Omron CJ2, CJ1-H, CJ1M, CJ1 User Manual
USER’S MANUAL
Cat. No. W472-E1-01
SYSMAC CJ Series
CJ2H-CPU@@-EIP
CJ2 CPU Unit Hardware
OMRON, 2008
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 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.
SYSMAC CJ Series
CJ2H-CPU@@-EIP
CJ2 CPU Unit Hardware
User’s Manual
Produced July 2008
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CJ2 CPU Unit Hardware User’s Manual
Introduction
Thank you for purchasing a CJ2H-CPU@@-EIP CJ-series CPU Unit. This manual contains information
that is necessary to use the CJ2H-CPU@@-EIP. Please thoroughly read and understand this manual
before you use the CJ2H-CPU@@-EIP.
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.
z Definition of CJ Series
In this manual, CJ Series is a general term to refer to the CJ2 CPU Units, CJ1-H CPU Units, CJ1M CPU
Units, and CJ1 CPU Units.
Intended Audience
Applicable Products
CS1H-CPU@@H
CS1G-CPU@@H
CS1-H CPU Units
CS-series Power Supply Units
CS-series Basic I/O Units
CS-series CPU Bus Units
CS-series SpecialI/O Units
CS Series
CS1 CPU Units
CS1H-CPU@@(-V)
CS1G-CPU@@(-V)
CS1D CPU Units
CS1D CPU Units
for Duplex Systems
CS1D-CPU@@H
CS1D-CPU@@S
CS1D-CPU@@P
CJ1H-CPU@@H-R
CJ1H-CPU@@H
CJ1G-CPU@@H
CJ1G -CPU@@P
(Loop CPU Units)
CJ1-H CPU Units
CJ-series Power Supply Units
CJ-series Basic I/O Units
CJ-series CPU Bus Units
CJ-series Special I/O Units
CJ1 CPU Units
CJ Series
CJ1G-CPU@@
CJ1M CPU Units
CJ1M-CPU@@
NSJ5-TQ@@(B)-G5D
NSJ5-SQ@@(B)-G5D
NSJ8-TV@@(B)-G5D
NSJ10-TV@@(B)-G5D
NSJ12-TS@@(B)-G5D
NSJ Controllers
NSJ-series Expansion Units
NSJ Series
NSJ5-TQ@@(B)-M3D
NSJ5-SQ@@(B)-M3D
NSJ8-TV@@(B)-M3D
NSJ Controllers
CJ2 CPU Units
CJ2H-CPU@@-@@@
CS1D CPU Units
for Simplex Systems
CS1D Process-control CPU Units
Note: A special Power Supply Unit must
be used for CS1D CPU Units.
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CJ2 CPU Unit Hardware User’s Manual
CJ2 CPU Unit Manuals
Information on the CJ2 CPU Units is provided in the following manuals. Refer to the appropriate manual
for the information that is required.
Mounting and Setting Hardware
1
2
3
4
5
6
7
Wiring
Connecting Online to the PLC
Software Setup
Creating the Program
Checking and Debugging Operation
Maintenance and Troubleshooting
CJ-series CJ2 CPU Unit Hardware User’s Manual (W472) CJ-series CJ2 CPU Unit Software User’s Manual (W473)
This Manual
CX-Programmer Support Software
Connecting Cables
Error codes and remedies if a problem
occurs
Procedures for connecting the
CX-Programmer Support Software
Software setting methods for the CPU Unit
(including I/O memory allocation, PLC Setup
settings, Special I/O Unit parameters, CPU Bus
Unit parameters, and routing tables. )
For details on built-in EtherNet/IP port, refer to
the EtherNet/IP Unit Operation Manual (W465)
• Checking I/O wiring, setting the Auxiliary Area
settings, and performing trial operation
• Monitoring and debugging with the
CX-Programmer
• Unit part names and specifications
• Basic system configuration
• Unit mounting procedure
• Setting procedure for DIP switch and rotary
switches on the front of the CPU Unit
For details on built-in EtherNet/IP port, refer
to the EtherNet/IP Unit Operation Manual
(W465)
• Wiring the Power Supply Unit
• Wring Basic I/O Units and external I/O
devices
• Program types and basic information
• CPU Unit operation
• Internal memory
• Data management using file memory in the
CPU Unit
• Built-in CPU functions
• Settings
For details on instructions, refer to the
Instructions Reference Manual (W474).
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CJ2 CPU Unit Hardware User’s Manual
The CJ2 CPU manuals are organized in the sections listed in the following tables. Refer to the appropriate section in the manuals as required.
Manual Configuration
Hardware User’s Manual (W472) (This Manual)
Section Content
Section 1 Overview
This section gives an overview of the CJ2 CPU Units and describes the features and
specifications.
Section 2 Basic System Configuration and Devices
This section describes the system configuration for the CJ2 CPU Unit.
Section 3 Nomenclature and
Functions
This section describes the part names and functions of the CPU Unit and Configuration
Units.
Section 4 Support Software
This section describes the types of Support Software to use to perform programming and
debugging and how to connect the PLC to the Support Software.
Section 5 Installation
This section describes the installation locations and how to wire CPU Units and Configuration Units.
Section 6 Troubleshooting
This section describes how to check the status for errors that occur during system operation and the remedies for those errors.
Section 7 Inspection and Maintenance
This section describes periodic inspection, the service lifes of the Battery and Power
Supply Unit, and how to replace the Battery.
Section 8 Backup Operations This section describes the procedure to back up PLC data.
Appendices
The appendices provide Unit dimensions, details on fatal and non-fatal errors, information on connecting to serial ports on the CPU Unit, the procedure for installing the USB
driver on a computer, and information on load short-circuit protection and line disconnection detection.
Software User’s Manual (W473)
Section Content
Section 1 Overview This section gives an overview of the CJ2 CPU Units and describes the features and
specifications.
Section 2 Internal Memory in the
CPU Unit
This section describes the types of memory in the CPU Unit and the data that is stored.
Section 3 CPU Unit Operation This section describes the internal operation of the CPU Unit.
Section 4 CPU Unit Initialization This section describes the initial setup of the CPU Unit.
Section 5 Understanding Program-
ming
This section describes program types and programming details, such as symbols and
programming instructions.
Section 6 I/O Memory Areas This section describes the I/O memory areas in the CPU Unit.
Section 7 File Operations This section describes the files that can be stored in the CPU Unit, the storage destina-
tion for those files, and file operations.
Section 8 I/O Allocations and Unit
Settings
This section describes the I/O allocations used to exchange data between the CPU Unit
and other Units.
Section 9 PLC Setup This section describes details on the PLC Setup settings, which are used to perform
basic settings for the CPU Unit.
Section 10 CPU Unit Functions This section describes functions that are built into the CPU Unit.
Section 11 Programming Devices
and Communications
This section describes the procedure for connecting the CJ2 CPU Unit to the CX-Pro-
grammer or other Support Software and to other devices.
Section 12 CPU Unit Cycle Time This section describes how to monitor and calculate the cycle time.
Appendices The appendices provide information on programming instructions, execution times, num-
ber of steps, Auxiliary Area words and bits, a memory map of the continuous PLC mem-
ory addresses, I/O memory operation when power is interrupted, and a comparison of
CJ-series and CS-series PLCs.
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CJ2 CPU Unit Hardware User’s Manual
Manual Structure
The following page structure is used in this manual.
Special information in this manual is classified as follows:
Page Structure
Special Information
Precautions for Safe Use
Precautions on what to do and what not to do to ensure using the product safely.
Precautions for Correct Use
Precautions on what to do and what not to do to ensure proper operation and performance.
Additional Information
Additional information to increase understanding or make operation easier.
Level 1 heading
Level 2 heading
Level 3 heading
Level 2 heading
A step
in a procedure
Manual name
Level 3 heading
Page tab
Gives the current
headings.
Gives the number
of the section.
This illustration is provided only as a sample and may not literally appear in this manual.
Special Information
(See below.)
5-13
5 Installation
CJ2 CPU Unit Hardware User’s Manual
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5
5-2 Installation
The Units that make up a CJ-series PLC can be connected simply by pressing the Units together and
locking the sliders by moving them toward the back of the Units. The End Cover is connected in the
same way to the Unit on the far right side of the PLC.
1. Join the Units so that the connectors fit exactly.
2. The yellow sliders at the top and bottom of each Unit lock the Units together. Move the sliders
toward the back of the Units as shown below until they click into place.
Precautions for Correct UsePrecautions for Correct Use
If the locking tabs are not secured properly, the connectors may become loose and not function
properly. Be sure to slide the locking tabs until they are securely in place.
5-2-1 Connecting PLC Components
Connector
Hook
Hook holes
Slider
Lock
Release
Move the sliders toward the back
until they lock into place.
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CJ2 CPU Unit Hardware User’s Manual
Sections in this Manual
1
2
3
4
5
6
7
8
A
1
2
3
4
5
6
7
8
A
Overview
Basic System Configuration and Devices
Nomenclature and Functions
Support Software
Installation
Troubleshooting
Inspection and Maintenance
Backup Operations
Appendices
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CJ2 CPU Unit Hardware User’s Manual
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CJ2 CPU Unit Hardware User’s Manual
CONTENTS
Introduction............................................................................................................... 1
CJ2 CPU Unit Manuals ............................................................................................. 2
Manual Structure ...................................................................................................... 4
Sections in this Manual............................................................................................ 5
Safety Precautions ................................................................................................. 15
Application Precautions......................................................................................... 21
Operating Environment Precautions .................................................................... 25
Regulations and Standards ................................................................................... 26
Related Manuals ..................................................................................................... 28
Section 1 Overview
1-1 Overview of CJ2 CPU Units ....................................................................................................1-2
1-1-1 Overview..................................................................................................................................... 1-2
1-1-2 CJ2 CPU Unit Features .............................................................................................................. 1-3
1-2 Basic Operating Procedure ....................................................................................................1-7
1-3 Specifications .......................................................................................................................... 1-8
1-3-1 General Specifications................................................................................................................ 1-8
1-3-2 Performance Specifications ........................................................................................................ 1-9
1-3-3 Function Specifications............................................................................................................. 1-13
Section 2 Basic System Configuration and Devices
2-1 Basic System Configuration...................................................................................................2-2
2-1-1 Basic System Configuration........................................................................................................ 2-2
2-1-2 CPU Rack................................................................................................................................... 2-3
2-1-3 Expansion Racks........................................................................................................................ 2-7
2-1-4 Configuration Units ................................................................................................................... 2-10
2-1-5 Calculating Unit Current Consumption ..................................................................................... 2-18
2-1-6 Calculating Power Consumption............................................................................................... 2-20
2-2 Expanded System Configuration ......................................................................................... 2-22
2-2-1 Serial Communications............................................................................................................. 2-22
2-2-2 Communications Networks....................................................................................................... 2-24
Section 3 Nomenclature and Functions
3-1 CPU Units ................................................................................................................................. 3-2
3-1-1 CPU Section ............................................................................................................................... 3-2
3-1-2 Built-in EtherNet/IP Section ........................................................................................................ 3-7
3-2 Memory Card.......................................................................................................................... 3-12
3-2-1 Models and Specifications........................................................................................................ 3-12
3-2-2 Operating Procedures............................................................................................................... 3-12
3-2-3 Installing and Removing ........................................................................................................... 3-13
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CJ2 CPU Unit Hardware User’s Manual
3-3 Power Supply Units ............................................................................................................... 3-16
3-3-1 Models and Specifications ........................................................................................................3-16
3-3-2 Components..............................................................................................................................3-19
3-3-3 Selecting a Power Supply Unit..................................................................................................3-21
3-4 CJ-series Basic I/O Units ...................................................................................................... 3-23
3-4-1 Basic I/O Units with Terminal Blocks.........................................................................................3-23
3-4-2 Thirty-two/Sixty-four-point Basic I/O Units with Connectors...................................................... 3-25
3-5 I/O Control Units and I/O Interface Units ............................................................................. 3-26
3-5-1 Component Names ...................................................................................................................3-26
3-5-2 System Configuration................................................................................................................3-26
Section 4 Support Software
4-1 Support Software..................................................................................................................... 4-2
4-1-1 CX-One FA Integrated Tool Package ..........................................................................................4-2
4-2 Connection Methods ............................................................................................................... 4-6
4-2-1 Connecting by USB.....................................................................................................................4-6
4-2-2 Connecting by RS-232C ............................................................................................................. 4-8
4-2-3 Connecting by Ethernet ............................................................................................................4-10
Section 5 Installation
5-1 Fail-safe Circuits...................................................................................................................... 5-2
5-2 Installation................................................................................................................................ 5-4
5-2-1 Installation and Wiring Precautions.............................................................................................5-4
5-2-2 Installation in a Control Panel .....................................................................................................5-6
5-2-3 Assembled Appearance and Dimensions ................................................................................... 5-8
5-2-4 Connecting PLC Components................................................................................................... 5-11
5-2-5 DIN Track Installation ................................................................................................................5-14
5-2-6 Connecting CJ-series Expansion Racks................................................................................... 5-16
5-3 Wiring ..................................................................................................................................... 5-19
5-3-1 Power Supply Wiring.................................................................................................................5-19
5-3-2 Wiring CJ-series Basic I/O Units with Terminal Blocks ............................................................. 5-25
5-3-3 Wiring Basic I/O Units with Connectors ....................................................................................5-27
5-3-4 Connecting to Connector-Terminal Block Conversion Units or I/O Relay Terminals .................5-31
5-3-5 Connecting I/O Devices ............................................................................................................5-32
5-3-6 Wiring with Ethernet Cable .......................................................................................................5-36
5-4 Control Panel Installation ..................................................................................................... 5-39
5-4-1 Temperature ..............................................................................................................................5-39
5-4-2 Humidity .................................................................................................................................... 5-41
5-4-3 Vibration and Shock..................................................................................................................5-41
5-4-4 Atmosphere............................................................................................................................... 5-41
5-4-5 Electrical Environment ..............................................................................................................5-42
5-4-6 Grounding .................................................................................................................................5-46
Section 6 Troubleshooting
6-1 CPU Unit Errors ....................................................................................................................... 6-2
6-1-1 Errors and Remedies ..................................................................................................................6-2
6-1-2 Checking Errors ..........................................................................................................................6-2
6-1-3 Checking Detailed Status............................................................................................................6-3
6-1-4 Reading Error Log Information....................................................................................................6-3
6-1-5 I/O Table Verification ...................................................................................................................6-5
6-1-6 Types of Errors ............................................................................................................................6-6
6-1-7 Handling Errors ...........................................................................................................................6-7
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CJ2 CPU Unit Hardware User’s Manual
6-2 Built-in EtherNet/IP Port Errors and Remedies................................................................... 6-23
6-2-1 Checking Built-in EtherNet/IP Port Error Status ....................................................................... 6-23
6-2-2 Checking Error Status at the EtherNet/IP Port Seven-segment Display................................... 6-24
6-3 Non-CPU Unit Errors and Remedies.................................................................................... 6-26
6-3-1 Error Causes and Remedies .................................................................................................... 6-26
Section 7 Inspection and Maintenance
7-1 Inspections............................................................................................................................... 7-2
7-1-1 Inspection Points ........................................................................................................................ 7-2
7-1-2 Unit Replacement Precautions ................................................................................................... 7-4
7-2 Replacing the Battery.............................................................................................................. 7-5
7-2-1 Battery Replacement .................................................................................................................. 7-5
7-2-2 Operation When Battery Is Exhausted or Not Installed .............................................................. 7-8
7-3 Power Supply Unit Replacement Time ................................................................................ 7-10
Section 8 Backup Operations
8-1 Backing Up Data ...................................................................................................................... 8-2
8-2 Using a Computer to Back Up Data ....................................................................................... 8-3
8-2-1 PLC Backup Tool ........................................................................................................................ 8-3
8-2-2 PLC Backup Tool Operations...................................................................................................... 8-4
8-3 Simple Backup......................................................................................................................... 8-7
8-3-1 Overview..................................................................................................................................... 8-7
8-3-2 Operating Procedures................................................................................................................. 8-8
8-3-3 Verifying Backup Operations with Indicators ............................................................................ 8-10
8-3-4 Related Auxiliary Bits/Words .................................................................................................... 8-12
8-3-5 Time Required for Simple Backup............................................................................................8-12
8-3-6 Data Backed Up Using Simple Backup..................................................................................... 8-12
Appendices
A-1 Specifications of Basic I/O Units ...........................................................................................A-2
A-1-1 Overview of Units........................................................................................................................A-2
A-1-2 Basic I/O Units............................................................................................................................A-4
A-1-3 Precautions on Contact Output Units .......................................................................................A-51
A-1-4 Connecting Connector-Terminal Block Conversion Units and I/O Relay Terminals.................. A-53
A-2 Dimensions ............................................................................................................................A-86
A-2-1 CJ2H CPU Units.......................................................................................................................A-86
A-2-2 Power Supply Units................................................................................................................... A-86
A-2-3 Basic I/O Units..........................................................................................................................A-89
A-2-4 I/O Control Unit and I/O Interface Unit......................................................................................A-92
A-2-5 I/O Memory Card ......................................................................................................................A-92
A-3 Fatal and Non-fatal Error Details..........................................................................................A-93
A-3-1 Fatal Errors...............................................................................................................................A-93
A-3-2 Non-fatal Errors ........................................................................................................................ A-98
A-4 Connecting to the RS-232C Serial Port on the CPU Unit .................................................A-101
A-4-1 RS-232C Port Specifications ..................................................................................................A-101
A-4-2 Connection Examples.............................................................................................................A-102
A-4-3 Applicable Connectors and Recommended Cables ...............................................................A-105
A-4-4 Example of Recommended RS-232C Wiring .........................................................................A-106
A-4-5 Wiring Connectors ..................................................................................................................A-107
A-5 Installing the USB Driver ....................................................................................................A-110
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CJ2 CPU Unit Hardware User’s Manual
A-6 Load Short-circuit Protection and Line Disconnection Detection for Basic I/O Units..A-115
A-6-1 Load Short-circuit Protection and Line Disconnection Detection for CJ1W-OD202................A-115
A-6-2 Load Short-circuit Protection for CJ1W-OD204/OD212/OD232/MD232.................................A-117
A-7 Relay Output Noise Reduction Methods ...........................................................................A-119
index................................................................................................................ Index-1
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CJ2 CPU Unit Hardware User’s Manual
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.
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CJ2 CPU Unit Hardware User’s Manual
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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CJ2 CPU Unit Hardware User’s Manual
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.
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CJ2 CPU Unit Hardware User’s Manual
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CJ2 CPU Unit Hardware User’s Manual
Safety Precautions
The following notation is used in this manual to provide precautions required to ensure safe usage of a
CJ-series PLC. The safety precautions that are provided are extremely important to safety. Always read
and heed the information provided in all safety precautions.
Definition of Precautionary Information
WARINING
Indicates an imminently hazardous situation which, if not
avoided, will 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.
Precautions for Safe Use
Indicates precautions on what to do and what not to do to ensure using the product safely.
Precautions for Correct Use
Indicates precautions on what to do and what not to do to ensure proper operation and performance.
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CJ2 CPU Unit Hardware User’s Manual
Symbols
The triangle symbol indicates precautions (including warnings).
The specific operation is shown in the triangle and explained in
text. This example indicates a precaution for electric shock.
The circle and slash symbol indicates operations that you must
not do. The specific operation is shown in the circle and
explained in text. This example indicates “do not disassemble.”
The filled circle symbol indicates operations that you must do.
The specific operation is shown in the circle and explained in
text. This example shows a general precaution for something
that you must do.
The triangle symbol indicates precautions (including warnings).
The specific operation is shown in the triangle and explained in
text. This example indicates a general precaution.
The triangle symbol indicates precautions (including warnings).
The specific operation is shown in the triangle and explained in
text. This example indicates a precaution for hot surfaces.
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CJ2 CPU Unit Hardware User’s Manual
WARNING
Do not attempt to take any Unit apart while the power is being supplied.
Doing so may result in electric shock.
Do not touch any of the terminals or terminal blocks while the power is being
supplied. Doing so may result in electric shock.
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. 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 deposition 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-VDC output (service power supply to the PLC) is overloaded
or short-circuited, 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.
Confirm safety before transferring data files stored in the file memory (Memory Card or EM file memory) to the I/O area (CIO) of the CPU Unit using a
peripheral tool. Otherwise, the devices connected to the output unit may malfunction regardless of the operation mode of the CPU Unit.
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.
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CJ2 CPU Unit Hardware User’s Manual
WARNING
When restoring data, carefully check that the selected data is the correct
data to be restored before executing the restore operation. Depending on the
contents of the selected data, the control system may operate unexpectedly
after the data is restored.
Some Special I/O Units and CPU Bus Units operate with parameters stored
in the CPU Unit (e.g., words allocated in DM Area, data link tables, or Ethernet settings). Information on restrictions will be displayed in the Information
Area in the PLC Backup Tool if there are any restrictions for the selected
CPU Bus Unit or Special I/O Unit. Check the restrictions, and then be sure to
select both the CPU Unit and the CPU Bus Unit or Special I/O Unit when
backing up or restoring data. The control system may operate unexpectedly if
the equipment is started with the data backed up or restored without selecting both Units.
Information on restrictions will be displayed in the Information Area in the
PLC Backup Tool if the data to be stored includes a Unit that has restrictions
on backup. Check the information on restrictions and take the required countermeasures. The control system may operate unexpectedly when the equipment is operated after the data is restored
Before restoring data during PLC operation, be sure that there will be no
problem if PLC operation stops. If the PLC stops at an unexpected time, the
control system may operate unexpectedly.
Be sure to turn the PLC power supply OFF and then back ON after restoring
data. If the power is not reset, the system may not be updated with the
restored data, and the control system may operate unexpectedly.
Data on forced status can be backed up but it cannot be restored. Perform
the procedure to force-set or force-reset bits from the CX-Programmer as
required before starting operation after restoring data that includes forced
status. Depending on the difference in the forced status, the control system
may operate unexpectedly.
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CJ2 CPU Unit Hardware User’s Manual
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.
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.
The CJ2 CPU Units automatically back up the user program and parameter
data to flash memory when these are written to the CPU Unit. I/O memory
including the DM, EM, and Holding Areas), however, is not written to flash
memory.
The DM, EM, and Holding Areas can be held during power interruptions with
a battery. If there is a battery error, the contents of these areas may not be
accurate after a power interruption. If the contents of the DM, EM, and Holding Areas are used to control external outputs, prevent inappropriate outputs
from being made whenever the Battery Error Flag (A402.04) is ON.
Tighten the screws on the terminal block of the AC Power Supply Unit to the
torque specified in the user’s manual. The loose screws may result in burning
or malfunction.
Do not touch the Power Supply Unit when power is being supplied or immediately after the power supply is turned OFF. The Power Supply Unit will be hot
and you may be burned.
Be careful when connecting personal computers or other peripheral devices
to a PLC to which is mounted a non-insulated Unit (CS1W-CLK1@/5@(-V1)
or CS1W-ETN01) connected to an external power supply. A short-circuit will
be created if the 24 V side of the external power supply is grounded and the
0 V side of the peripheral device is grounded. When connecting a peripheral
device to this type of PLC, either ground the 0 V side of the external power
supply or do not ground the external power supply at all.
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CJ2 CPU Unit Hardware User’s Manual
Caution
If a symbol or memory address (only symbols are allowed for ST programming) is specified for the suffix of an array variable in ladder or ST programming, be sure that the specified element number does not exceed the
maximum memory area range. For example, write the program so that processing is executed only when the indirect specification is within the memory
area range by using a symbol comparison instructions or an IF statement.
Specifying an element number that exceeds the maximum range of the
memory area specified for the symbol will result accessing data in a different
memory area, and may result in unexpected operation.
If a symbol or address is specified for an offset in a ladder diagram, program
so that the memory area of the start address is not exceeded when the offset
is specified indirectly using a word address or symbol. For example, write the
program so that processing is executed only when the indirect specification
does not cause the final address to exceed the memory area by using an
input comparison instruction or other instruction.
If a indirect specification causes the address to exceed the area of the start
address, the system will access data in other area, and unexpected operation may occur.
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CJ2 CPU Unit Hardware User’s Manual
Application Precautions
Observe the following precautions when using a CJ-series PLC.
z Power Supply
• Always use the power supply voltages specified in the user’s manuals. An incorrect voltage may
result in malfunction or burning.
• Exceeding the capacity of the Power Supply Unit may prevent the CPU Unit or other Units from
starting.
• 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.
• 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, or any other Units.
• Assembling the Units.
• Setting DIP switches or rotary switches.
• Connecting cables or wiring the system.
• Connecting or disconnecting the connectors.
• When cross-wiring terminals, the total current for all the terminal will flow in the wire. Make sure
that the current capacity of the wire is sufficient.
• Observe the following precautions when using a Power Supply Unit that supports the Replacement Notification Function.
• Replace the Power Supply Unit within six months if the display on the front of the Power Supply Unit alternates between 0.0 and A02, or if the alarm output automatically turns OFF.
• Keep the alarm output cable separated from power line and high-voltage lines.
• Do not apply a voltage or connect a load exceeding the specifications to the alarm output.
• Whe storing the Power Supply Unit for more than three months, store it at −20 to 30°C and
25% to 70% humidity to preserve the Replacement Notification Function.
• If the Power Supply Unit is not installed properly, heat buildup may cause the replacement notification signal to appear at the wrong time or may cause interior elements to deteriorate or
become damaged. Use only the standard installation method.
• Do not touch the terminals on the Power Supply Unit immediately after turning OFF the power
supply. Residual voltage may cause electrical shock.
• Observe the following precautions to prevent failure due to difference in electrical potential if the
computer is connected to the PLC.
• Before connecting a laptop computer to the PLC, disconnect the power supply plug of the
computer from the AC outlet. Residual current in the AC adaptor may cause difference in electrical potential to occur between the computer and the PLC. After you connect the computer
and PLC, supply the power again from the AC adaptor.
• If the computer has a FG terminal, make the connections so that it has the same electrical
potential as the FG (GR) terminal on the PLC.
• If the computer is grounded to a separate location, difference in electrical potential may occur
depending on the grounding conditions.
z Installation
• Do not install the PLC near sources of strong high-frequency noise.
• 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.
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CJ2 CPU Unit Hardware User’s Manual
• Be sure that the connectors, terminal blocks, expansion cables, and other items with locking
devices are properly locked into place. Improper locking may result in malfunction.
• The sliders on the tops and bottoms of the Power Supply Unit, CPU Unit, I/O Units, Special I/O
Units, and CPU Bus Units must be completely locked (until they click into place) after connecting
to adjacent Units. The Unit may not operate properly if the sliders are not locked in place. It may
not be possible to achieve proper functionality if the sliders are not locked.
• Always attach the End Cover that comes with the CPU Unit to the right end of the CPU Rack. The
PLC will not operate correctly if the End Cover is not attached.
z Wiring
• Wire all connections correctly.
• Double-check all wiring and switch settings before turning ON the power supply. Incorrect wiring
may result in burning.
• Be sure that all terminal screws, and cable connector screws are tightened to the torque specified
in the relevant manuals. Incorrect tightening torque may result in malfunction.
• Do not apply a force exceeding 100 N to the terminal block when tightening it.
• Mount Units only after checking terminal blocks and connectors completely.
• 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.
• Do not apply voltages to the Input Units in excess of the rated input voltage. Excess voltages may
result in burning.
• Always connect to a ground of 100 Ω or less when installing the Units. Not connecting to a ground
of 100 Ω or less may result in electric shock.
• A ground of 100 Ω or less must be installed when shorting the GR and LG terminals on the Power
Supply Unit.
• 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.
• 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.
• 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.
• Do not use commercially available RS-232C personal computer cables. Always use the special
cables listed in this manual or make cables according to manual specifications. Using commercially available cables may damage the external devices or CPU Unit.
• Never connect pin 6 (5-V power supply) on the RS-232C port on the CPU Unit to any device other
than an NT-AL001 or CJ1W-CIF11 Adapter. The external device or the CPU Unit may be damaged.
z Handling
• The Power Supply Unit may possibly be damaged if the entire voltage for a dielectric strength test
is applied or shut OFF suddenly using a switch. Use a variable resistor to gradually increase and
decrease the voltage.
• Separate the line ground terminal (LG) from the functional ground terminal (GR) on the Power
Supply Unit before performing withstand voltage tests or insulation resistance tests. Not doing so
may result in burning.
• Make sure that the DIP switches and DM Area are set correctly before starting operation.
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CJ2 CPU Unit Hardware User’s Manual
• Make sure that the required data for the DM Area, Holding Area, and other memory areas has
been transferred to a CPU Unit that has been replaced before restarting 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 (including the setting of the startup operating mode).
• Force-setting/force-resetting any bit in memory.
• Changing the present value of any word or any set value in memory.
• Do not attempt to disassemble, repair, or modify any Units. Any attempt to do so may result in malfunction, fire, or electric shock.
• Do not drop the PLC or subject abnormal vibration or shock to it.
• 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.
• When transporting or storing Units or Board, static electricity can destroy LSIs or ICs. Cover the
PCBs with a conductive material and maintain the specified storage temperature.
• 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.
• The life of the battery will be reduced if a CPU Unit is left for a period of time without a battery
installed and without power supply, and then a battery is installed without turning ON the power
supply.
• Before replacing the battery, turn ON power for at least 5 minutes before starting the replacement
procedure and complete replacing the battery within 5 minutes of turning OFF the power supply.
Memory contents may be corrupted if this precaution is not obeyed.
• If the Battery Error Flag is used in programming the application, confirm system safety even if the
system detects a battery error before you replace the battery while the power is ON.
• Do not short the battery terminals or charge, disassemble, heat, or incinerate the battery. Do not
subject the battery to strong shocks. Doing any of these may result in leakage, rupture, heat generation, or ignition of the battery. Dispose of any battery that has been dropped on the floor or otherwise subjected to excessive shock. Batteries that have been subjected to shock may leak if they
are used.
• UL standards require that only an experienced engineer can replace the battery.
Make sure that an experienced engineer is in charge of battery replacement. Follow
the procedure for battery replacement given in this manual.
• Unexpected operation may result if inappropriate data link tables or parameters are set. Even if
appropriate data link tables and parameters have been set, confirm that the controlled system will
not be adversely affected before starting or stopping data links.
• CPU Bus Units will be restarted when routing tables are transferred from a Programming Device
to the CPU Unit. Restarting these Units is required to read and enable the new routing tables.
Confirm that the system will not be adversely affected before allowing the CPU Bus Units to be
reset.
• When creating an AUTOEXEC.IOM file from a Programming Device (a Programming Console
or the CX-Programmer) to automatically transfer data at startup, set the first write address to
D20000 and be sure that the size of data written does not exceed the size of the DM Area.
When the data file is read from the Memory Card at startup, data will be written in the CPU
Unit starting at D20000 even if another address was set when the AUTOEXEC.IOM file was
created. Also, if the DM Area is exceeded (which is possible when the CX-Programmer is
used), the remaining data will be written to the EM Area.
• A battery is mounted to a CJ-series CPU Unit when the Unit is shipped from the factory. Also, the
time is set on the internal clock. It is thus not necessary to clear memory and set the clock before
using a CJ-series CPU Unit. This point differs from the CS-series CS1 CPU Units.
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CJ2 CPU Unit Hardware User’s Manual
• The user program and parameter area data in the CJ2 CPU Units are backed up in the built-in
flash memory. The BKUP indicator will light on the front of the CPU Unit when the backup operation is in progress. Do not turn OFF the power supply to the CPU Unit when the BKUP indicator is
lit. The data will not be backed up if power is turned OFF.
• Check the user program and Unit parameter settings for proper execution before actually running
them on the Unit. Not checking the program and parameter settings may result in an unexpected
operation.
• When setting a Special I/O Unit or CPU Bus Unit in the I/O tables, carefully check the safety of the
devices at the connection target before restarting the Unit.
• A CS1 or CJ1 CPU Unit program file (.OBJ) cannot be transferred directly to a CJ2 CPU Unit
using a Memory Card. It must first be converted for use with a CJ2 CPU Unit using the CX-Programmer.
z External Circuits
• Interlock circuits, limit circuits, and similar safety measures in external circuits (i.e., not in the Programmable Controller) must be provided by the customer.
• Always turn ON power to the PLC before turning ON power to the control system. If the PLC
power supply is turned ON after the control power supply, temporary errors may result in control
system signals because the output terminals on DC Output Units and other Units will momentarily
turn ON when power is turned ON to the PLC.
• Fail-safe measures must be taken by the customer to ensure safety in the event that outputs from
Output Units remain ON as a result of internal circuit failures, which can occur in relays, transistors, and other elements.
• If the I/O 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(007) instruction,
all outputs from Output Unit will be turned OFF and only the internal output status will be maintained.)
• Install external breakers and take other safety measures against short-circuiting in external wiring.
Insufficient safety measures against short-circuiting may result in burning.
• Dispose of the product and batteries according to local ordinances as they apply.
• Do not turn OFF the power supply to the PLC when reading or writing a Memory Card. Also, do
not remove the Memory Card when the BUSY indicator is lit. Doing so may make the Memory
Card unusable.
• To remove a Memory Card, first press the memory card power supply switch and then wait for the
BUSY indicator to go out before removing the Memory Card.
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