Omron CJ1W-CTL41-E Operation Manuals
Cat. No. W02E-EN-01
SYSMAC CJ-series
CJ1W-CTL41-E
4-Channel Counter Unit
OPERATION MANUAL
SYSMAC CJ-series
CJ1W-CTL41-E
4-Channel Counter Unit
Operation Manual
Produced September 2004
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Notice:
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 pay attention to the information provided with them. Failure to comply with the precautions can result in injury to people or damage to the product.
!DANGER Indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
!WARNING Indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
!Caution Indicates an potentially hazardous situation which, if not avoided, may
result in minor or moderate injury, or property damage.
OMRON Product References
All OMRON products are capitalised in this manual. The word “Unit” is also capitalised 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 Logic Controller and is not used as an abbreviation for anything else.
Visual Aids
The following headings appear in the left column of the manual to help you locate different types of information.
1, 2, 3… Indicates lists of one sort or another, such as procedures, checklists, etc.
©
OMRON, 2004
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any
form, or by any means, mechanical, electronic, photocopying, recording, or otherwise, without the prior written
permission of 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 man ual 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 dam ages resulting
from the use of the information contained in this publication.
Note Indicates information of particular interest for efficient and convenient operation of
the product.
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TABLE OF CONTENTS
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
1 Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x
2 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x
3 Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x
4 Operating Environment Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
5 Application Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xii
6 EC Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
SECTION 1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-1 Features and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-2 Basic Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-3 Specifications and Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1-4 Quick Start Up Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1-5 Operating Procedure Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1-6 Application Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SECTION 2
Components, Installation and Wiring . . . . . . . . . . . . . . . . . 15
2-1 Components and Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2-2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2-3 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SECTION 3
Operation and Configuration . . . . . . . . . . . . . . . . . . . . . . . . 27
3-1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3-2 Counter Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3-3 Input Signal Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3-4 Controlling a Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3-5 Output Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3-6 Reset Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3-7 Extra Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
SECTION 4
Exchanging Data with CPU. . . . . . . . . . . . . . . . . . . . . . . . . . 57
4-1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4-2 Memory Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4-3 IOWR-Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4-4 IORD-Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4-5 Supported IOWR/IORD-Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4-6 Interrupts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
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TABLE OF CONTENTS
SECTION 5
Error Processing, Maintenance and Inspection . . . . . . . . . 91
5-1 Error Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5-2 Error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
5-3 Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Appendices
A Using Input Terminal Block Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
B Assigning External Interrupt Tasks to Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
C Application Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
D Comparison between CJ1W-CTL41-E and other Counter Units . . . . . . . . . . . . . . . . . . . . . 107
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
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About this Manual:
This manual describes the installation and operation of the CJ1W-CTL41-E Counter Unit 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 the CJ1W-CTL41-E Counter Unit.
Be sure to read the precautions provided in the following sections.
Section 1 introduces the CJ1W-CTL41-E Counter Unit and describes the features, functions, and specifi-
cations. It gives short instructions on how to operate the Unit.
Section 2 provides information about components, wiring and installation of the CJ1W-CTL41-E Counter
Unit.
Section 3 provides information about configuration and operation of the CJ1W-CTL41-E Counter Unit.
Section 4 provides information on the data-exchange and the communication interface between the
CJ1W-CTL41-E Counter Unit and the PLC CPU.
Section 5 provides details of the CJ1W-CTL41-E Counter Unit’s errors, error -codes and indicators and
guidelines for troubleshooting.
The Appendices describe a comparison with CQM1-CBT41 and CJ1W-CTL41-E Counter Units, the use
of Terminal Block Units, and the numbering of External Interrupt Tasks to Outputs.
All through this manual where a double word is defined as for instance “n+2, n+3” this must be interpreted
as follows:
n+3 (MSW) n+2 (LSW)
sign x106x105x104x103x102x101x100 :BCD Double Word
0 = + (positive)
F = - (negative)
n+3 (MSW) n+2 (LSW)
x167x166x165x164x163x162x161x160 :Hexadecimal Double Word
LSW = Least Significant Word
MSW = Most Significant word
!WARNING Failure to read and understand the information provided in this manual may
result in personal 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.
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PRECAUTIONS
This section provides general precautions for using the Programmable Controller (PLC) and the Counter Unit.
The information contained in this section is important for the safe and reliable application of the Counter Unit. You
must read this section and understand the information contained before attempting to set up or operate a Counter
Unit and PLC system.
1 Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x
2 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x
3 Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x
4 Operating Environment Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
5 Application Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii
6 EC Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
ix
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 installing and operating OMRON Counter
Units. Be sure to read this manual before operation 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 specified
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 The CPU Unit refreshes I/O even when the program is stopped (i.e., even in
PROGRAM mode). Confirm safety thoroughly in advance before changing the
status of any part of memory allocated to I/O Units, Special I/O Units, or CPU
Bus Units. Any changes to the data allocated to any Unit may result in unexpected operation of the loads connected to the Unit. Any of the following operation may result in changes to memory status.
• Transferring I/O memory data from a Programming Device to the CPU Unit.
• Changing present values in memory with a Programming Device.
• Force-setting/-resetting bits with a Programming Device.
• Transferring I/O memory files from a Memory Card or EM file memory to the
CPU Unit.
• Transferring I/O memory from a host computer or from another PLC on a network.
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Operating Environment Precautions 4
!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 Do not attempt to disassemble, repair, or modify any Units. Any attempt to do so
may result in malfunction, fire, or electric shock.
!Caution Execute online edit 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 transferring a program to another
node or changing contents of the I/O memory area. Doing either of these without
confirming safety may result in injury.
!Caution Tighten the screws on the terminal block of the AC Power Supply Unit to the
torque specified in the operation manual. Loose screws may result in burning or
malfunction.
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, or chemicals.
• Locations subject to shock or vibration.
!Caution 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.
!Caution The operating environment of the PLC System can have a large effect on the lon-
gevity and reliability of the system. Improper operating environments can lead to
malfunction, failure, and other unforeseeable problems with the PLC System. Be
sure that the operating environment is within the specified conditions at installation and remains within the specified conditions during the life of the system.
xi
Application Precautions 5
5 Application Precautions
Observe the following precautions when using the Counter Unit or the PLC.
!WARNING Failure to comply with the following precautions could lead to serious or possibly
fatal injury. Always follow these precautions.
• Always ground the system with 100 Ω or less when installing the system, to
protect against electrical shock.
• Always turn OFF the power supply to the PLC before attempting any of the
following. Performing any of the following with the power supply turned ON
may lead to electrical shock
• Mounting or removing any Units (e.g., I/O Units, CPU Unit, etc.) or memory
cassettes.
• Assembling any devices or racks.
• Connecting or disconnecting any connectors, cables or wiring.
• Setting DIP switch or rotary switches.
!Caution Failure to comply with the following precautions could lead to faulty operation of
the PLC or the system, or could damage the PLC or PLC Units. Always follow
these precautions.
• 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, and similar safety measures in external circuits (i.e., not in the Programmable Controller) must be provided by the customer.
• If the IOM Hold Bit is turned ON, the outputs from the PLC will not be turned
OFF and will maintain their previous status when the PLC is switched from
RUN or MONITOR mode to PROGRAM mode. Make sure that the external
loads will not produce dangerous conditions when this occurs. (When operation stops for a fatal error, including those produced with the FALS instruction, all outputs from Output Unit will be turned OFF and only the internal
output status will be maintained.)
• Use the Units only with the power supplies and voltages specified in the
operation manuals. Other power supplies and voltages may damage the
Units.
• 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.
• Install external breakers and take other safety measures against short-circuiting in external wiring. Insufficient safety measures against short-circuiting
may result in burning.
• Do not apply voltages to Input sections in excess of the rated Input voltage.
Excess voltages may result in burning.
• Do not apply voltages or connect loads in excess of the maximum switching
capacity to output sections. Excess voltage or loads may result in burning.
xii
Application Precautions 5
!Caution • Install the Units properly as specified in the operation manuals. Improper
installation of the Units may result in malfunction.
• Be sure that all the mounting screws, terminal screws, and cable connector
screws are tightened to the torque specified in the relevant manuals. Incorrect
tightening torque may result in malfunction.
• 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 the wiring and the connectors before turning ON the power
supply. Incorrect wiring or bad connections may result in burning or malfunction.
• Be sure that the terminal blocks, Memory Units, expansion cables, and other
items with locking devices are properly locked into place. Improper locking may
result in malfunction.
• Check switch settings, the contents of the DM Area, and other preparations
before starting operation. Starting operation without the proper settings or data
may result in an unexpected operation.
• Check the user program for proper execution before actually running it on the
Unit. Not checking the program may result in an unexpected operation.
• Confirm that no adverse effect will occur in the system before attempting any of
the following. Not doing so may result in an 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.
• Do not pull on the cables or bend the cables beyond their natural limit. Doing
either of these may break the cables.
• Do not place objects on top of the cables or other wiring lines. Doing so may
break the cables.
• 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.
• Before touching a Unit, be sure to first touch a grounded metallic object in order
to discharge any static built-up. Not doing so may result in malfunction or damage.
• Do not touch circuit boards or the components mounted to them with your bare
hands. There are sharp leads and other parts on the boards that may cause
injury if handled improperly.
• Provide proper shielding when installing in the following locations:
• Locations subject to static electricity or other sources of noise.
• Locations subject to strong electromagnetic fields.
• Locations subject to possible exposure to radiation.
• Locations near power supply lines.
• Do not attempt to take any Units apart, to repair any Units, or to modify any
Units in any way.
• After connecting Power Supply Units, CPU Units, I/O Units, Special I/O Units,
or CPU Bus Units together, secure the Units by sliding the sliders at the top and
bottom of the Units until they click into place. Correct operation may not be possible if the Units are not securely properly. Be sure to attach the end cover pro-
xiii
Application Precautions 5
vided with the CPU Unit to the right most Unit. CJ-series PLCs will not operate
properly if the end cover is not attached.
xiv
EC Directives Section
6 EC Directives
6-1 Applicable Directives
• EMC Directives
• Low Voltage Directive
6-2 Concepts
EMC Directives
OMRON devices that comply with EC Directives also conform to the related EMC
standards 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 standards (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):EN61000-6-2
EMI (Electromagnetic Interference):EN61000-6-4
(Radiated emission: 10-m regulations)
Low Voltage Directive
Always ensure that devices operating at voltages of 50 to 1,000 VAC and 75 to
1,500 VDC meet the required safety standards for the PLC (EN61131-2).
6-3 Conformance to EC Directives
6-3-1 Applicable Directives
•EMC Directives
• Low voltage directive
6-3-2 Concepts
EMC Directives
OMRON Units complying with EC Directives also conform to related EMC standards making them easier to incorporate in other Units or machines. The actual
products have been checked for conformity to EMC standards. (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 OMRON Units complying with EC Directives will
vary depending on the configuration, wiring, and other conditions of the equipment or control panel in which OMRON devices are installed. The customer
must, therefore, perform final checks to confirm that units and the overall system
conforms to EMC standards.
xv
EC Directives Section
Note Applicable EMS (Electromagnetic Susceptibility) and EMI (Electromagnetic Inter-
ference standards in the EMC (Electromagnetic Compatibility) standards are as
follows:
Unit EMS EMI
CJ1W-CTL41-E EN 61000-6-2:2001 EN 61000-6-4:2001
6-3-3 Conformance to EC Directives
Units that meet EC directives also meet the common emission standard
(EN61000-6-4). The measures necessary to ensure that the standard is met will
vary with the overall configuration. You must therefore confirm that EC directives
are met for the overall configuration, particularly any radiated emission requirement (10 m).
xvi
SECTION 1
Introduction
This section gives specifications of the CJ1W-CTL41-E and a brief description of the functions and features of the Unit and
the areas of application.
1-1 Features and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-2 Basic Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-3 Specifications and Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1-3-1 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1-3-2 Functional Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1-3-3 Input Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1-4 Quick Start Up Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1-4-1 Configuring the Counter Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1-5 Operating Procedure Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1-6 Application Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1
Features and Functions
1-1 Features and Functions
CTL41
RUN
C
H4
CH
3
CH
2
C
H
1
ERC
ERH
CH1
CH2
Section 1-1
CH3
CH4
3
4
2
5
1
6
0
7
9
8
3
4
2
5
1
6
0
7
9
8
CJ1W-CTL41-E The CJ1W-CTL41-E, a Special I/O Unit for CJ-series PLC-systems, is a freely
configurable Counter Unit. Depending on the requirements of your application, the specific behaviour of the Unit can be adjusted by changing the configuration settings.
CJ1W-CTL41-E Counters The CJ1W-CTL41-E Counter Unit is equipped with 4 Counters and counts
over a maximum binary range of 32-bits. Accepting input pulse frequencies of
up to 100 kHz allows precise control of fast motions. The Unit’s bi-directional
counting ability allows movement detecting in either direction. Each Counter
of the Unit can be configured independently. The Unit is equipped with 32
Software Outputs, each of which can be linked to Counter events. The Unit
can generate interrupts to the PLC CPU, to allow immediate CPU action upon
Counter events.
Counter Type Configuring the Unit starts with choosing one out of two Counter Types:
• Circular Counter (refer to section 3-2-1 Circular Counter)
• Linear Counter (refer to section 3-2-2 Linear Counter)
By default each Counter is set to Circular Counter. For all Counter Types the
full counting range is available. Circular and Linear Counters can be fully (DM) configured according to the application that is to be controlled.
Input Signal Type Depending on the type of input signal your application requires, every Counter
allows a choice out of three input signal types:
• Phase Differential Inputs (multiplication by either 1, 2 or 4)
(refer to section 3-3-1 Phase Differential)
• Up/Down Pulse Inputs (refer to section 3-3-2 Up & Down)
• Pulse & Direction Inputs (refer to section 3-3-3 Pulse & Direction)
Output Control Modes To control the Software Outputs the Unit can be configured in one of the two
following Output Control Modes:
• Range Mode (refer to section 3-5-1 Range Mode)
• Comparison Mode (refer to section 3-5-2 Comparison Mode)
In Range Mode, a configurable number of up to 4 Ranges can be applied to
individual Counters. Every Range can control up to a maximum of 32 Soft-
2
Features and Functions
ware Outputs. An Output is turned ON when the Counter is in the corresponding Range.
In Comparison Mode a configurable number of up to 8 Comparison Values
can be applied to individual Counters. Depending on the direction of counting,
an Output can be set or reset (configurable) on reaching the Comparison
Value. Every Comparison Value can control up to maximum 32 Outputs.
Resetting Counter Value Resetting of the Counter Value can be configured depending on the applica-
tion needs. The following sources can trigger a reset:
• CIO bit in the PLC
• Z-Input
To enable resetting a Counter Value, the Software Enable Reset bit can be used
(refer to section 3-6 Reset Signals).
Hysteresis For Counters in Range Mode a hysteresis can be configured [1 to 255
counts], to prevent Outputs from toggling due to unwanted oscillating of
encoding equipment (e.g. rotary incremental encoder). Refer to section 3-7-1
Hysteresis.
Noise Filtering For the purpose of suppressing noise on the signal lines A, B of every
Counter, noise filters are provided. The cut-off frequencies for all signal lines
A and B are fixed to 100 kHz.
Section 1-1
Run-time Configurable Configuration settings of the Unit can be changed at Run-time by using the
IOWR-instruction to be able to quickly adjust to changing application needs
without the need of restarting the Unit or stopping the Counters. Care, however, must be taken when changing configuration settings. Refer to section 3-
5 Output Control for information.
Interrupt Support All Outputs can be configured to generate interrupts to the PLC. Generating
interrupts is only possible when the Counter Unit is mounted in a CPU-rack.
Support Software The Unit can be configured by using CX-Programmer Support Software or a
Programming Console.
Quick Start Up Reference
Guide
For a quick overview of all the features and functions the Counter Unit offers,
refer to section 1-4 Quick Start Up Reference Guide. This section also contains references to the particular section(s) in the Manual where more detailed
information about specific features and functions of the Counter Unit can be
found.
3
Basic Configuration
1-2 Basic Configuration
Typical applicable Pulse Generators for
Counter Inputs
Incremental Encoder
Proximity Sensor
CTL41
RUN CH1
CH4
CH3
CH2
CH1
Section 1-2
CH3
ERC
CH2
CH4
ERH
3
4
2
5
1
6
0
7
9
8
3
4
2
5
1
6
0
7
9
8
Other Pulse
Generators
Mounting Restrictions The CJ1W-CTL41-E Counter Unit is a Special I/O Unit belonging to the CJ
Series. A CJ1W-CTL41-E Counter Unit can be mounted to either a CJ CPU
Rack or CJ Expansion Rack.
Note 1. In case of a CJ1-H CPU Unit, the Counter Unit must be in one of the five
positions immediately to the right of the CJ1-H CPU Unit on the CPU Rack,
in order to allow the CJ1W-CTL41-E Counter Unit to generate interrupts
which activate interrupt tasks in a CJ1-H CPU Unit.
2. In case of a CJ1M CPU Unit, the Counter Unit must be in one of the three
positions immediately to the right of the CJ1M CPU Unit on the CPU Rack,
in order to allow the CJ1W-CTL41-E Counter Unit to generate interrupts
which activate interrupt tasks in a CJ1M CPU Unit
3. No interrupt tasks can be activated in CJ1-H or CJ1M CPU Units if the
CJ1W-CTL41-E Counter Unit is in any other position (i.e., 6th Unit position
or further away from the CJ1-H CPU Unit, or 4th Unit position or further
away from the CJ1M CPU Unit), or if it is on a CJ-series Expansion Rack.
Maximum Number of
CJ1W-CTL41-E Units
The maximum number of CJ1W-CTL41-E Counter Units which can be
mounted to a CJ CPU Rack or CJ Expansion Rack is equal to the number of
slots of the Rack. In a configuration with multiple Racks the maximum number
of CJ1W-CTL41-E Counter Units is limited to 24.
Furthermore, the number of Counter Units that can be mounted to one Rack
(i.e., a CPU Rack or Expansion Rack) depends on the maximum supply current from the Power Supply Unit that supplies the Rack and the current consumption of other Units on the Rack.
I/O Connection Methods To connect the Input signal wires to the Unit two methods are available:
4
Specifications and Characteristics
• Directly connecting the wires by soldering them to the external connector.
• Indirectly connecting the wires by connecting them to screwless terminals
on an XW2G-40G7-E Input Terminal Block Unit. This Input Terminal Block
Unit allows connection of Line Driver or 24 V Encoder signals. The
XW2G-40G7-E is connected to the Unit via standard available OMRON I/
O-cables (XW2Z-xxxK).
• Indirectly connecting the wires by connecting them to screw terminals on
a standard XW2B-40G4, XW2B-40G5 or XW2D-40G6 OMRON Terminal
Block Unit, i.e. the Terminal Block Unit is connected to the Unit via standard available OMRON I/O-cables (XW2Z-xxxK).
Refer to section 2-3-2 Connector Wiring Methods for more details.
1-3 Specifications and Characteristics
1-3-1 General Specifications
Item CJ1W-CTL41-E
Unit type CJ-series Special I/O Unit
General Specifications Conform to general specifications for SYSMAC CJ-series
Operating Temperature 0 to 55 ° C
Storage Temperature -20 to 70 ° C
Humidity 10% to 90% without condensation
Internal Current Consumption 320 mA (at 5 V)
Dimensions (mm) 31 x 90 x 65 (W x H x D)
Weight 100 g
Mounting Position CJ-series CPU Rack or CJ-series Expansion Rack
Maximum Number of CTL41-E
Units per Rack
Maximum Number of CTL41-E
Units per basic CJ PLC
Data Exchange with CPU Unit • I/O Refresh Data Area: CIO-words 2000 to 2959. See Note 2.
Equal to the number of slots of the Rack (see Note 1)
24
• Special I/O Unit DM-Area: D-words 20000 to 29599: 90 DM-words per Unit are
transmitted from the CPU to the Unit at Power Up or when the Unit is restarted.
See Note 3.
Section 1-3
Note 1. The maximum number of Units per Rack also depends on the maximum
supply current of the Power Supply Unit and the current consumption of
other Units on the Rack.
2. The CJ1W-CTL41-E Special I/O Unit allocates space for 33 words in the
Special I/O Unit (CIO) Area (refer to section 4-2-3 CIO-Memory Mapping).
3. For a CJ1W-CTL41-E Special I/O Unit the same space as for 4 Units in the
Special I/O Unit DM Area are reserved. However, only the first 90 words
are used to make the DM-settings. The remaining 310 words can be used
as work-words (refer to section 4-2-4 DM-Memory Mapping).
5
Specifications and Characteristics
Section 1-3
1-3-2 Functional Specifications
Item CJ1W-CTL41-E
Number of Counters 4
Counter Type • Circular Counter (refer to section 3-2-1 Circular Counter)
• Linear Counter (refer to section 3-2-2 Linear Counter)
The Counter Type can be selected using the appropriate DM bits (refer to section 4-2-4
DM-Memory Mapping).
Maximum Input Frequency 100 kHz, refer to section 1-3-3 Input Specifications for details
Signals per Counter Phase A, B and Z
Input Signal Types • Phase Differential (multiplication x1), (multiplication x2) and (multiplication x4) (refer to
section 3-3-1 Phase Differential)
• Up/Down (refer to section 3-3-2 Up & Down)
• Pulse & Direction (refer to section 3-3-3 Pulse & Direction)
Counter Control using CIOsoftware bits
Output Control Mode • Automatic Output Control in:
Reset Signals Every Counter can be reset to zero by (a combination of) the following sources:
Extra Functions • Hysteresis: To prevent Outputs from being switched On and Off by very small fluctua-
Noise Filtering Counter Inputs To suppress noise on the signal lines of the Counter Inputs (A, B) a fixed Noise Filter is
Initial Counter Value • The Initial Counter Value is transferred to the Unit when the Unit is Powered Up or
IORD- and IOWR-instructions Run-time configuration (See Note 2) and operation of the Counter Unit is possible by
Interrupts of Outputs The Soft Outputs of the Unit Output Pattern can all be configured to generate interrupts
Error History Log Function Stores up to 30 error log records (refer to section 5-2 Error codes)
• Open Gate / Start Counter: Counter is enabled to count pulses
• Close Gate / Stop Counter: Counter is disabled to count pulses
• Preset Counter: Preset Value can be set in CIO
• Reset Counter to zero
• Capture Counter Value: Captured Counter Value can be read using IORD-instruction
(refer to section 4-5-3-1 Captured Counter Value)
• Range Mode (Refer to section 3-5-1 Range Mode)
• Comparison Mode (Refer to section 3-5-2 Comparison Mode)
• Software Counter Reset Bit
• Z-Input
Refer to section 3-6 Reset Signals.
tions in the Counter Value around Range Limits, for every Counter an Hysteresisvalue [1, 255] can be defined (the Unit must in Range Mode). Refer to section 3-7-1
Hysteresis.
provided:
• Counter Inputs A and B: 100 kHz
Restarted. The Initial Counter Value is very useful to overcome problems in case of
power failure. Refer to section 3-7-2 Initial Counter Value.
using IORD- and IOWR-instructions. The following data can be read or written:
• DM-configuration data (refer to section 4-5-1 DM-data).
• Range- and Comparison Data (refer to section 4-5-2 Range- and Comparison data).
• Captured Counter Value (refer to section 4-5-3-1 Captured Counter Value)
• Counter Value (refer to section 4-5-3-2 Counter Value)
• (Re) Configure Counter Unit (refer to section 4-5-3-3 (Re) Configure Unit).
• Error Clear (refer to section 4-5-3-4 Error Clear Command)
to the CJ1-H/CJ1M CPU Unit. Refer to section 4-6-1 Outputs Generating Interrupts. See
also Note 1.
Note 1. A CJ1G-CPU@@H, CJ1H-CPU@@H or CJ1M-CPU@@ CPU Unit must be
used. The older CJ1G-CPU@@ CPU Units (without H suffix) do not support external interrupt tasks. To activate external interrupt tasks in a CJ1GH/ CJ1H-H CPU Unit, the CJ1W-CTL41-E Counter Unit must be in one of
6
Specifications and Characteristics
Section 1-3
the five positions immediately to the right of the CPU Unit. For CJ1M CPU
Units, the CJ1W-CTL41-E Counter Unit must be in one of the three positions immediately to the right of the CJ1M CPU Unit. No external interrupt
tasks can be activated if the Unit is in any other position (i.e., 6th Unit position or further away from the CJ1-H CPU Unit, or 4th Unit position or further away from the CJ1M CPU Unit), or if it is on a CJ-series Expansion
Rack.
Power Supply Unit
CJ1-H or CJ1M CPU Unit
1st Unit
2ndUnit
3rd Unit
4th Unit
5th Unit
6thUnit
10th Unit
2. If an IOWR- or IORD-instruction is used during operation, comparison will
stop during instruction execution. Care must be taken, therefore, with the
timing of executing instructions. (Refer to section 3-5 Output Control for details.)
1-3-3 Input Specifications
Input Voltage Line Driver
Input Current
(typical)
Voltage levels Connectable to RS-422 compatible Line Drivers.
Note The Counter Inputs (A, B, Z) are insulated from each other. All Counter Inputs
are reverse polarity protected and insulated from the I/O-bus.
For CJ1-H CPU Units: External interrupt tasks can be
activated only from these Units.
For CJ1M CPU Units: External interrupt tasks can be
activated only from these Units.
Item Counter Inputs A, B and Z
11 mA
7
Specifications and Characteristics
24V input signals (via Input Terminal Block) RS-422 Line Driver signals
Section 1-3
Counter Inputs A, B and Z
Counter inputs A and B
Input pulses with a duty factor of 50%
C
BB
On
50%
Off
AA
Relationship between A and B phases with phase
differential inputs
Phase A
On
50%
Off
Phase B
Counter inputs A and B
Input pulses with a duty factor of 50%
F
GG
On
0V
Off
Relationship between A and B phases with phase
differential inputs
On
0V
Off
Phase A
On
0V
Off
DDD
D
Counter Input Z *
On
50%
Off
Z
*Maximum allowed frequency of Z-pulses is 10 kHz *Maximum allowed frequency of Z-pulses is 10 kHz
E
Phase B
II
On
0V
Off
Z
Counter Input Z *
I
J
I
Timing requirement [µs]
JIHGFEDCBA
<3
>50<3
>10<3
>2
>100
>20
>4
>1
>10>4.5
>10
>20
>2
>50>100>10>23
>10
>1
>100
>20
>4
>23
>4.5
>10
>10
>10>1
Note As a general guideline it can be stated that if you want the timing requirements
for the Counter Inputs to satisfy the above mentioned specifications, you must
pay attention to the type of output driver of the encoder being used, the length
of the encoder cable and the frequency of the count pulses generated. For
8
Quick Start Up Reference Guide
example, if you use an Open Collector encoder (e.g. E6B2-CWZ6C) at 24 V
with 10 m cable, you can typically generate count pulses up to 20 kHz. Therefore,
if you want to generate count pulses with higher frequencies, you should use a
different type of encoder (e.g. E6B2-CWZ1X with Line Driver output or a fast
push-pull 24 V encoder, e.g. E6C2-CWZ5GH) or reduce the length of the
encoder cable.
1-4 Quick Start Up Reference Guide
Section 1-4
Operation and
Configuration
Counter Inputs
1
(A, B, Z
Each individual Counter of the Counter Unit can be configured as Circular or
Linear Counter (refer to section the section 1-5 Operating Procedure Guide-
lines for quick start up information).
The diagram below shows the functions the Unit has available to operate and
configure the Unit (refer to SECTION 3 Operation and Configuration). The
numbers in grey refer to section the table on page 16.
Capture
2 2
Register
Circular
Linear
Counter
Preset
Register
Automatic
3
Output Control
5
Hysteresis
Outputs
8
Counter
2, 4 2, 4
Start/Stop
Counter
Reset
Exchanging data with CPU The diagram below shows the functions the Unit provides to exchange data
with the CPU (refer to section SECTION 4 Exchanging Data with CPU).
CJ-series CPU Unit
7
7
8
IOWR
IORD
Interrupts
CJ1W-CTL41-E
Unit Output Pattern
9
Quick Start Up Reference Guide
Section 1-4
Ref Item Circular/Linear Counter Reference
1 Input Signal types Phase Differential (x1, x2, x4) 3-3-1
Up & Down 3-3-2
Pulse & Direction 3-3-3
2 Counter control • Open Gate / Start Counter
• Close Gate / Stop Counter
• Preset Counter
• Reset Counter
• Capture Counter Value
3 Output control • Range Mode 3-5-1
• Comparison Mode 3-5-2
4 Counter reset • Software Reset Bit
• Z-signal
5 Hysteresis Yes 3-7-1
6 Initial counter values Yes 3-7-2
7 Supported IORD / IOWR-
instructions
8 Interrupts of Outputs Yes 4-6-1
Captured Counter Value 4-5-3-1
Counter Value 4-5-3-2
Error Clear 4-5-3-4
DM-data 4-5-1
Range- and Comparison Data 4-5-2
(Re) Configure Unit 4-5-3-3
section
3-4
3-6
1-4-1 Configuring the Counter Unit
Configuring the Counter
Type
Configuring the Input
Type
Configuring the Output
Mode
Indirect Addressing for
Circular and Linear
Counters
Configuring each Counter starts with choosing the Counter Type, i.e. it must
be configured for Circular or Linear Counter (refer to section 3-2-1 Circular
Counter, section 3-2-2 Linear Counter and section 1-5 Operating Procedure
Guidelines for details).
Next, the Input Type (Phase Differential, Up/Down, or Pulse & Direction) for
every Counter has to be defined. During operation of the Counter, the Counter
can be Started, Stopped, Reset, Captured or Preset by using the corresponding
bits in CIO.
In order to link the Units Software Outputs to Counter events, the Output Control Mode (Range or Comparison Mode) must be selected. Furthermore, an
additional Hysteresis mechanism is available to control the Outputs. Refer to
section 3-5 Output Control.
The CJ1W-CTL41-E Counter Unit allocates 90 DM-words in the Special I/O
Unit DM-Area and a block of 34 CIO-words in the Special I/O Unit Area of the
PLC. The configuration of the Unit is done by making the appropriate DM-settings in the Special I/O Unit DM-Area allocated to the Unit.
The Special I/O Unit DM-Area is divided in an area of 10 words to make the
General Unit Settings and 4 blocks of 20 DM-words each to make the Counter
Specific Settings, which are unique for every Counter.
10
Operating Procedure Guidelines
Depending on the Output Control Mode, Counter Range or Comparison Data
can be set. For each Counter, up to a maximum of 4 Ranges or 8 Comparison
Values can be assigned. You can set the Range or Comparison Data in a part
of DM or EM which is not being used. If you only intend to use a limited number of Ranges or Comparison Values then it is also possible to use the workwords of the Special I/O Unit DM-Area to store the Range or Comparison
Data (287 work-words for the CJ1W-CTL41-E are available). Therefore, at the
end of every block with Counter Specific Settings, you can specify an Indirect
Address. This Indirect Address points to the actual memory location where
the Range- or Comparison Settings of that specific Counter are stored.
For a detailed description about the CIO- and DM-Memory Allocation refer to
section 4-2 Memory Allocation.
Note During operation of the Unit, for Circular and Linear Counters run-time config-
uration is possible by using the IOWR-instruction from the PLC Ladder Program (refer to section 4-5 Supported IOWR/IORD-Instructions). Additionally,
Outputs can be configured to generate interrupts to the PLC by setting the
appropriate Interrupt Masks in DM. (refer to section 4-6 Interrupts)
Section 1-5
1-5 Operating Procedure Guidelines
In order to setup the Counter, follow the steps outlined below.
1, 2, 3… 1. Set the Machine Number to assign the start addresses of the allocated
CIO and DM areas. Refer to section 2-1-3 Machine Number Switch for further details.
CTL41
RUN
ERC
CH1
CH3
ERH
CH2
CH4
3
4
2
5
1
6
0
7
9
8
3
4
2
5
1
6
0
7
9
8
2. Install and wire the Unit. Refer to section 2-2 Installation and 2-3 Wiring for
further details.
Machine Number Switch:
3
MACH
2
4
1
5
0
6
No.
7
9
8
1
×
10
3
2
4
1
5
0
6
7
9
8
0
×
10
Set between 00 - 92
C
T
L
4
1
RUN
ERC
CH1
CH3
ERH
CH2
CH4
3
2
4
1
5
0
6
7
9
8
3
2
4
1
5
0
6
7
9
8
11
Operating Procedure Guidelines
3. Turn ON the Power to the PLC.
Power ON
4. Create the I/O table. The I/O table can be created by using CX-Program-
CX-Programmer
CTL41
R
U
N
ER
C
H
C
1
C
H
3
ER
H
C
H
2
C
H
4
3
2
4
1
5
0
6
7
9
8
3
2
4
1
5
0
6
7
9
8
mer Support Software or a Programming Console.
CTL41
RUN
ERC
CH1
CH3
ERH
CH2
CH4
3
2
4
1
5
0
6
7
9
8
3
2
4
1
5
0
6
7
9
8
Section 1-5
Programming Console
Unit Configuration After the I/O table is created in step 4, you have to configure the Unit by mak-
ing the appropriate DM-settings. The Unit can be configured by using CX-Programmer Support Software or a Programming Console. Two Programming
Consoles can be used with the CJ-series CPU Units: the C200H-PRO27-E
and the CQM1-PRO01-E. The CS1W-KS001 Key Sheet must be used for
both.
1, 2, 3… 1. Every Counter can now be separately (DM-) configured. The configuration
of the Counter Type (Linear or Circular Counter) is done by DM-setting.
Refer to section SECTION 3 Operation and Configuration for detailed information about configuring the Unit.
2. Power up the PLC again or turn the Special I/O Unit Restart Bit to ON (to
transfer the DM-settings). All data related to Circular /Linear Counters is now
being exchanged between the PLC and the Unit in CIO-memory and available for usage in the Ladder Program.
3. Create and RUN a Ladder Program in the PLC. Refer to section SECTION
4 Exchanging Data with CPU for details on the interface between the CJseries Counter Unit and the CPU. Refer to section sections 6-2 to 6-5 for
application examples using Circular and Linear Counters.
12
Application Areas
Refer to section 3-2-1 Circular Counter and 3-2-2 Linear Counter for more
details about both Counter Types. Refer to section 4-1-2 Special I/O Units
Restart bits for more information about restarting the Unit.
1-6 Application Areas
The main application areas of the Counter Unit are where signals with high
frequencies are counted and high-speed responses have to be triggered at
predefined Counter Values. Application areas include:
• Packaging and Sorting plants
• Dosing or proportioning plants
• Process Industry
Typical applications in which the CJ1W-CTL41-E can be used:
• (CAM)-Positioning
• Position Monitoring
• Length Measurement
• Flow Control
• Energy Measurement
Section 1-6
13
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