT2 are RS485。

PORT0 support the special programming protocol, Modbus RTU protocol (as a slave)
Communication Port
and free-protocol communication mode.
PORT1 andPORT2 support the special programming protocol, Modbus RTU protocol (as
a slave or master) and free-protocol communication mode.
High-speed counters 2
Single phase 2, max.60KHz
Two phase 2, max.20KHz
High-speed pulse output 2,max. 200KHz.(For 200KHz, load resistance must be less than 1.5 KΩ).
I/O Interrupts 4 channel , can be set as rising or falling edge interrupts
memory area
1K 4K instructions
Max. User program
instructions
User Data M area: 1K bytes; V area: 4K bytes
DI mapping area 1 byte 10 bytes 32 bytes
DO mapping area 1 byte 10 bytes 32 bytes
AI mapping area -- 32 bytes 64 bytes
AO mapping area -- 32 bytes 64 bytes
Data Backup FRAM, 448 bytes
Retentive Ranges -- 4K bytes, lithium cell as backup power, 3 years at normal temperature.
Others
Timers 256 totally: 1ms time-base: 4 ; 10ms time-base: 16; 100ms time-base: 236
Timed interrupts 2 with 0.1 ms resolution。
Counters 256, (retained by lithium cell)
Real-time clock -- Yes, deviation less than 2 min/month at 25°C
DC24V Sensor Supply 300mA 500mA

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2.2Functions

2.2.1OperationMode

The CPU has two operation modes: RUN mode and STOP mode.
24
In RUN mode, the CPU executes the main scan cycle and all interrupt tasks.

In STOP mode, the CPU will set all output channels (including DO and AO) to values which are specified in the

[Hardware Configuration>>Output States While Stop] through Kincobuilder, and only mange

communication requests which comes from KincoBuilder software and other Modbus RTU master device.

 Change CPU Operation Mode

Kinco-K5 provides two ways to changing the operation mode manually: Using the operation switch

(RUN/STOP); Executing [Debug] -> [RUN] or [STOP] menu command in Kincobuilder.

The following table lists the combined results of these two ways.

Operation Switch Position KincoBuilder command Actual Operation Mode

[RUN] RUN
RUN
[STOP] STOP

[RUN] STOP
STOP
[STOP] STOP

Table 2-2 Changing the operation mode

Besides, if CPU detects error in operation, it enters STOP status.

 CPU Status LED

The CPU module provides 4 status LEDs: RUN, STOP, Comm. and Err.

 The RUN LED is green and indicates the CPU is in RUN mode.

 The STOP LED is red and indicates the CPU is in STOP mode.

 The Comm. LED is green and indicates the CPU is sending or receiving

communication data.

 The Err LED is red and indicates that an error occurred and detected. Common errors just cause Err. LDE

turning on. Serious errors cause the CPU changing to STOP mode and turning on both the Err. LED and the

STOP LED.

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2.2.2Communication Port

Kinco-K5provides 1-3 communication ports, which are named as PORT0, PORT1 and PORT2. PORT0 is RS232,
PORT1 and PORT2 are RS485. RS485 ports are fully isolated in hardware (including their power supply and
communication port) to enhance anti-interference ability.
25 PORT0 supports the special programming protocol,Modbus RTU protocol (as a slave) and free-protocol
communication mode. PORT1 and PORT2 support Modbus RTU protocol (as a slave or master) and free-protocol
communication mode.
Each type of CPU has different number of communication ports. The number and location of the PORTs are as

following table. And please refers to 2.3 Wiring Diagramto know about their pin assignment.
CPU Type RS232 RS485 Comment
CPU504 1 -
CPU504EX 1 1 PORT0 and PORT1 are all in the DB9.
CPU506 1 2 PORT0 and PORT1 are all in the DB9.
PORT1 is on the left side of the upper connector.
CPU506EA 1 2 PORT0 is in the right DB9.
CPU508 1 2 PORT1 and PORT2 are in the left DB9.
Table 2-3 Communication Ports

2.2.3Data Keep-in and Back Up

The CPU provides an E2PROMto store the user program and hardware configuration permanently. At power on,

the CPU will restore the program and configuration data from E2PROM into RAM to execute.

For permanently Data Backup, the CPU provides an FRAM to store the data in the special range of V area

(VB3648—VB4095). If the data change, they shall be written into FRAM at the end of current scan cycle. if the

CPU loses power, the data in the FRAM shall be permanently backup for next power on.

Also, the CPU provides a Data Retention method using lithium cell. Through [Hardware] configuration in

KincoBuilder, you can define four retentive ranges to select the areas of the RAM you want to retain when power

loss. If the CPU loses power, the instantaneous data in the RAM will be maintained by the lithium cell, and the

retentive ranges will be left unchanged at next power on. The retaining duration is 3 years at normal temperature.

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26

2.2.4Real-time Clock (RTC)

The real-time clock built in the all CPU modules (except CPU504) can provide real-time clock/calendar indication.

The real-time clock/calendar adopts BCD-format coding through second to year, when the CPU looses power,the

RTC can also work by the power supply from back battery, in normal temperature , this battery can last about five

years for RTC, and can store data for about 3 years with power off.

KincoBuilder can be used to set/read the RTC online (PLC>>Time of Day Clock). Besides, KincoBuilder also

provides RTC setting/reading instructions（READ_RTC, SET_RTC, RTC_W, RTC_R）to realize the applications

related to the clock.

2.2.5High-speed counter and High-speed pulse output

The CPU provides two high-speed counters, HSC0 and HSC1 and their counting value is stored in HC0

and HC1. High speed counter supports 11 counting mode, it can count single phase, double phase, AB phase (4

times frequency is also supported) . The max counting frequency are 60KHz (single phase) and 20KHz(double

phase, including AB phase)

Besides, The CPU provides two PTO/PWM high-speed output, their channel are Q0.0 and Q0.1, they

support pulse train output (PTO) and pulse-width modulation (PWM), and the maximum output frequency can

reach 200kHz. Note: For 200KHz, load resistance must be less than 1.5 KΩ.

2.2.6 Trigger interrupt

The CPU inputs I0.0~I0.3 supports trigger interrupt detecting function, user can use rising trigger and falling

trigger to generate interrupt. User can use this function to catch the rising or falling trigger whose pulse width is

smaller than the CPU scan time.

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2.3 Wiring Diagram

27

Diagram 2-2 Wiring Diagram of K504-14AR

Diagram 2-3 Wiring Diagram of K504-14AT

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Diagram 2-4 Wiring Diagram of K504-14DR

Diagram 2-5 Wiring Diagram of K504-14DT

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- -
+ +
PORT0/PORT1
5 1

29 9 6

1L 0.0 0.1 0.2 * 2L 0.3 0.4 0.5 * N L Pin Description

1M 0.0 0.1 0.2 0.3 2M 0.4 0.5 0.6 0.7 * VO- VO+ 5 GND
PORT0 3 TxD
2 RxD
8 B RS485 -
PORT1
7 A RS485 +
+ - + -
- + - +
DC24V Sensor Supply

Real line means source input; Broken line means sink input.

Diagram 2-6 Wiring Diagram of K504EX-14AR

Diagram 2-7 Wiring Diagram of K504EX-14AT

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30

Diagram 2-8 Wiring Diagram of K504EX-14DR

Diagram 2-9 Wiring Diagram of K504EX-14DT

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31

Diagram 2-10 Wiring Diagram of K506-24AR

Diagram 2-11 Wiring Diagram of K506-24AT

Diagram 2-12 Wiring Diagram of K506-24DR

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32

Diagram 2-13 Wiring Diagram of K506-24DT

AC220V
DC24V
5

5
9

9
PORT1/PORT2

PORT0
6

6
1

Diagram 2-14 Wiring Diagram of K506EA-30AT

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33

Diagram 2-15 Wiring Diagram of K506EA-30DT

Diagram 2-16 Wiring Diagram of K508-40AR

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34

Diagram 2-17 Wiring Diagram of K508-40AT

DC24V
5

5
9

9
PORT1/PORT2

PORT0
6

6
1

Diagram 2-18 Wiring Diagram of K508-40DR

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35

Diagram 2-19 Wiring Diagram of K508-40DT

2.4Specifications

2.4.1CPU Specifications

CPU504 CPU504EX CPU506 CPU506EA CPU508

Built-in I/O and Communication

Digital channel 8*DI/6*DO 8*DI/6*DO 14*DI/10*DO 14*DI/10*DO 24*DI/16*DO
Analog channel -- -- -- 4*AI / 2*AO --
Max. expansion modules -- 4 10

1 (PORT0) 2 (PORT0, PORT1) 3 (PORT0, PORT1, PORT2)

PORT0 is RS232,PORT1 andPORT2 are RS485。

PORT1 supports Modbus RTU protocol (as a slave) and free-protocol communication
Communication Port
mode.
PORT2 supports Modbus RTU protocol (as a slave or master) and free-protocol
communication mode.
High-speed counters 2
Single phase 2, max.60KHz
Two phase 2, max.20KHz
High-speed pulse output 2, max. 200KHz. (For 200KHz, load resistance must be less than 1.5 KΩ).

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I/O Interrupts 4 rising/falling edge interrupts

memory area
1K 4K instructions
Max. User program
instructions
User Data M area: 1K bytes; V area: 4K bytes
36
DI mapping area 1 byte 10 bytes 32 bytes
DO mapping area 1 byte 10 bytes 32 bytes
AI mapping area -- 32 bytes 64 bytes
AO mapping area -- 32 bytes 64 bytes
Data Backup FRAM, 448 bytes
Retentive memory
-- 4K bytes, lithium cell as backup power, 3 years at normal temperature.
Ranges
Others
Timers 256 totally: 1ms time-base: 4 ; 10ms time-base: 16; 100ms time-base: 236
Timed interrupts 2 with 0.1 ms resolution。
Counters 256, (retained by lithium cell)
Real-time clock -- Yes, deviation less than 2 min/month at 25°C
DC24V Sensor Supply 300mA 500mA

2.4.2 CPU DI Specifications

Input type Source/leakage

Rated input voltage DC 24V (DI will be on when input is DC11~30V)
Rated input current 3.5mA 24VDC
Max input voltage of logic 0 5V 0.7mA

Common channel:11V 2.0mA

Minimum input voltage of logic 1
HSC channel: 18V 2.5mA

Input delay time

Common channel: 12μs; HSC channel: 8μs;
· off-to-on
Common channel: 40μs; HSC channel: 12μs;
· on-to-off

Isolation between input and internal circuit

·Isolation Mode Opto-electrical isolation
·Isolation Voltage 500VAC/1 min
Status indicator Green LED

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2.4.3 CPU DO Specifications(Transistor)

Output type Source

Rated power supply voltage DC 24V, allowable range:DC20.4~DC28.8V
· Reverse polarity protection Yes
37
Rated output voltage DC 24V
Output current per channel Max 500mA at 24VDC
Output leakage current Max 0.5цA
Output impedance Max 0.2Ω
Output delay
· off-to-on 0.3--5μs
· on-to-off 5μs
Isolation between output and internal circuit
· Mode Opto-electrical isolation
· Voltage 500VAC/1 min
Power supply reverse protection yes
Inductance load protection Yes
Short-circuit protection Yes
Output polarity reverse protection Yes
Parallel connection of outputs Yes (in the same group)
Status indication Green LED

2.4.4 CPU Output Specifications(Relay)

Output type Relay

Load voltage DC30V/AC250V
Output current per channel 2A(DC30V/AC250V)
Output current per group Max 10A
Output off-to-on delay Max 10ms
Output on-to-off delay Max 5ms
Contact lifetime
·Mechanical (No load) 20000000 times (12,000 times/min)
Electrical·Rated load 100000 times (100 times/min)
Isolation
·Mode Relay
·Between coil and contact 2000Vrms
Status indication Green LED

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2.4.5 AI channel parameters on CPU

Signal type 4~20mA、1~5V、0~20mA、0-10V

Resolution 12 bits
precision 0.3% F.S.
38
Convert Speed(each channel) About 30 per second
Current Mode：<=500Ω
Input Resistor
Voltage Mode：>4MΩ
(signal voltage＋com-mode voltage)≤12V. If the voltage
Anti Com-mode voltage
exceeds 12V, the channel will be in protection status.
Status Indicator The red led means the input is out of range.

2.4.6 AO Channel Parameters on CPU

Signal type 4~20mA、1~5V、0~20mA、0~10V

Resolution(including ) 12 bits
Precision of output signal 0.3% F.S.
Convert Speed(each channel) 300 times per second
Current Mode：Maximum 500Ω
External Load
Voltage Mode：Minimum 1KΩ

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Chapter III DI (Digital Input) Modules

A DI module receives digital input signals from the field and writes their status to the CPU’s I area through the
39 expansion bus. It provides opto-electrical isolation between the input signal and the internal circuit.

DI modules are called PM521.

3.1 DI 8*DC24V

Order No.: Kinco-K521-08DX.

The module has 8 channels, and each channel has a LED to indicate the input status.

3.1.1 Wiring Diagram

DC24V
DC24V

Diagram 3-1 Wiring Diagram of K521-08DX

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3.1.2 Technical Data

Electrical Data

Number of channels 8 (4 channels/group)

40 Input type Source/leakage

Rated input voltage DC 24V

Rated input current 3.5mA at 24VDC

Max input voltage of logic 0 5V at 0.7mA

Minimum input voltage of logic 1 11V at 2.0mA

Input filter time delay

· off-to-on 12μs
· on-to-off 40μS

5V <180mA
Current consumption in expansion bus
24V -

Isolation between input and internal circuit

·Mode Opto-electrical isolation

·Voltage 500VAC/1 min

Status indicator Green LED

Address occupied

DI mapping area 1 byte

DO mapping area -

Dimension and weight

Dimension (L×W×H) 114×50×70mm

Net weight 125g

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3.2 DI 16*DC24V

Order No.: Kinco-K521-16DX

The module has 16 channels, and each channel has a LED to indicate the input status.

41

3.2.1 Wiring Diagram

DC24V

- +
+ -

1M * .0 .1 .2 .3 .4 .5 .6 .7 * * *
2M * .0 .1 .2 .3 .4 .5 .6 .7 * * *
DC24V

+ -
- +

DC24V Power Suplly:

Real line means source input;
Broken line means sink input.

Diagram 3-2 Wiring Diagram of K521-16DX

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3.2.2 Technical Data

Electrical data
Number of channels 16 (8 channels/group)
Input type Source/leakage
42
Rated input voltage DC 24V
Rated input current 3.5mA at 24VDC
Max input voltage of “0” 5V at 0.7mA
Minimum input voltage of “1” 11V at 2.0mA
Input filter time delay
· off-to-on 12μs
· on-to-off 40μS
5V < 210mA
Current consumption via expansion bus
24V -
Isolation between input and internal circuit
· Mode Opto-electrical isolation
· Voltage 500VAC/1 min
Status indication Green LED
Address occupied
DI mapping area 2 bytes
DO mapping area -
Dimension and weight
Dimension (L×W×H) 114×75×70mm
Net weight 150g

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Chapter IV DO (Digital Output) Modules

There are two types of DO modules: DC24V output through solid state-MOSFET(Transistor), and Relay
43 contact output(Relay).

All types of DO module are called PM522.

4.1 DO 8*DC24V

Order No: Kinco-K522-08DT

The module has 8 channels, and each channel is has a LED to indicate the output status. It receives control data

from CPU and converts it to DC 24V signal.

4.1.1 Wiring Diagram

Diagram 4-1 Wiring Diagram of K522-08DT

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4.1.2 Technical Data

Electrical data
Number of output channels 8 (4 channels/group)
Output type Source
44
Rated power supply voltage DC 24V
· Reverse polarity protection Yes
Rated output voltage DC 24V
Output current per channel Max 500mA at 24VDC
Output leakage current Max 0.5цA
Output impedance Max 0.2Ω
Output delay
· off-to-on 0.3--5μs
· on-to-off 5μs
5V <200mA
Current consumption via expansion bus
24V -
Isolation between output and internal circuit
·Mode Opto-electrical isolation
·Voltage 500VAC/1 min
Inductance load protection Yes
Short-circuit protection Yes (when output current per group exceeds 3A)
Parallel connection of outputs Yes (in the same group)
Status indication Green LED
Address occupied
DI mapping area -
DO mapping area 1 byte
Dimension and weight
Dimension (L×W×H) 114×50×70mm
Net weight 125g

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4.2 DO 8*relay

Order No.: KINCO-K522-08XR

The module has 8 relay-output channels, and each channel is has a LED to indicate the output status. It receives

45
control data from CPU and converts it to electrical signals to control relay outputs.

The operation power supply and relay coil power supply are from the expansion bus cable.

4.2.1 Wiring Diagram

-
+

1L 1L .0 .1 .2 .3 * *

2L 2L .4 .5 .6 .7 * *

+
-

Diagram 4-2 Wiring Diagram of K522-08XR

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4.2.2 Technical Data

Electrical data
Number of relay outputs 8 (4 channels/group)
Load voltage Max DC 30V/AC250V
46
Output current per channel Max 2A(DC 30V/AC250V)
Output current per group Max 10A
Output off-to-on delay Max 10ms
Output on-to-off delay Max 5ms
5V <180mA
Current consumption via expansion bus
24V <60mA
Max. switching rate
·No load 12,000 times/min
·Rated load 100 times/min
Expected lifetime of the contacts
·Mechanical life (no-load) 20,000,000 times (1200 times/min)
· Electrical life (rated load) 100,000 times (6 times/min)
Isolation
·Mode Relay
·Between coil and contact 2000Vrms
Status indication Green LED
Address occupied
DI mapping area -
DO mapping area 1 byte
Dimension and weight
Dimension (L×W×H) 114×50×70mm
Net weight 150g

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4.3 DO 16*DC24V

Order No.: KINCO-K522-16DT

The module has 16 channels, and each channel is has a LED to indicate the output status. It receives control

47
data from the expansion bus and converts it to DC24 output signal. The module requires a power supply of

DC24V via the appropriate terminals.

4.3.1 Wiring Diagram

DC24V
DC24V

Diagram 4-3 Wiring Diagram of K522-16DT

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4.3.2 Technical Data

Electrical data
Number of output channels 16 (4 channels/group)
Output type Source
48
Rated power supply voltage DC 24V
· Reverse polarity protection Yes
Rated output voltage DC 24V
Output current per channel Max 500mA at 24VDC
Output leakage current Max 0.5цA
Output impedance Max 0.2Ω
Output delay
· off-to-on 0.3--5μs
· on-to-off 5μs
5V < 240mA
Current consumption via expansion bus
24V -
Isolation between output and internal circuit
·Mode Opto-electrical isolation
·Voltage 500VAC/1 min
Inductance load protection Yes
Yes (when output current per group exceeds
Short-circuit protection
3A)
Parallel connection of outputs Yes (in the same group)
Status indication Green LED
Address occupied
DI mapping area -
DO mapping area 2 bytes
Dimension and weight
Dimension (L×W×H) 114×75×70mm
Net weight 170g

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4.4 DO 16*Relay

Order No.: KINCO-K522-16XR

The module has 16 relay-output channels, and each channel is has a LED to indicate the output status. It

49
receives control data from the expansion bus and converts it to electrical signal to control relay outputs. The

module derives operation power supply and relay coil power supply are from the expansion bus. The load

voltage must be connected to the appropriate terminals.

4.4.1 Wiring Diagram

AC
DC

Diagram 4-4 Wiring Diagram of K522-16XR

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4.4.2Technical Data

Electrical data
Number of relay outputs 16 (4 channels/group)
Load voltage Max DC 30V/AC250V
50
Output current per channel Max 2A(DC 30V/AC250V)
Output current per group Max 10A
Output off-to-on delay Max 10ms
Output on-to-off delay Max 5ms
5V <210mA
Current consumption via expansion bus
24V <120mA
Max. switching rate
·No load 12,000 times/min
·Rated load 100 times/min
Expected lifetime of the contacts
·Mechanical lifetime (no-load) 20,000,000 times (1200 times/min)
· Electrical lifetime (rated load) 100,000 times (6 times/min)
Isolation
·Mode Relay
·Between coil and contact 2000Vrms
Status indication Green LED
Address space occupied
DI mapping area -
DO mapping area 2 bytes
Dimension and weight
Dimension (L×W×H) 114×75×70mm
Net weight 235g

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Chapter V DI/O Modules

DI/O modules are the modules on which a certain number of DI and DO channels are provided. Each channel
51 has the unique function and cannot be used for other purposes.

All types of DI/O module are called PM523.

5.1 DI/O, DI4*DC24V DO4*DC24V

Order No.: KINCO-K523-08DT

This module has 8 channels. 4 channels are inputs and 4 as outputs.

Each channel is has a LED to indicate its status.

5.1.1Wiring Diagram
D C 2 4V
DC24V

Diagram 5-1 Wiring Diagram of K523-08DT

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5.1.2Technical Data

Electrical data
Number of inputs 4 (4 channels/group)
Input type Source/Leakage
52
Rated input voltage DC 24V
Rated input current 3.5mA at 24VDC
Max input voltage of logic 0 5V at 0.7mA
Minimum input voltage of logic 1 11V at 2.0mA
Input filter time delay 5ms
Isolation between input and internal circuit
·Mode Opto-electrical isolation
·Voltage 500VAC/1 min
Number of output channels 4 (4 channels/group)
Output type Source
Rated power supply voltage DC 24V
· Reverse polarity protection Yes
Rated output voltage DC 24V
Output current per channel Max 500mA at 24VDC
Output leakage current Max 0.5цA
Output impedance Max 0.2Ω
Output delay
· off-to-on 0.3--5μs
· on-to-off 5μs
Isolation between output and internal circuit
·Mode Opto-electrical isolation
·Voltage 500VAC/1 min
Inductance load protection Yes
Short-circuit protection Yes (when output current per group exceeds 3A)
Parallel connection of outputs Yes (in the same group )
5V <200mA
Current consumption via expansion bus
24V -
Status indication Green LED
Address occupied
DI mapping area 1 byte
DO mapping area 1 byte

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Dimension and weight

Dimension (L×W×H) 114×50×70mm
Net weight 125g

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5.2 DI/O,DI 4*DC24VDO 4*Relay

Order No.: KINCO-K523-08DR

This module has 8 channels. 4 channels DI(DC 24V) input and another 4 are relay outputs.

54
Each channel is has a LED to indicate its status.

5.2.1Wiring Diagram

Diagram 5-2 Wiring Diagram of K523-08DR

5.2.2Technical Data

Electrical Parameter
Number of inputs 4 (4 channels/group)
Input type Source/Leakage
Rated input voltage DC 24V (“1”, when DC15~30V)
Rated input current 3.5mA at 24VDC
Max input voltage of logic 0 5V at 0.7mA
Minimum input voltage of logic 1 11V at 2.0mA
Input filter time delay 5ms
Isolation between input and internal circuit Opto-electrical isolation
·Mode 500VAC/1 min

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·Voltage
Number of relay outputs 4 (4 channels/group)
Load voltage Max DC 30V/AC250V
Output current per channel Max 2A(DC 30V/AC250V)
Output current per group Max 10A
55
Output off-to-on delay Max 10ms
Output on-to-off delay Max 5ms
Max. switching rate
·No load 12,000 times/min
·Rated load 100 times/min
Expected life of the contacts
·Mechanical life (no-load) 20,000,000 times (1200 times/min)
· Electrical life (rated load) 100,000 times (6 times/min)
Isolation
·Mode Relay
·Between coil and contact 2000Vrms
5V <180mA
Current consumption via expansion bus
24V <30mA
Status indication Green LED
Address occupied
DI mapping area 1 byte
DO mapping area 1 byte
Dimension and weight
Dimension (L×W×H) 114×50×70mm
Net weight 145g

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5.3 DI/O, DI 8*DC24VDO 8*DC24V

Order No.: KINCO-K523-16DT

This module has 16 channels. 8 channels are DC 24V inputs and another 8 are outputs (transistor).
56
Each channel is has a LED to indicate its status.

5.3.1Wiring Diagram

Diagram 5-3 Wiring Diagram of K523-16DT

5.3.2Technical Data

Electrical data
Number of inputs 8 (8 channels/group)
Input type Source/Leakage
Rated input voltage DC 24V (“1”, when DC15~30V)
Rated input current 3.5mA at 24VDC
Max input voltage of logic 0 5V at 0.7mA

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Minimum input voltage of logic 1 11V at 2.0mA

Input filter time delay 5ms
Isolation between input and internal circuit
·Mode Opto-electrical isolation
·Voltage 500VAC/1 min
57
Number of output channels 8 (4 channels/group)
Output type Source
Rated power supply voltage DC 24V
· Reverse polarity protection Yes
Rated output voltage DC 24V
Output current per channel Max 500mA at 24VDC
Output leakage current Max 0.5цA
Output impedance Max 0.2Ω
Output delay
· off-to-on 0.3--5μs
· on-to-off 5μs
Isolation between output and internal circuit
·Mode Opto-electrical isolation
·Voltage 500VAC/1 min
Inductance load protection Yes
Yes (when output current per group
Short-circuit protection
exceeds 3A)
Parallel connection of outputs Yes (in the same group )
Status indication Green LED
5V <230mA
Current consumption via expansion bus
24V -
Address occupied
DI mapping area 1 byte
DO mapping area 1 byte
Dimension and weight
Dimension (L×W×H) 114×75×70mm
Net weight 165g

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5.4 DI/O, DI 8*DC24V DO 8*Relay

Order No.: KINCO-K523-16DR

This module has 16 channels. 8 channels are inputs and another 8 are relay outputs.

58 Each channel is has a LED to indicate its status.

5.4.1Wiring Diagram

Diagram 5-11 Wiring Diagram of K523-16DR

5.4.2Technical Data

Electrical data
Number of inputs 8 (8 channels/group)
Input type Source/Leakage
Rated input voltage DC 24V (“1”, when DC15~30V)
Rated input current 3.5mA at 24VDC
Max input voltage of logic 0 5V at 0.7mA

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Minimum input voltage of logic 1 11V at 2.0mA

Input filter time delay 5ms
Isolation between input and internal circuit
·Mode Opto-electrical isolation
·Voltage 500VAC/1 min
59
Number of relay outputs 8 (4 channels/group)
Load voltage Max DC 30V/AC250V
Output current per channel Max 2A(DC 30V/AC250V)
Output current per group Max 10A
Output off-to-on delay Max 10ms
Output on-to-off delay Max 5ms
Max. switching rate
·No load 12,000 times/min
·Rated load 100 times/min
Expected life of the contacts
·Mechanical life (no-load) 20,000,000 times (1200 times/min)
· Electrical life (rated load) 100,000 times (6 times/min)
Isolation
·Mode Relay
·Between coil and contact 2000Vrms
Status indication Green LED
5V <210mA
Current consumption via expansion bus
24V <60mA
Address occupied
DI mapping area 1 byte
DO mapping area 1 byte
Dimension and weight
Dimension (L×W×H) 114×75×70mm
Net weight 165g

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Chapter VI AI (Analoginput) Modules

60 All types of AI module are called PM531.

6.1 AI 4*IV, Multi-signal Input

Order No.: Kinco-K531-04IV

This module has 4 channels for current and voltage measurement, and the measurement type (4-20mA, 1-5V,

0-20mA, 0-10V) is optional for each channel in KincoBuilder

Each channel is has a LED, when the signal is exceeds the range of current and voltage , the LED will be red.

Note: Unused channel should be shor- circuited between the positive pole and the negative pole. So there

will be no out of range error for these unused channel.

6.1.1Wiring Diagram

Diagram 6-2 Current Measurement of K531-04IV

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6.1.2Measurement Ranges and The measured value Representation

In the following table, I represents input current value, unit mA; V represents input voltage value, unit V.

Measurement Measurement Measured

Remark
Type Range value
61
4~20mA(1) 3.92~20.4mA(3) I×1000
If input signal exceeds the upper limit of measuring
1~5V(2) 0.96~5.1V(3) V×1000
range, the measured value will be kept at 32767.
If input signal exceeds the lower limit of measuring
0~20mA 0~20.4mA(3) I×1000
range, the measured value will be kept at -32767.
(3)
0~10V 0~10.2V V×1000

Table 6-1 Measurement Range and The measured value Representation

6.1.3Technical Data

Electrical data

Number of channels 4

Measurement types 4~20mA, 1~5V, 0~20mA, 0-10V

Rated power supply DC 24V, >=100mA

Resolution (including polarity symbol) 12 bits

Measurement accuracy 0.3% F.S.

Conversion rate (per channel) About 15 times/s

Current mode: <500Ω

Input impedance
Voltage mode: >4MΩ

5V <172mA
Current consumption via expansion bus
24V -

Status indication Red LED

Address occupied

AI mapping area 8 bytes (2 bytes per channel)

AO mapping area -

Dimension and weight

Dimension (L×W×H) 114×50×70mm

Net weight 136g

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6.2 AI 4*RD, RTD Input

Order No.: Kinco-K531-04RD

This module has 4 channels for temperature measurement using RTD, and the measurement type (Pt100, Cu50,

Pt1000 and Resistance) is optional for each channel. 24-bit high-performance A/D converter is adopted in the
62
module.

The module requires 8 bytes (2 bytes per channel) in the AI mapping area. The parameters of each channel, such

as address, function, filter, etc, can be configured through KincoBuilder individually.

Each channel is has a LED, when the signal is exceeds the range of current and voltage, the LED will be red

Note: Unused channel should be short-circuited between its terminals!

6.2.1Wiring Diagram

Diagram 6-4Connection of -K531-04RD

6.2.2Measurement Ranges and The measured value Representation

In the following table, T represents measured temperature, unit: °C, R represents measure Resistance, unit: Ω.

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Measurement Type Measurement Range Measured value

Pt100 -200~850°C T×10

Cu50 -50~150°C T×10

63
Pt1000 -50~300°C T×10

Resistance 0~2000Ω R×10

Table 6-2 Measurement Range and The relationship between measured value and actual value

6.2.3Technical Data

Electrical data

Number of channels 4

Measurement types Pt100, Cu50, Pt1000, R

Connection 2-wire or 3-wire

Rated power supply DC 24V,>=100mA

Resolution (including polarity symbol) 24 bits

Measurement accuracy Temperature:±0.5℃, Resistance:±1Ω

Conversion rate (per channel) About 1 times/s

Input impedance >1MΩ

5V <172mA
Current consumption via expansion bus
24V -

Status indication Red LED

Address occupied

AI mapping area 8 bytes (2 bytes per channel)

AO mapping area -

Dimension and weight

Dimension (L×W×H) 114×50×70mm

Net weight 132g

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6.3 AI 4*TC, thermocouple Input

Order No.: Kinco-K531-04TC

This module has 4 channels for temperature measurement by using thermocouples, and the measurement type

(Type J, Type K, Type E and Type S) is optional for each channel, additionally cold junction internal
64
compensation or external compensation is optional.24-bit high-performance A/D converter is adopted in the

module.

Note: if internal compensation is adopted, the internal temperature sensor will acquire the temperature of the

module interior and supply a compensation voltage, so the heat generated by the module will affect the

measured value. Generally speaking, measured temperature with internal compensation will be 2~4°C higher

than the actual temperature.

The module requires 8 bytes (2 bytes per channel) in the AI mapping area. The parameters of each channel, such

as address, function, filter, etc, can be configured through KincoBuilder individually.

Each channel is has a red LED to indicate wire break.

Note: Unused channel should be short-circuited between the positive pole and the negative pole!

6.3.1Wiring Diagram

Diagram 6-6 Wiring Diagram of K531-04TC

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6.3.2Measurement Ranges and The measured value Representation

In the following table, T represents measured temperature, unit: °C.

Measurement Method Measurement Range Measured value

65 Type J -210~1200°C

Type K -270~1300°
T×10
Type E -270~1000°C

Type S -50~1600°C

Table 6-4 Measurement Range and The relationship between measured value and actual value

6.3.3 Technical Data

Electrical data

Number of channels 4

Measurement types Type J, Type K, Type E, Type S

Cold junction compensation Internal/external compensation optional

Rated power supply DC 24V,>=100mA

Resolution (including polarity symbol) 24 bits

Measurement accuracy 0.1% F.S.

Conversion rate ( per channel ) About 1 times/s

Input impedance >20kΩ

5V <172mA
Current consumption via expansion bus
24V -

Status indication Red LED to indicate wiring problem

Address occupied

AI mapping area 8 bytes (2 bytes per channel)

AO mapping area -

Dimension and weight

Dimension (L×W×H) 114×50×70mm

Net weight 132g

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Chapter VII AO (Analog Output) Modules

All types of AO module are called PM532.

66

7.1 AO 2*IV, Multi-signal Output

Order No.: KINCO-K532-02IV

This module has 2 channels, suitable for connecting with actuators requiring standard voltage or current signals

(4-20mA, 1-5V, 0-20mA and 0-10V). The module has corresponding output ranges for different outputs, and if

the output value specified in the user program exceeds the upper/lower limit of the output range, the actual output

value will be kept at the upper/lower limit to prevent the connected equipment from damage. 12-bit

high-performance D/A converter is adopted in the module.

The module requires 4 bytes (2 bytes per channel) in the AQ mapping area. The parameters of each channel, such

as address, function, etc, can be configured through KincoBuilder individually.

7.1.1Wiring Diagram

Diagram 7-2 Wiring Diagram of K532-02IV

7.1.2Output Ranges and the Output Value Representation

In the following table, I represents actual output current value, unit mA; V represents actual output voltage value,

unit V.

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Output Value
Output Signal Output Range Remark
Representation

4~20mA 3.92~20.4mA I×1000

If the output value specified in the user
1~5V 0.96~5.1V V×1000 program exceeds the upper/lower limit of

67 0~20mA 0~20.4mA I×1000 the output range, the actual output value
will be kept at the upper/lower limit.
0~10V 0~10.2V V×1000

Table 7-1 Output Range and the relationship Output Value and actual value

7.1.3Technical Data

Electrical data
Number of outputs 2
Output signal 4~20mA, 1~5V, 0~20mA,0-10V
Rated power supply DC 24V
Resolution (including polarity symbol) 12 bits
Output Accuracy 0.3% F.S.
Current mode: max. 500Ω
Resistance load
Voltage mode: min. 1kΩ
5V <160mA
Current consumption via expansion bus
24V -
Address occupied
AI mapping area -
AO mapping area 4 bytes (2 bytes per channel)
Dimension and weight
Dimension (L×W×H) 114×50×70mm
Net weight 125g

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Chapter VIII AI/O (Analog Input/Output) Modules

68 AI/O modules are the expansion modules which has some analog input and analog output channels.

All types of AO module are called PM533.

8.1 AI/O, AI 2×IVAO 2×IV, Multi-signal Output

Order No.: KINCO-K533-04IV

This module has 2 channels for current and voltage measurement, and the measurement type (4-20mA, 1-5V,

0-20mA or 0-10V) is optional for each channel. 24-bit high-performance A/D converter is adopted in the module.

Each channel is has a red LED, which indicates the input signal over-range if the channel’s measuring method is

configured to 4-20mA or 1-5V

This module has 2 channels, suitable for connecting with actuators requiring standard voltage or current signals

(4-20mA, 1-5V, 0-20mA or 0-10V). The module has corresponding output ranges for different outputs, and if the

output value specified in the user program exceeds the upper/lower limit of the output range, the actual output

value will be kept at the upper/lower limit to prevent the connected equipment from damage. 12-bit

high-performance D/A converter is adopted in the module.

The module requires 4 bytes (2 bytes per channel) in the AI mapping area and 4 bytes (2 bytes per channel) in the

AQ mapping area. The parameters of each channel, such as address, function, etc, can be configured through

KincoBuilder individually.

Note: Unused AI channel should be shor- circuited between the positive pole and the negative pole!

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8.1.1Wiring Diagram

69

Diagram 8-2 Wiring Diagram of K533-04IV

8.1.2Measurement Ranges and The measured value Representation

In the following table, I represents actual input current value, unit mA; V represents input voltage value, unit V.

Measurement Measurement
Measured value Remark
Type Range
4~20mA(1) 3.92~20.4mA(3) I×1000 If input signal exceeds the upper limit of measuring
(2) (3)
1~5V 0.96~10.2V V×1000 range, the measured value will be kept at 32767.
0~20mA 0~20.4mA (3)
I×1000 If input signal exceeds the lower limit of measuring
0~10V 0~10.2V (3)
V×1000 range, the measured value will be kept at -32767.

Table 8-1 Measurement Range and The relationship between measured value and actual value

Note:

(1) If input signal is less than 4mA or greater than 20mA, then the red LED of this channel lights.

(2) If input signal is less than 1V or greater than 5V, then the red LED of this channel lights.

(3) If the input signal is beyond the measuring range, the module may be damaged.

8.1.3 Output Ranges and the Output Value Representation

In the following table, I represents actual output current value, unit mA; V represents actual output voltage value,

unit V.
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Output Value
Output Signal Output Range Remark
Representation

4~20mA 3.92-20.4mA I×1000

If the output value specified in the user
1~5V 0.96-5.1V V×1000 program exceeds the upper/lower limit of

70 0~20mA 0-20.4mA I×1000 the output range, the actual output value
will be kept at the upper/lower limit.
0~10V 0-10.2V V×1000

Table 8-2 Output Range and the relationship between measured value and actual value

8.1.4Technical Data

Electrical data
Number of AI channels 2
Measurement types 4~20mA, 1~5V, 0~20mA, 0~10V
Rated power supply DC 24V, >=100mA
Resolution (including polarity symbol) 12 bits
Measurement accuracy 0.3% F.S.
Conversion rate (per channel) About 15 times/s
Current mode: <500Ω
Input impedance
Voltage mode: >4MΩ
Status indication Red LED
Number of AO outputs 2
Output signal 4~20mA, 1~5V, 0~20mA, 0~10V
Rated power supply DC 24V
Resolution (including sign) 12 bits
Output Accuracy 0.3% F.S.
Current mode: max. 500Ω
Resistance load
Voltage mode: min. 1kΩ
5V < 166mA
Current consumption via expansion bus
24V -
Address occupied
AI mapping area 4 bytes (2 bytes per channel)
AO mapping area 4 bytes (2 bytes per channel)
Dimension and weight
Dimension (L×W×H) 114×50×70mm
Net weight 136g

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Chapter IX Expansion Function Modules

Expansion function module provides a certain function and it has no I/O channels.

71
9.1 K541, CAN bus Module

Order No.: KINCO-K541.

K541 is a CAN bus expansion module. Cooperating with a CPU, it can serve as a CANOpen master, or as a

free-protocol CAN bus node.

K541 has two CAN port named as CAN1 and CAN2.

CAN1 is internal port used for communicating with the CPU through the expansion bus. CAN2 is an external

port and use for communicating with other CAN devices, including CANOpen slaves. CAN2 port is fully isolated

in hardware (including its power supply and communication port) to enhance anti-interference ability.

When using in a Kinco-K5 plc system, K541 must be arranged at the end of all modules, and it does not need to

be configured in Kincobuilder software.

9.1.1 Main Features

K541 supports CANOpen mater and CAN free-protocol mode.

 CANOpen Master

 Supporting CAN2.0A, and accords with DS301 V4.2.0.

 Supporting NMT (Network Management) protocol and serving as a NMT master.

 Supporting normal expedited SDO as a client, and providing SDO_READ and SDO_WRITE instructions.

 Supporting for 72 CANOpen slaves.

 At most 8 TPDOs and 8 RPDOs for a slave,and 256 TPDOs and 256 RPDOs for all.

 Supporting Heartbeat protocol and Node-guarding protocol.

 For CAN free-protocol communication

 Supporting CAN2.0A and CAN2.0B.

 Providing various necessary CAN communication instructions for user application.

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9.1.2Terminals and Status LEDs

72

Diagram 9-1Kinco-K541 Front View

 Status LED

 PW1:CAN1 power indication: Green LED. LED on means power on, and off means power off.

LED on means CAN1 port is powered on, and off means is powered off.

 PW2: CAN2 power indication. Green LED. LED on means power on, and off means power off.

 RUN: CANOpen status indication. Green LED.

LED on means Operation state, flashing means Pre-Operational state, off means stop status .

 BUS: CAN2 communication indication. Green LED. Flashing means CAN2 is communicating.

 ERR: CAN2error indication. Green LED.

LED on means that CAN controller chip detects CAN errors whose levels are above Error Active.

Note: If ERR led is on, there must be some errors on your CAN bus, such as wrong wiring, wrong Baudrate,

Terminal resistance mismatching and etc. These errors have nothing to do with K541.

 Terminals

 GND, L and H are GND/0V, CAN_L and CAN_H of CAN2 port

 R, R：K541 provides a 120Ωresistance internally.

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Connecting these two terminals together means adding this internal resistance into your CAN bus network.

 V+、V-: External DC24V power supply for K541.‘

9.1.3Wiring and Arranging

73 When using K541 in a Kinco-K5 plc system, K541 must be arranged at the end of all modules, and it does not

need to be configured in Kincobuilder.

The dotted line in the diagram means user can add terminal resistor at K541 side.

Diagram 9-2 Kinco-K541 Wiring and Application

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9.1.4Technical data

Electrical data
Rated power supply DC24V，≥100mA，tolerance ±5%。
CAN standard CAN2.0A, CAN2.0B
74
Baud rate Standard 10K-1Mbps
5V < 170mA
Current consumption via expansion bus
24V -
Isolation
·power supply 2500VAC/1 minute
·CAN bus Opto-electrical isolation, 500VAC/1 minute
Status indication Various LEDs
Dimension and weight
Dimension (L×W×H) 114×50×70mm
Net weight 136g

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9.2 Expansion Power Module

Order No: Kinco-K580

The expansion power module provides both DC5V power and DC24V power for the connected expansion

modules through expansion bus. In a PLC system, the power requirements for all the expansion modules must not
75
exceed the capacity of the CPU’s expansion supply, otherwise you have to add a PS580 module to provide extra

expansion power, or select a CPU with higher capacity of the expansion supply. The module supply +5V and

+24V to the expansion modules which are after this module. The position of expansion bus power module is

decided by calculating the current offered by CPU module and the consumption of the expansion modules. The

+5V and +24V of expansion modules which are between the CPU module and PS580 are supplied by CPU

module. And the expansion modules after the PS580 are supplied by PS580.

To use the PS580, just plug the expansion cable to the previous module, and connect the next module to PS580.

This module does not occupy the I/O mapping of the CPU. You don’t need to configure this module in

KincoBuilder. The module requires AC85～265V input via the terminals.

Suggestion：If the number of expansion modules is greater than 7, even the +5V and +24V of expansion bus

is enough, Expansion Bus Power Module is needed also.

This module does not have I/O mapping address in CPU, user does not need to configure it Hardware

Configure of KincoBuilder either.

In the same control system, PS580 and CPU module need the same AC85～265V.

9.2.1 Main Specifications.

• PS580 does not need to be configured in Kinco builder.

• PS580 does not have I/O mapping address in CPU

• PS580 is not counted in the total expansion module number

• Power supply of PS580：AC85～265V

• When the power supply is normal, the PW indicator is ON.

• Module Width:75mm

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9.2.2 PS580 used in the actual application

76

9.2.3 CPU selection and PS580 Calculation

Steps to select the CPU and modules models.

1) Choose CPU first, user can choose it according to power supply (24V DC or 220V AC), I/O number,

communication ports, output type (relay or transistor) and so on.

2) Then choose the expansion module, user can choose it according to I/O number, analog channel output

type(relay or transistor) and so on.

3) At last, user needs to consider the power supply for the expansion modules, including extension +5V and

24V , output power supply(V0+,V0-)24V, analog power supply and so on.。

Take a actual application for example.

Hardware Requirements：8 DI, 85 outputs(relay), 6AI,2AO

1) CPU selection：The max IO number for CPU504EX is 78, the requirement is 85 relay outputs, so CPU504EX

is not suitable.CPU506 has 14DI and 10 DO；CPU506EA has 4AI and 2AO，but there are no relay output model,.

Consider the above situation, it is better to choose CPU506, the model is Kinco-K506-24AR

2) Expansion module selection: only 8 DI is required, the DI on CPU itself is enough, so we do not need

expansion DI. 85 relay outputs are required, CPU itself has 10 relay outputs, so another 75 relay outputs are

needed, we have 8 and 16 outputs, we choose 16 outputs model, so we need 5 this kind of model. The model

name is K522-16XR. We also need 6 AI and 4AO, so we need 1 K531-04IV and 1 K533-04IV.

3) Power supply calculation in this example:

Expansion +5V consumption: consumed by chips, indicators, optocoupler, circuit and so on.
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Expansion +24V consumption: consumed by relay coil in expansion module, circuit.

Each expansion module has these two specifications; user can get this data in the technical data sheet of each

module. Each CPU can provide this +5V and +24V power supply, it is also in the technical data sheet of each

CPU. Take the above CPU and expansion modules for example:
77
Take the above CPU and expansion modules for example:

Expansion power supply source:

Model Expansion power Expansion power 24VDC power supply

supply(+5V ) supply(+24V ) output(V0+、V0-)

Kinco-K506-24AR 1500mA 360mA 500mA

Kinco-K580 1000mA 250mA none

Expansion power supply consumption：

Model number Expansion power Expansion power 24V DC power

supply(+5V ) supply(+24V ) supply(V0+、V0-)

K522-16XR 5 210*5=1050mA 120*5=600mA -

K531-04IV 1 172mA - 10mA

K333-04IV 1 166mA - 10mA

total 1388 600 20

We can get the conclusion from above sheets:

CPU506 can provide 1500mA +5V expansion power supply, all expansion modules need 1388mA, so the

+5V power supply on CPU is enough for this system.

CPU506 can provide 360mA +24V expansion power supply, all expansion modules need 600mA, so the

+24V expansion power supply is not enough, we need to add a expansion power module (PS580), according to

the calculation (600-360=240mA), one PS580 which can provide 250mA +24V expansion is enough.

CPU506 can provide 500mA 24V (VO+, VO-) output power supply, expansion modules needs 48mA, so the

24V output power supply on CPU is enough for this system.

The modules are connected as the following picture.

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78

9.2.4 Technical Data

Electrical data

Supply voltage AC85～265V

+5V ≤1000mA
Capability for expansion bus
+24V ≤250mA

Status indication Green LED（PW）

Dimension and weight

Dimension (L×W×H) 114×75×70mm

Net weight 195g

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Chapter X Installation&Wiring Guidelines

79 This chapter contains the information required to install and wire the KINCO-K5 modules.

10.1 Plastic Case Dimension

There are 5 different types of plastic cases for KINCO-K5 modules with the same length and height; the widths

(expansion direction) are 200, 125, 97, 75 and 50mm respectively. The plastic cases of 200mm, 125mm and

97mm width are used for the CPU modules; 75mm and 50mm width are used for the expansion modules.

Professional design of the case ensures the system surface flat and exquisite appearance when you combine

modules.

Please refer to installation dimension diagrams in the above chapters for details.

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10.2 Installation Guidelines

10.2.1 Module Connection

In actual connection, the CPU is arranged at left side, expansion port is at the right side of CPU, then the
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expansion modules at connected to each other from left to right. The steps are as follows: connect the first

expansion module’s cable to CPU expansion port, connect the second expansion module’s cable to the first

expansion module’s port and so on. After connecting all the expansion modules, put them together tightly and

put the expansion cable into the slot, close the slot cover. After finishing above steps, the CPU and expansion

modules are connected as following picture:

Figure 10-2 Actual picture about CPU connected to expansion moduls

Note：

1.The expansion cable must be fixed will on the expansion port, or it will be bad connection to make the system

not stable

2.After finishing installation, put the cable into the expansion slot and close the slot cover to protect expansion

cable from external damaging.

3. When CPU connects with too many expansion modules, it’s recommended that the 9th and 10th pins of the

expansion port of the last module should be short-circuited by placing a jumper

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10.2.2 Installing the KINCO-K5 modules

You can install the KINCO-K5 modules either on a panel or on a DIN rail; also, you can arrange the modules

either horizontally or vertically. For horizontal mounting, the CPU module shall be located at the lef side;

81 for vertical mounting, the CPU shall be at the upper side. The horizontal installation effect is shown in the

following diagram.

Diagram 8-1 Installation Effect

Note:

(1) For appropriate cooling, make sure that aclearance of at least 60mm above and below the modules. In

addition, at least 100mm of depth should be provided.

(2) For vertical mounting, the maximum ambient temperature in the operating environment is reduced by 10°C.

10.2.2.1 Panel Mounting by M4 Screw

(1) Each module has 2 M4 mounting holes, which are respectively located on the top-left corner and the

bottom-right corner. Both of the two mounting holes should be secured with bolts.

(2) Locate and drill the M4mounting holes according to the module’s dimension.

(3) Mount the module securely to the panel using M4 bolts. If you are using an expansion module, connect the

expansion bus cable into the expansion port of the prior module. Before fixing each expansion

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module, make some adjustments to make the expansion bus slide into the slot on the right side of

the module with a purpose to achieve a better appearance.

To prevent the loosing by vibration, please add spring washer and spacer.

82 10.2.2.2DIN Rail Mounting

(1) Prepare a standard 35mm DIN rail. There are 2 specifications as shown in the following diagram.

35mm
1mm
35mm
1mm

15mm
7.5mm

(2) Mount the rail to the appropriate position of the mounting panel. If it is horizontal mounting, make sure

three are at lease 60mm space and upper and bottom side. If it is vertical mounting, make sure three are at

lease 60mm space and left and right side.

(3) Connect the modules on the DIN rail. Pull download the slider of 35mm DIN rail slot on the module first,

put the module on the DIN rail then pull back the slider to fix the module.

(4) If an expansion module is used, connect its expansion bus cable into the expansion port of the prior

module; make some adjustments to make the expansion cable slide into the slot on the right side

of the module; push tight all the modules after connection.

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10.3 installation and removing the wiring terminal row

The wiring terminals row of K5 is removable, it is convenient for customer to change this part.

10.3.1 Remove wiring terminal row

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1. Open the terminal raw cover

2. Use the screw driver to insert the small slot at the middle of terminal row.

3. Pry the terminal row outward to remove it.

10.3.2 Install the terminal row

1. Open the terminal row cover

2. Put the embossment of terminal row in the positioning hole on the CPU shell.

3. Make sure holes of terminal row are right at the pin position, then press the terminal row downward to fix

terminal row.

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10.4 Protection circuit and ground connection

10.4.1 Protection function of transistor digital Output

84 In transistor DO channel of K5, there is short circuit protection function, if the output current is larger than

3A, the protection function will be triggered, the output group which the short circuit channel is in will be

protected, there will be no output for all the channels of this group. Besides, there is inductance load protection

function in the internal circuit, user can connect inductance load directly , it can suitable for most of the

application.

10.4.2 Protection function of Relay output

Relay output of K5 supports voltage below AC250V/DC30V, maximum current 3A, so it is not suitable to

connect to large current load, we suggest user connect a external intermediate relay or solid state relay to drive

large current load. Besides, the usage lifetime of relay contact is also limited. For example, mechanical lifetime

(without load) is 20 million times, electrical lifetime (rated voltage, current 3A, resistance load and on/off

frequency 6times/minute) is 100 thousand times. The actual lifetime of relay output depends on the actual load

and usage conditions.

Relay output can connect to DC load or AC load, so there is no inductance load protection function. When

the relay output is connected to inductance load and the moment relay is off, there will be high back-EMF at

two ends of load, so we suggest user to connect suppression circuit in parallel at two ends of load, this circuit

can improve the lifetime of relay contact. Check the following picture for the suppression circuit for DC

inductance load and AC inductance load:

DC inductance load suppression circuit

Connect overvoltage suppression diode in parallel at two end of load, pay attention to the polarity of diode.

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In most of the applications, just add A is enough, if the relay will be on/off faster, a additional B is

recommended. Make sure the Zener diode satisfy for the current and voltage requirements of output circuit.

AC inductance load suppression circuit

Connect resistor and capacitor network in parallel at both ends of load; make sure the resistor and capacitor

satisfy the current and voltage requirements of output circuit. User also can connect metal oxide variable

resistor (MOV), make sure operation voltage of MOV is at least 20% higher than normal line voltage.

10.4.3 Grounding

Generally speaking, there are two kinds of electrical groundings:

Protection grounding (safety GND): this kind of grounding is for operator personal safety and equipment

safety. Icon means protection grounding,

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Operation grounding, this kind of grounding is used to make sure the system/equipment works properly

and reliably, this grounding also can guarantee the precision of the system.

Good grounding is one of the most effective methods to improve PLC electromagnetic compatibility

(EMC), check the following grounding principles:

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In the whole factory, the PLC system should have separated operation grounding.

The grounding cable should be as short as possible and as thick as possible, the ground resistance should

be smaller than 4 ohms.

The single point grounding method is recommended, which is connecting plc and other related devices

together, then connect this point to ground, check the following grounding diagram:

Note: if there are high power range VFDs, motors and other high power range devices, do not connect PLC

to these devices together for grounding.

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