Omron CJ1W-CRM21 User Manual

0 (0)

Cat. No. W456-E1-03

CompoNet CS1W-CRM21/CJ1W-CRM21

CompoNet Master Units

OPER ATION MANUAL

CompoNet

CS1W-CRM21/CJ1W-CRM21 CompoNet Master Units

Operation Manual

Revised March 2009

Notice:

r f

OMRON products are manufactured for use according to proper procedures by a qualified operator and only for the purposes described in this manual.

The following conventions are used to indicate and classify precautions in this manual. Always heed the information provided with them. Failure to heed precautions can result in injury to people or damage to property.

!DANGER Indicates an imminently hazardous situation which, if not avoided, will result in death or

serious injury. Additionally, there may be severe property damage.

!WARNING Indicates a potentially hazardous situation which, if not avoided, could result in death or

serious injury. Additionally, there may be severe property damage.

!Caution Indicates a potentially hazardous situation which, if not avoided, may result in minor or

moderate injury, or property damage.

OMRON Product References

All OMRON products are capitalized in this manual. The word “Unit” is also capitalized when it refers to an OMRON product, regardless of whether or not it appears in the proper name of the product.

The abbreviation “Ch,” which appears in some displays and on some OMRON products, often means “word” and is abbreviated “Wd” in documentation in this sense.

The abbreviation “PLC” means Programmable Controller. “PC” is used, however, in some Programming Device displays to mean Programmable Controller.

Visual Aids

The following headings appear in the left column of the manual to help you locate different types of information.

 OMRON, 2006

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form, o by any means, mechanical, electronic, photocopying, recording, or otherwise, without the prior written permission o OMRON.

No patent liability is assumed with respect to the use of the information contained herein. Moreover, because OMRON is constantly striving to improve its high-quality products, the information contained in this manual is subject to change without notice. Every precaution has been taken in the preparation of this manual. Nevertheless, OMRON assumes no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of the information contained in this publication.

Note Indicates information of particular interest for efficient and convenient opera-

tion of the product.

1,2,3... 1. Indicates lists of one sort or another, such as procedures, checklists, etc.

TABLE OF CONTENTS

PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv

1 Intended Audience. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi

2 General Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi

3 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi

4 Operating Environment Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii

5 Application Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xviii

6 Conformance to EC Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xx

7 Conformance to Shipbuilding Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxi

SECTION 1

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1 CompoNet Networks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

1-2 CompoNet Network Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1-3 Devices in a CompoNet Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1-4 Overview of Design Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

1-5 Overview of Operating Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1-6 Design and Operating Procedure Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

SECTION 2

Master Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

2-1 Master Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

SECTION 3

Wiring Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

3-1 Wiring Formations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

3-2 CompoNet Network Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

SECTION 4

Installation and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

4-1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

4-2 Connecting Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

4-3 Preparing and Mounting Flat Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

4-4 Power Supply Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

SECTION 5

Remote I/O Communications . . . . . . . . . . . . . . . . . . . . . . . . 101

5-1 Exchanging Data with the CPU Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

5-2 Allocations to Slave Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

5-3 Remote I/O Communications Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

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TABLE OF CONTENTS

SECTION 6

Message Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

6-1 Message Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

6-2 Overview of FINS Commands and Responses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

6-3 Using FINS Message Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

6-4 Sending Explicit Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159

SECTION 7

Other Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

7-1 Simple Backup Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168

SECTION 8

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

8-1 Handling Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

8-2 Error History Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

Appendix

A FINS Commands Addressed to CompoNet Master Units and Responses . . . . . . . . . . . . . . 183

Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

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About this Manual:

This manual describes the installation and operation of the CS1W-CRM21 and CJ1W-CRM21 CompoNet Master Units and includes the sections described below.

Please read this manual carefully and be sure you understand the information provided before attempting to install or operate a CompoNet Master Unit. Be sure to read the precautions provided in the following section. Also be sure to read the CompoNet Slave Unit Operation Manual (see following table) together with this manual.

Precautions provides general precautions for using the CompoNet Master Unit, Programmable Controller, and related devices.

Section 1 provides an overview of CompoNet Networks.

Section 2 provides the specifications of the CompoNet Master Units.

Section 3 describes the configurations of CompoNet Networks.

Section 4 describes how to install and wire a CompoNet Network.

Section 5 describes the remote I/O communications that are possible with CompoNet Networks.

Section 6 describes the message communications that are possible with CompoNet Networks.

Section 7 provides information on dealing with problems that might occur with CompoNet Master

Units.

Related Manuals:

Cat. No. Models Name Description

W456 (this manual)

W457 CRT1 Series CompoNet Slave Units

W464 CXONE-AL@@C-V@

CS1W-CRM21 and CJ1WCRM21

CXONE-AL@@D-V@

CS/CJ-series CompoNet Master Units Operation Manual

and Repeater Unit Operation Manual

CX-Integrator Operation Manual

Provides an overview of CompoNet Networks, communications specifications, wring methods, and CompoNet Master Unit functions.

Provides the specifications of CompoNet Slave Units and Repeater Unit.

Describes CX-Integrator operating methods, e.g., for setting up and monitoring networks.

!WARNING Failure to read and understand the information provided in this manual may result in per-

sonal injury or death, damage to the product, or product failure. Please read each section in its entirety and be sure you understand the information provided in the section and related sections before attempting any of the procedures or operations given.

Read and Understand this Manual

Please read and understand this manual before using the product. Please consult your OMRON representative if you have any questions or comments.

Warranty and Limitations of Liability

WARRANTY

OMRON's exclusive warranty is that the products are free from defects in materials and workmanship for a period of one year (or other period if specified) from date of sale by OMRON.

OMRON MAKES NO WARRANTY OR REPRESENTATION, EXPRESS OR IMPLIED, REGARDING NONINFRINGEMENT, MERCHANTABILITY, OR FITNESS FOR PARTICULAR PURPOSE OF THE PRODUCTS. ANY BUYER OR USER ACKNOWLEDGES THAT THE BUYER OR USER ALONE HAS DETERMINED THAT THE PRODUCTS WILL SUITABLY MEET THE REQUIREMENTS OF THEIR INTENDED USE. OMRON DISCLAIMS ALL OTHER WARRANTIES, EXPRESS OR IMPLIED.

LIMITATIONS OF LIABILITY

OMRON SHALL NOT BE RESPONSIBLE FOR SPECIAL, INDIRECT, OR CONSEQUENTIAL DAMAGES, LOSS OF PROFITS OR COMMERCIAL LOSS IN ANY WAY CONNECTED WITH THE PRODUCTS, WHETHER SUCH CLAIM IS BASED ON CONTRACT, WARRANTY, NEGLIGENCE, OR STRICT LIABILITY.

In no event shall the responsibility of OMRON for any act exceed the individual price of the product on which liability is asserted.

IN NO EVENT SHALL OMRON BE RESPONSIBLE FOR WARRANTY, REPAIR, OR OTHER CLAIMS REGARDING THE PRODUCTS UNLESS OMRON'S ANALYSIS CONFIRMS THAT THE PRODUCTS WERE PROPERLY HANDLED, STORED, INSTALLED, AND MAINTAINED AND NOT SUBJECT TO CONTAMINATION, ABUSE, MISUSE, OR INAPPROPRIATE MODIFICATION OR REPAIR.

Application Considerations

SUITABILITY FOR USE

OMRON shall not be responsible for conformity with any standards, codes, or regulations that apply to the combination of products in the customer's application or use of the products.

At the customer's request, OMRON will provide applicable third party certification documents identifying ratings and limitations of use that apply to the products. This information by itself is not sufficient for a complete determination of the suitability of the products in combination with the end product, machine, system, or other application or use.

The following are some examples of applications for which particular attention must be given. This is not intended to be an exhaustive list of all possible uses of the products, nor is it intended to imply that the uses listed may be suitable for the products:

• Outdoor use, uses involving potential chemical contamination or electrical interference, or conditions or uses not described in this manual.

• Nuclear energy control systems, combustion systems, railroad systems, aviation systems, medical equipment, amusement machines, vehicles, safety equipment, and installations subject to separate industry or government regulations.

• Systems, machines, and equipment that could present a risk to life or property.

Please know and observe all prohibitions of use applicable to the products.

NEVER USE THE PRODUCTS FOR AN APPLICATION INVOLVING SERIOUS RISK TO LIFE OR PROPERTY WITHOUT ENSURING THAT THE SYSTEM AS A WHOLE HAS BEEN DESIGNED TO ADDRESS THE RISKS, AND THAT THE OMRON PRODUCTS ARE PROPERLY RATED AND INSTALLED FOR THE INTENDED USE WITHIN THE OVERALL EQUIPMENT OR SYSTEM.

PROGRAMMABLE PRODUCTS

OMRON shall not be responsible for the user's programming of a programmable product, or any consequence thereof.

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Disclaimers

CHANGE IN SPECIFICATIONS

Product specifications and accessories may be changed at any time based on improvements and other reasons.

It is our practice to change model numbers when published ratings or features are changed, or when significant construction changes are made. However, some specifications of the products may be changed without any notice. When in doubt, special model numbers may be assigned to fix or establish key specifications for your application on your request. Please consult with your OMRON representative at any time to confirm actual specifications of purchased products.

DIMENSIONS AND WEIGHTS

Dimensions and weights are nominal and are not to be used for manufacturing purposes, even when tolerances are shown.

PERFORMANCE DATA

Performance data given in this manual is provided as a guide for the user in determining suitability and does not constitute a warranty. It may represent the result of OMRON's test conditions, and the users must correlate it to actual application requirements. Actual performance is subject to the OMRON Warranty and Limitations of Liability.

ERRORS AND OMISSIONS

The information in this manual has been carefully checked and is believed to be accurate; however, no responsibility is assumed for clerical, typographical, or proofreading errors, or omissions.

xiii

xiv

PRECAUTIONS

This section provides general precautions for using the CS1W-CRM21 and CJ12-CRM21 CompoNet Master Units.

The information contained in this section is important for the safe and reliable application of the CompoNet Master Units. You must read this section and understand the information contained before attempting to set up or operate a CompoNet Network using CompoNet Master Units.

1 Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi

2 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi

3 Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi

4 Operating Environment Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii

5 Application Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xviii

6 Conformance to EC Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xx

6-1 Applicable Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xx

6-2 Concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xx

6-3 Conformance to EC Directives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxi

7 Conformance to Shipbuilding Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxi

7-1 Applicable Shipping Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxi

7-2 Installation Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxi

7-3 Conditions for Use Under Shipping Standards. . . . . . . . . . . . . . . . . xxi

Intended Audience 1

1 Intended Audience

This manual is intended for the following personnel, who must also have knowledge of electrical systems (an electrical engineer or the equivalent).

• Personnel in charge of installing FA systems.

• Personnel in charge of designing FA systems.

• Personnel in charge of managing FA systems and facilities.

2 General Precautions

The user must operate the product according to the performance specifications described in the operation manuals.

Before using the product under conditions which are not described in the manual or applying the product to nuclear control systems, railroad systems, aviation systems, vehicles, combustion systems, medical equipment, amusement machines, safety equipment, and other systems, machines, and equipment that may have a serious influence on lives and property if used improperly, consult your OMRON representative.

Make sure that the ratings and performance characteristics of the product are sufficient for the systems, machines, and equipment, and be sure to provide the systems, machines, and equipment with double safety mechanisms.

This manual provides information for programming and operating the Unit. Be sure to read this manual before attempting to use the Unit and keep this manual close at hand for reference during operation.

!WARNING It is extremely important that a PLC and all PLC Units be used for the speci-

fied purpose and under the specified conditions, especially in applications that can directly or indirectly affect human life. You must consult with your OMRON representative before applying a PLC System to the above-mentioned applications.

3 Safety Precautions

!WARNING Do not attempt to take any Unit apart while the power is being supplied. Doing

so may result in electric shock.

!WARNING Do not touch any of the terminals or terminal blocks while the power is being

supplied. Doing so may result in electric shock.

!WARNING Fail-safe measures must be taken by the customer to ensure safety in the

event of incorrect, missing, or abnormal signals caused by broken signal lines, momentary power interruptions, or other causes. Serious accidents may result from abnormal operation if proper measures are not provided.

xvi

Operating Environment Precautions 4

!WARNING Provide safety measures in external circuits (i.e., not in the Programmable

Controller), including the following items, to ensure safety in the system if an abnormality occurs due to malfunction of the PLC or another external factor affecting the PLC operation. (“PLC” includes CPU Units, other Units mounted in the PLC, and Remote I/O Terminals) Not doing so may result in serious accidents.

• Emergency stop circuits, interlock circuits, limit circuits, and similar safety measures must be provided in external control circuits.

• The PLC will turn OFF all outputs when its self-diagnosis function detects any error or when a severe failure alarm (FALS) instruction is executed. As a countermeasure for such errors, external safety measures must be provided to ensure safety in the system.

• The PLC outputs may remain ON or OFF due to deposits on or burning of the output relays, or destruction of the output transistors. As a countermeasure for such problems, external safety measures must be provided to ensure safety in the system.

• When the 24-V DC output (service power supply) is overloaded or shortcircuited, the voltage may drop and result in the outputs being turned OFF. As a countermeasure for such problems, external safety measures must be provided to ensure safety in the system.

!Caution Execute online editing only after confirming that no adverse effects will be

caused by extending the cycle time. Otherwise, the input signals may not be readable.

!Caution Confirm safety at the destination node before changing or transferring to

another node the contents of a program, the PLC Setup, I/O tables, or I/O memory. Changing or transferring any of these without confirming safety may result in unexpected equipment operation.

4 Operating Environment Precautions

!Caution Do not operate the control system in the following locations:

• Locations subject to direct sunlight.

• Locations subject to temperatures or humidity outside the range specified in the specifications.

• Locations subject to condensation as the result of severe changes in temperature.

• Locations subject to corrosive or flammable gases.

• Locations subject to dust (especially iron dust) or salts.

• Locations subject to exposure to water, oil, of chemicals (including acids).

• Locations subject to shock or vibration.

!Caution The operating environment of the PLC System can have a large effect on the

longevity and reliability of the system. Improper operating environments can lead to malfunction, failure, and other unforeseeable problems with the PLC System. Make sure that the operating environment is within the specified conditions at installation and remains within the specified conditions during the life of the system.

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Application Precautions 5

5 Application Precautions

Observe the following precautions when using a CompoNet Network.

• When more than one CompoNet system use Flat Cables, always separate the Flat Cables from each other by at least 5 mm regardless of whether Flat Cable I or II cables are used. Do not bundle the Flat Cables. This is to prevent unstable operation of the system due to interference.

• Fail-safe measures must be taken by the customer to ensure safety in the event of incorrect, missing, or abnormal signals caused by broken signal lines, momentary power interruptions, or other causes.

• Interlock circuits, limit circuits, emergency stop circuits, and similar safety measures in external circuits (i.e., not in the Programmable Controller) must be provided by the customer.

• Always configure control circuits so that they turn ON power to the I/O Slave Units before turning ON power to the PLC. If the PLC power supply is turned ON first, normal operation will not be possible temporarily.

• Do not attempt to disassemble, repair, or modify any Units. Any attempt to do so may result in malfunction, fire, or electric shock.

• When installing the Unit, ground to 100

• Make sure that all the Backplane mounting screws, Slave Unit mounting screws, terminal block screws, and cable connector screws are tightened to the torque specified in the relevant manuals. Incorrect tightening torque may result in malfunction.

• Wire all connections correctly according to instructions in this manual.

• Confirm the orientation and polarity before connecting terminal blocks or connectors.

• Confirm voltage specifications before wiring communications lines, power supplies, and I/O circuits. Incorrect specification may result in malfunctions.

• Install external breakers and take other safety measures against short-circuiting in external wiring. Insufficient safety measures against short-circuiting may result in burning.

• Leave the label attached to the Unit when wiring. Removing the label may result in malfunction if foreign matter enters the Unit.

• Remove the label after the completion of wiring to ensure proper heat dissipation. Leaving the label attached may result in malfunction.

• Use crimp terminals for wiring. Do not connect bare stranded wires directly to terminals. Connection of bare stranded wires may result in burning.

• Double-check all wiring and switch settings before turning ON the power supply. Incorrect wiring may result in burning.

• Make sure that the terminal blocks, connectors, expansion cables, communications cables, and other items with locking devices are properly locked into place. Improper locking may result in malfunction.

• Disconnect the functional ground terminal when performing withstand voltage tests. Not disconnecting the functional ground terminal may result in burning.

• Always use the power supply voltages specified in the operation manual. An incorrect voltage may result in malfunction or burning.

Ω min.

xviii

Application Precautions 5

• Take appropriate measures to ensure that the specified power with the rated voltage and frequency is supplied. Be particularly careful in places where the power supply is unstable. An incorrect power supply may result in malfunction.

• Do not apply voltages to the Input Units in excess of the rated input voltage. Excess voltages may result in burning.

• Do not apply voltages or connect loads to the Output Units in excess of the maximum switching capacity. Excess voltage or loads may result in burning.

• Check the user program for proper execution before actually running it on the Unit. Not checking the program may result in unexpected operation.

• Always turn OFF the power supply to the PLC before attempting any of the following. Not turning OFF the power supply may result in malfunction or electric shock.

• Mounting or dismounting Power Supply Units, I/O Units, CPU Units, Memory Cassettes, Master Units, or any other Units.

• Removing or attaching terminal blocks to Remote I/O Terminals.

•Assembling Racks.

• Setting DIP switches or rotary switches.

• Connecting cables or wiring the system.

• Connecting or disconnecting the connectors.

• Before touching a Unit, be sure to first touch a grounded metallic object in order to discharge any static build-up. Not doing so may result in malfunction or damage.

• Confirm that no adverse effect will occur in the system before attempting any of the following. Not doing so may result in unexpected operation.

• Changing the operating mode of the PLC.

• Force-setting/force-resetting any bit in memory.

• Changing the present value of any word or any set value in memory.

• When replacing parts, be sure to confirm that the rating of a new part is correct. Not doing so may result in malfunction or burning.

• After replacing Units, resume operation only after transferring to the new CPU Unit and/or Special I/O Units the contents of the DM Area, HR Area, and other data required for resuming operation. Not doing so may result in unexpected operation.

• When transporting the Unit, use special packing boxes and protect it from being exposed to excessive vibration or impact during transportation.

xix

Conformance to EC Directives 6

• Use only the specified communications cables.

• Do not extend connection distances beyond the ranges given in the specifications.

• Observe the following precautions when wiring the communications cable.

• Separate the communications cables from the power lines or high-tension lines.

• Do not bend the communications cables past their natural bending radius.

• Do not pull on the communications cables.

• Do not place heavy objects on top of the communications cables.

• Always lay communications cable inside ducts.

Take appropriate and sufficient countermeasures when installing systems in the following locations:

• Locations subject to static electricity or other forms of noise.

• Locations subject to strong electromagnetic fields.

• Locations subject to possible exposure to radioactivity.

• Locations close to power supplies.

6 Conformance to EC Directives

6-1 Applicable Directives

•EMC Directives

• Low Voltage Directive

6-2 Concepts

EMC Directives

OMRON devices are designed so that they comply with the related EMC Directives so that they can be more easily built into other devices or the overall machine. The actual products have been checked for conformity to EMC Directives (see the following note). Whether the products conform to the standards in the system used by the customer, however, must be checked by the customer.

EMC-related performance of the OMRON devices that comply with EC Directives will vary depending on the configuration, wiring, and other conditions of the equipment or control panel on which the OMRON devices are installed. The customer must, therefore, perform the final check to confirm that devices and the overall machine conform to EMC standards.

Note Applicable EMC (Electromagnetic Compatibility) standards are as follows:

EMS (Electromagnetic Susceptibility): EN 61000-6-2 EMI (Electromagnetic Interference): EN 61000-6-4

Low Voltage Directive

Always ensure that devices operating at voltages of 50 to 1,000 V AC and 75 to 1,500 V DC meet the required safety standards for EN 61131-2.

(Radiated emission: 10-m regulations)

Conformance to Shipbuilding Standards 7

6-3 Conformance to EC Directives

The CompoNet Master Units comply with EC Directives. To ensure that the machine or device in which a CompoNet Master Unit is used complies with EC Directives, the CompoNet Master Unit must be installed as follows:

1,2,3... 1. The CompoNet Master Unit must be installed within a control panel.

2. You must use reinforced insulation or double insulation for the DC power supplies used for the communications power supply and I/O power supplies.

3. CompoNet Master Units complying with EC Directives also comply with the Common Emission Standard (EN 61000-6-4). Radiated emission characteristics (10-m regulations) may vary depending on the configuration of the control panel used, other devices connected to the control panel, wiring, and other conditions. You must therefore confirm that the overall machine or equipment complies with EC Directives.

7 Conformance to Shipbuilding Standards

The CS1W-CRM21 and CJ1W-CRM21 Master Units conform to shipbuilding standards. Applicability of the shipbuilding standards is based on certain usage conditions. It may not be possible to use a Master Unit in some locations. Contact your OMRON representative before attempting to use a Master Unit on a ship.

7-1 Applicable Shipping Standards

The Master Units conform to the following standards: LR and DNV.

7-2 Installation Location

• The Master Unit cannot be installed on the bridge or on a deck.

• Install the Master Unit where there is not excessive vibration. Do not install it in the engine room or any other location with excessive vibration.

7-3 Conditions for Use Under Shipping Standards

• The Master Unit must be installed in a control panel.

• The following DC Power Supply must be used to supply power for communications.

DC Power Supply

Manufacturer OMRON

Model S82J Series

The DC Power Supply must provide the following specifications.

Item Specification

Output voltage 24 VDC

Output current The capacity of the Power Supply must be equal to or greater

than the total of the current consumptions of the following Units:

All Slaves, Repeater Units, and SmartSlice Units

xxi

Conformance to Shipbuilding Standards 7

xxii

This section provides an overview of CompoNet networks.

1-1 CompoNet Networks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1-1-1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1-1-2 Overall System Configuration and Elements . . . . . . . . . . . . . . . . . . 2

1-1-3 System Configuration Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1-1-4 Features of CompoNet Networks . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1-2 CompoNet Network Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1-2-1 Cable Types, Maximum Distances, and Number of Slave Units . . . 9

1-2-2 Branch Line Support for Cable Types and Baud Rates . . . . . . . . . . 11

1-2-3 Allocating Slave Units in the CPU Unit Memory Area by

Communications Mode Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1-3 Devices in a CompoNet Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1-3-1 Master Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1-3-2 Peripheral Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1-3-3 Selecting Peripheral Devices Used According to Connection

Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1-4 Overview of Design Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1-5 Overview of Operating Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1-6 Design and Operating Procedure Examples . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1-6-1 Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1-6-2 Operating Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

SECTION 1

Overview

CompoNet Networks Section 1-1

1-1 CompoNet Networks

1-1-1 Overview

CompoNet Networks feature easy operation and installation in a componentlevel network connecting PLCs and on-site I/O.

The PLC and CompoNet Slave Units cyclically exchange I/O information through a CompoNet Master Unit, refreshing I/O in sync with the PLC scan.

Message communications can also be used from host computers or the CPU Unit of the PLC to read and write CompoNet Slave Unit data.

1-1-2 Overall System Configuration and Elements

A CompoNet Network is a remote I/O system that consists of the following elements.

System Configuration Example

Trunk line

Terminating Resistor

Sub-trunk line

CompoNet Master Unit

Branch line

Repeater Unit

Branch line

Repeater Unit

Slave Unit

Sub-trunk line

Branch line

Slave Unit

: Repeater Unit

: Terminating Resistor

: T-branch

: Multidrop

Terminating Resistor

Repeater Unit

Sub-trunk line

Terminating Resistor

Sub-trunk line

Branch line Branch line

Sub-trunk line

Branch line Branch line

Terminating Resistor

Sub-branch lines

Terminating Resistor

Multidrop connection on branch line

CompoNet Networks Section 1-1

Communications Cables CompoNet Networks use Round Cable I, Round Cable II, Flat Cable I (DCA4-

4F10 Standard Flat Cable), and Flat Cable II (DCA5-4F10 Sheathed Flat Cable) for Communications Cables.

Master Unit The Master Unit manages the CompoNet Network and transfers I/O data

between the PLC and the Slave Units.

There is only one Master Unit per network. The Master Unit must be connected to the end of the trunk line.

Slave Units Some Slave Units receive output data from the Master Unit across the Com-

poNet Network and output it. Other Slave Units send data that has been input across the network to the Master Unit. There are two types of Slave Unit according to the I/O capacity of the Slave Unit.

• Word Slave Units: A Word Slave Unit is allocated 16 bits (i.e., 16 I/O points) in the I/O memory of the CPU Unit.

• Bit Slave Units: A Bit Slave Unit is allocated 2 bits (i.e., 2 I/O points) in the I/O memory of the CPU Unit.

Repeater Unit Using Repeater Units enables expanding network connections as follows:

• Extending the Communications Cable

• Increasing the number of nodes (Units)

• Creating long-distance T-branches from the trunk line and sub-trunk lines (See note.)

• Converting between different types of cable (round cable I, round cable II, Flat Cable I, and Flat Cable II)

A sub-trunk line downstream from a Repeater Unit can be connected with the same communications specifications (i.e., distances and number of Slave Units) as the trunk line.

Up to 64 Repeater Units can be connected per network (i.e., per Master Unit). When Repeater Units are connected in series from the Master Unit, up to two layers can be created.

Note The physical layer is not connected across a Repeater Unit. The

connection is thus different from a branch connection, which branches the same physical layer.

Terminating Resistors With a CompoNet Network, the Master Unit is located at one end of the trunk

line and a Terminating Resistor is connected to the other end of the trunk line. If Repeater Units are used, each Repeater Unit is treated like a Master Unit, i.e., Terminating Resistor is connected to the most remote end of the subtrunk line downstream from the Repeater Unit.

Note A Terminating Resistor reduces signal bouncing to stabilize com-

munications and must always be connected to the most remote end of the network lines below the Master Unit and each Repeater Unit. Always connect a Terminating Resistor to ensure the quality of the transmission path.

Trunk Lines and Branch Lines

The trunk lines and branch lines in a CompoNet Network are defined as follows:

• Trunk line: The transmission path between the Master Unit and the Terminating Resistor.

• Sub-trunk line: The transmission path between the Repeater Unit and the Terminating Resistor (when a Repeater Unit is used)

• Branch line: The transmission path created using a T-branch from the trunk line or sub-trunk line.

CompoNet Networks Section 1-1

• Sub-branch line: The transmission path created using a T-branch from a branch line. (T-branching is not possible from sub-branch lines.)

Note Due to differences in functionality, the same type of cable must be

used between the trunk line and a branch line, a sub-trunk line and a branch line, and a branch line and a sub-branch line. Different types of cable can be used between the trunk line and a sub-trunk line.

Branches There are two ways to create branch lines.

1) T-branch Connections

• T-branch connections using Flat Connectors (when Flat Cable I or Flat Cable II is used)

• T-branch connections using commercially available relay terminals (when round cable I or round cable II is used)

2) Multidrop Connections

• Multidrop connections using Flat Connectors and Multidrop Connectors (when Flat Cable I or Flat Cable II is used)

• Multidrop connections using Open Type Connectors (when round cable I or round cable II is used)

Note Flat Connectors can also be used to extend the Communications

Cable.

Communications Power Supply

This is the power supply for communications and internal operations for each Unit.

A commercially available 24-VDC power supply is used for communications and internal operations in each Unit.

One communications power supply can be connected for a trunk line or a subtrunk line. Communications power is supplied to the trunk line from the Master Unit and to a sub-trunk line from the Repeater Unit.

One power supply cannot be used to supply communications power to more than one line (i.e., to the trunk line and sub-trunk line or to two sub-trunk lines).

I/O Power Supply A commercially available 24-VDC power supply is used to power the I/O oper-

ations of the external I/O device connected to a Unit. It is connected to the I/O power supply terminal of the Unit.

1-1-3 System Configuration Patterns

Repeater Units connected with multidrop connections

Master Unit

Repeater Unit

Sub-trunk line

Slave Units connected with multidrop connections

Sub-trunk line

Slave Units

Tr unk line

Repeater Unit

Branch line

Slave Units

Slave Units connected with Tbranch connections

Repeater Units connected with T-branch connections

Branch line Branch line Branch line

Repeater Unit

Sub-trunk line

Slave Units

Slave Units connected with multidrop connections

Slave Units connected with T-branch and then multidrop connections

Repeater Unit

Branch line

Slave Units

Slave Units connected with T-branch connections

Slave Units connected with T-branch and then T-branch connections

Slave Units

Slave Unit

Sub-trunk line

Branch line

Sub-branch line

Repeater Unit connected to create second segment layer

Slave Units connected with multidrop connections

Ter minating Resistor

Repeater Unit

Branch line

Sub-trunk line

Repeater Unit

Slave Units

: Slave Unit : T-branch : Multidrop

: Terminating Resistor

CompoNet Networks Section 1-1

1-1-4 Features of CompoNet Networks

Programless Communications

High-speed Multi-point Processing

Repeater Units for Greater Flexibility

With the use of only Round Cable I, Round Cable II, Flat Cable I and Flat Cable II cables, cyclic data exchange or remote I/O communications can be achieved between a Master Unit mounted in a PLC and multiple Slave Units.

Remote I/O communications for up to 2,560 I/O points can be achieved at approximately 1,000 points per millisecond (at 4 Mbps, see note). This enables configuring CompoNet Network systems to replace systems previously configured with Basic I/O Units.

Note Branch lines cannot be used at 4 Mbps. Slave Units with Cables

(i.e., Bit Slave Units) can thus not be used.

Easy Introduction

Remote I/O communications can be started merely by connecting the Master Unit and Slave Units with communications cables, setting the switches on the Master Unit, and turning ON the power to the Slave Units and PLC.

Repeater Units can be used in a network to enable the following network expansions.

• Extending the cable length

• Increasing the number of nodes

• Branching from the trunk line

• Changing the type of cable

Repeater Units can be used to extend up to two segment layers (called subtrunk lines) from the trunk line. Up to 64 Repeater Units can be connected per Master Unit and up to 32 Repeater Units can be connected to the trunk line.

Note Communications power is supplied to a sub-trunk line from the Re-

peater Unit.

Bit-level Distribution Slave Units with industry-standard e-CON connectors or clamping terminal

blocks can be used to distribute I/O at the bit level. This enables distributed control in distributed devices, such as sensors and other devices located over a wide area on conveyors or in warehouses.

Bit Slave Units are available in two types: IP20 and IP54.

Five Communications Modes According to Number of Nodes, I/O Points, and Allocated Memory

Data Exchange with Message Communications

Easy Maintenance with Complete System Monitoring Functions

There are five communications modes that can be used according to number of Slave Units, the number of I/O points, and the location of allocated memory. Memory can be allocated to Slave Units in the Special I/O Unit portion of the CIO Area or, if the CX-Integrator software settings are used, in any part of the CIO, DM, Work, and Holding Areas.

This enables efficient application of memory according to the size of the system.

Message communications can be used from the CX-Integrator running on a host computer or from the CPU Unit of the PLC to access Slave Units and Repeater Units on the CompoNet Network. This enables easily improving network and system maintenance.

The CompoNet Network is constantly monitored to enable confirming system safety by quickly isolating errors and checking communications status.

■ CX-Integrator

The CX-Integrator provides the following network functionality.

• Uploading the network configuration

• Editing and transferring software setting tables

CompoNet Networks Section 1-1

• Editing and transferring registration tables

• Setting Input Data Zero Clear Mode for when communications error occur

• Setting I/O Communications Manual Startup Mode

• Monitoring Master Unit status

• Monitoring the Master Unit error history

• Monitoring Slave Unit network participation status

• Setting and transferring Slave Unit parameters

• Monitoring Slave Unit information

• Managing files

• Managing hardware (EDS files)

■ Smart Slave Unit Functions

The Slave Units provide Smart Functions that can record various added-value information in addition to the ON/OFF signals (I/O data). This enables preventive system maintenance (including operation time monitoring and contact operation counter monitoring) and aids in faster system introduction (including communications power voltage monitoring and I/O power status monitoring). Settings are possible from either the CX-Integrator or through message communications.

■ Master Unit Detection of Network Participation, Errors, and Status

When a Slave Unit joins the network, a bit corresponding to the node address called a Participation Flag will turn ON. If a Slave Unit that has been participating in the network leaves the network, a bit corresponding to the node address called an Error Flag will turn ON.

Network status, such as communications errors and redundant Slave Unit node address, and Slave Unit diagnostic results are detected by the Master Unit and display on the seven-segment display on the front panel and reflected in the Status Flags.

■ Registration Tables

Tables of the Slave Unit that should be participating at each node (i.e., the node address and corresponding Slave Unit model number) can be registered from the CX-Integrator to verify the Slave Units actually participating in the network and prevent unregistered Slave Units from participating in the network. A monitoring time for registered Slave Unit participation after power is turned ON can also be set.

Remote I/O communications can be stopped until all registered Slave Units are participating and remote I/O communications can be started as soon as all registered Slave Units are participating (called Registered Slave Unit Participation Standby Mode).

■ Stopping Communications at Communications Errors

A DIP switch on the front of the Master Unit can be set to stop remote I/O communications when a communications error has occurred in any of the Slave Units.

■ I/O Communications Manual Startup Mode

I/O Communications Manual Startup Mode can be set from the CX-Integrator so that remote I/O communications are not started when the power is turned ON. Remote I/O communications will not start until the Remote I/O Communications Start Switch is turned ON in memory.

CompoNet Network Specifications Section 1-2

■ Communications Error Input Data Zero Clear Mode

Input Data Zero Clear Mode can be set from the CX-Integrator for communications error. If a communications error occurs for a Slave Unit in this mode, all input data for that Slave Unit will be cleared to zeros. This can be used to suppress triggering operations when communications errors have occurred in systems where ON input data signals are used as triggers for operation.

■ Communications Status on Master Unit Seven-segment Display

The seven-segment display on the front of the Master Unit can be used to check communications status.

The baud rate is normally displayed, but if an error occurs, the error code is displayed in hexadecimal and the error node address is displayed in decimal.

Automatic Baud Rate Detection

The Slave Units will automatically detect and use the baud rate set on the DIP switch on the Master Unit. Setting the baud rate is not necessary for any of the Slave Units.

1-2 CompoNet Network Specifications

Item Specifications

Communications method CompoNet protocol

Types of communications Remote I/O communications (programless, constant sharing of data with Slave

Baud rate 4 Mbps (See note)., 3 Mbps, 1.5 Mbps, 93.75 kbps

Modulation Base-band

Coding Manchester code

Error control Manchester code rules, CRC

Communications media The following cables can be used.

Communications distance and wiring Refer to 1-2-1 Cable Types, Maximum Distances, and Number of Slave Units.

Connectable Master Units CompoNet Master Units

Connectable Slave Units CompoNet Slave Units

Maximum I/O capacity Word Slave Units: 1,024 inputs and 1,024 outputs (2,048 I/O points total)

Maximum number of nodes Word Slave Units: 64 input nodes and 64 output nodes

Bits allocated per node address Word Slave Units: 16 bits

Maximum number of nodes per trunk line or sub-trunk line

Applicable node addresses Word Slave Units: IN0 to IN63 and OUT0 to OUT63

Units) and message communications (explicit message communications as required with Slave Units and FINS message communications as required with PLCs)

Note A baud rate of 4 Mbps is not supported for branch lines and thus cannot

be used for Slave Units with Cables (i.e., Bit Slave Units).

• Round Cable I (VCTF 2-conductor cable, JIS C3306)

• Round Cable II (VCTF 4-conductor cable, JIS C3306)

• Flat Cable I (DCA4-4F10 Standard Flat Cable)

• Flat Cable II (DCA5-4F10 Sheathed Flat Cable)

Note Round Cable I, Round Cable II, Flat Cable I, and Flat Cable II cables are

all treated as different types of cables. When two or more type of cables are used in a single network, a Repeater Unit must be used to separate any two different types of cables between the trunk line and a sub-trunk line.

Bit Slave Units: 256 inputs and 256 outputs (512 I/O points total)

Bit Slave Units: 128 input nodes and 128 output nodes

Bit Slave Units: 2 bits

32 nodes including Repeater Units

Bit Slave Units: BIT IN0 to BIT IN127 and BIT OUT0 to OUT127 Repeater Units: 0 to 63

CompoNet Network Specifications Section 1-2

Item Specifications

Repeater Unit application conditions Up to 64 Repeater Units can be connected per network (i.e., per Master Unit).

Signal lines Two lines: BDH (communications data high) and BDL (communications data

Power lines Two lines: BS+ and BS- (power for communications and internal Slave Unit cir-

Communications power supply voltage 24 VDC ±10%

Connection forms Round Cable II, Flat Cable I, or Flat Cable II cables at a baud rate of 93.75

Remote I/O communications Automatic startup when power is turned ON (see note) or manual startup using

I/O Communications Manual Startup Mode

Communications Error Communications Stop Mode

Communications Error Input Data Zero Clear Mode

Duplicated Slave Unit address check If the same address is set for two different Slave Units or the same memory is

Registration Tables The Slave Units that can participate for each node address are registered in a

Up to 32 Repeater Units can be connected per trunk line or per sub-trunk line. When Repeater Units are connected in series from the Master Unit, up to two extra segment layers can be created (i.e., up to 2 Repeater Units are allowed between a Slave Unit and the Master Unit).

low)

cuits)

• Power is supplied from the Master Unit and Repeater Units.

kbps: No restrictions Other cables or other baud rates: Trunk line and branch lines

Connections for Slave Units and Repeater Units: T-branch or multidrop connections

the Remote I/O Communications Start Switch in I/O Communications Manual Start Mode

Note When power is turned ON to the PLC and the Slave Unit communica-

tions power is turned ON. Communications are not started in the following cases:

• In Registered Slave Unit Participation Standby Mode, communications is not started until all registered Slave Units are participating in the network.

• In Communications Error Communications Stop Mode, communications stop when a communications error occurs.

All remote I/O communications are stopped if a communications error occurs in any Slave Unit.

Note Communications will not stop for verification errors for registration tables

or duplicated address settings.

All input data will be cleared to zeros in any Slave Unit in which a communications error occurs.

allocated to two different nodes, the Slave Unit that joins communications last will cause a duplicated address error and will leave the network. The Duplicated Address Error Flag will turn ON.

Note This error will also occur if a Slave Unit leaves the network and then a

different type of Slave Unit joins the network.

table so that only the registered Slave Units can participate. If a different Slave Unit attempts to join the network, the Registration Table Verification Error Flag will turn ON. The Registration Table is generated automatically or manually edited from the CX-Integrator.

CompoNet Network Specifications Section 1-2

Item Specifications

Slave Unit status

Without Registration Table Participation Flag and Communications Error Flag for each Slave Unit

• Participation Flag: Turns ON and remains ON if the Slave Unit joins the network even one time after system power is turned ON.

• Communications Error Flag: Turns ON if the Slave Unit cannot communicate with the Master Unit for any reason after the Slave Unit has joined the network (i.e., if the Participation Flag is ON). (Turns OFF when the error is removed.)

Duplicated Address Error Flags and Alarm Flags

With Registration Table • Participation Flags and Communications Error Flags for each node address

for all Slave Units registered in the Registration Table

• Registration Table Verification Error Flags

• All Registered Slave Units Participating Flag

Note The Registered Slave Unit Participation Monitoring Time can be set (ver-

ification error check timing). Registered Slave Unit Participation Standby Mode can be set. (Remote I/O communications will not start until all registered Slave Units are participating.)

1-2-1 Cable Types, Maximum Distances, and Number of Slave Units

This section provides specifications on the maximum cable length and the maximum number of connectable Slave Units for each type of cable. The cables and Units must be used within the specifications.

: Slave Unit

: T-branch

: Multi-drop

Master Unit

Trunk line length

Branch line length

: Terminating Resistor

Sub-trunk line length

Repeater Unit

Subtrunk line length

Slave Units

Sub-trunk line len

Trunk line

Repeater Unit

Branch line

Subtrunk line length

Branch line

Repeater Unit

Sub-trunk line length

Branch line

Repeater Unit

Branch lines

Branch line

Sub-branch line

Sub-branch line length

Slave Unit

Sub-trunk line length

Terminating Resistor

Repeater Unit

Branch line length

Branch lines

Repeater Unit

Slave Units

■ Baud Rate of 4 Mbps (No branching allowed. See note.)

Item Round Cable I or II Flat Cable I or II

Length per trunk line or sub-trunk line (maximum

30 m (90 m) 30 m (90 m)

length with two Repeater Units)

Branch line length Lines cannot be branched from the trunk line. (Only multidrop con-

Total branch line length

nections are possible from the trunk line or subtrunk lines.)

Restrictions on branch line locations

Number of Slave Units (including Repeater Units)

32 32

per trunk line or sub-trunk line

Note Bit Slave Units come with Flat Cables and cannot be connected. The network

must consist of only Word Slave Units (use DCN4-MD4 Multidrop Connectors for the Flat Cable I or Flat Cable II cables) and multidrop connections must be used.

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