Omron CS1D Duplex System OPERATION MANUAL

Cat. No. W405-E1-09

SYSMAC CS Series

CS1D-CPU_H CPU Units
CS1D-CPU_S CPU Units
CS1D-DPL01/02D Duplex Unit
CS1D-PA/PD_ Power Supply Unit

CS1D Duplex System

OPERATION MANUAL

CS1D-CPU@@H CPU Units
CS1D-CPU@@S CPU Units

CS1D-DPL01/02D Duplex Unit

CS1D-PA/PD@@@ Power Supply Unit

CS1D Duplex System

Operation Manual

Revised October 2009

iv

Notice:

r
f

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

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

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

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

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

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

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

moderate injury, or property damage.

OMRON Product References

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

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

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

Visual Aids

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

 OMRON, 2002

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

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

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

tion of the product.

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

v

Unit Versions of CS/CJ-series CPU Units

Unit Versions A “unit version” has been introduced to manage CPU Units in the CS/CJ

Series according to differences in functionality accompanying Unit upgrades.
This applies to the CS1-H, CJ1-H, CJ1M, and CS1D CPU Units.

Notation of Unit Versions
on Products

CS/CJ-series CPU Unit

The unit version is given to the right of the lot number on the nameplate of the
products for which unit versions are being managed, as shown below.

Product nameplate

CS1H-CPU67H

CPU UNIT

Lot No.

Lot No. 031001 0000 Ver.2.0

OMRON Corporation MADE IN JAPAN

Unit version
Example for Unit version 2.0

• CS1-H, CJ1-H, and CJ1M CPU Units (except for low-end models) manu­factured on or before November 4, 2003 do not have a unit version given
on the CPU Unit (i.e., the location for the unit version shown above is
blank).

• The unit version of the CS1-H, CJ1-H, and CJ1M CPU Units, as well as
the CS1D CPU Units for Single CPU Systems, begins at version 2.0.

• The unit version of the CS1D CPU Units for Duplex CPU Systems, begins
at version 1.1.

• CPU Units for which a unit version is not given are called Pre-Ver. @.@
CPU Units, such as Pre-Ver. 2.0 CPU Units and Pre-Ver. 1.1 CPU Units.

Confirming Unit Versions
with Support Software

CX-Programmer version 4.0 or later can be used to confirm the unit version
using one of the following two methods.

• Using the PLC Information

• Using the Unit Manufacturing Information (This method can be used for
Special I/O Units and CPU Bus Units as well.)

Note CX-Programmer version 3.3 or lower cannot be used to confirm unit versions.

PLC Information

• If you know the device type and CPU type, select them in the Change
PLC Dialog Box, go online, and select PLC - Edit - Information from the

menus.

• If you don’t know the device type and CPU type, but are connected
directly to the CPU Unit on a serial line, select PLC - Auto Online to go
online, and then select PLC - Edit - Information from the menus.

In either case, the following PLC Information Dialog Box will be displayed.

vi

Unit version

Use the above display to confirm the unit version of the CPU Unit.

Unit Manufacturing Information

In the IO Table Window, right-click and select Unit Manufacturing informa-
tion - CPU Unit.

The following Unit Manufacturing information Dialog Box will be displayed.

Unit version

Use the above display to confirm the unit version of the CPU Unit connected
online.

vii

Using the Unit Version
Labels

The following unit version labels are provided with the CPU Unit.

Ver.

2.0

Ver.

2.0

These Labels can be
used to manage
differences in the
available functions
among the Units.
Place the appropriate
label on the front of
the Unit to show what
Unit version is
actually being used.

Ver.

Ver.

These labels can be attached to the front of previous CPU Units to differenti­ate between CPU Units of different unit versions.

Unit Version Notation In this manual, the unit version of a CPU Unit is given as shown in the follow-

ing table.

Product nameplate

CPU Units on which no unit version is given Units on which a version is given

(Ver. @.@)

Lot No. XXXXXX XXXX

OMRON Corporation MADE IN JAPAN

Lot No. XXXXXX XXXX

OMRON Corporation MADE IN JAPAN

Meaning

Designating individual CPU

Pre-Ver. 2.0 CS1-H CPU Units CS1H-CPU67H CPU Unit Ver. @.@

Units (e.g., the CS1H­CPU67H)

Designating groups of CPU

Pre-Ver. 2.0 CS1-H CPU Units CS1-H CPU Units Ver. @.@

Units (e.g., the CS1-H CPU
Units)

Designating an entire series

Pre-Ver. 2.0 CS-series CPU Units CS-series CPU Units Ver. @.@

of CPU Units (e.g., the CS­series CPU Units)

System Configuration Support by Unit Version

System configuration CS1D-CPU@@H/P CS1D-CPU@@S

Pre-Ver. 1.1 Ver. 1.1 Ver. 1.2 Ver. 1. 3 Ver. 2.0

Duplex CPU, Dual I/O Expansion System --- --- --- OK --­Duplex CPU, Single I/O Expansion System OK OK OK OK --­Single CPU System --- --- --- --- OK

Note 1. OK: Supported, ---: Not supported

Ver.

.





viii

2. Only CS1D-CPU@@H/P CPU Units with unit version 1.3 support the Du-

plex CPU, Dual I/O Expansion System. If a Dual I/O Expansion System is
connected to a CPU Unit with an earlier unit version, an I/O bus error will
occur and the PLC will not operate.

Function Support by Unit Version

CS1D CPU Units

Function CS1D-CPU@@H CS1D-CPU@@S

Duplex CPU, Single I/O Expansion

System

Pre-Ver.

1.1

Functions
unique to
CS1D CPU
Units

Downloading and Uploading Individual
Tasks

Improved Read Protection Using Pass­words

Write Protection from FINS Commands
Sent to CPU Units via Networks

Online Network Connections without I/O
Ta bl e s

Communications through a Maximum of 8
Network Levels

Connecting Online to PLCs via NS-series
PTs

Setting First Slot Words --- --- --- --- --- OK for up to 64

Automatic Transfers at Power ON without a
Parameter File

Automatic Detection of I/O Allocation
Method for Automatic Transfer at Power ON

Operation Start/End Times --- OK OK OK OK OK
Automatic Allocation of Communications

Por ts

Duplex CPU Units OK OK OK OK OK --­Online Unit Replacement

using a Programming Device
Duplex Power Supply Units OK OK OK OK OK OK
Duplex Controller Link Units OK OK OK OK OK OK
Duplex Ethernet Units --- OK OK OK OK OK
Unit Removal without a Pro-

gramming Device
Removal/Addition of Units

without a Programming
Device (See note 2.)

Duplex Connecting Cables --- --- --- --- OK --­Online Addition of Units and

Backplanes

Online Addition of Duplex Unit --- --- --- --- OK OK

OK OK OK OK OK OK

--- --- OK OK OK ---

--- --- --- --- OK (See note 2.) ---

--- --- --- OK

--- --- --- --- --- OK

--- --- --- --- --- OK

--- --- --- --- --- OK

--- --- --- --- --- OK

--- --- --- --- --- OK

--- --- --- --- --- OK

--- --- --- --- --- OK

--- --- --- --- --- ---

--- --- --- OK OK OK

Ver. 1.1 Ver. 1. 2 Ver. 1. 3 Ver. 1.3 Ver. 2.0

(See
notes 3
and 4.)

Duplex CPU,

Dual I/O Expan-

sion System

OK (See note 3.) ---

groups

CS1D CPU Units

for Single CPU

Systems

ix

New Appli­cation
Instruc­tions

Function CS1D-CPU@@H CS1D-CPU@@S

Duplex CPU, Single I/O Expansion

Pre-Ver.

1.1

MILH, MILR, MILC --- --- --- --- --- OK
=DT, <>DT, <DT, <=DT, >DT,

>=DT
BCMP2 --- --- --- --- --- OK
GRY --- --- --- --- --- OK
TPO --- --- --- --- --- OK
DSW, TKY, HKY, MTR, 7SEG --- --- --- --- --- OK
EXPLT, EGATR, ESATR,

ECHRD, ECHWR
Reading/Writing CPU Bus

Units with IORD/IOWR
Instructions

--- --- --- --- --- OK

--- --- --- --- --- OK

--- --- --- --- --- OK

System

Ver. 1.1 Ver. 1.2 Ver. 1.3 Ver. 1.3 Ver. 2.0

Duplex CPU,

Dual I/O Expan-

sion System

CS1D CPU Units

for Single CPU

Systems

Note 1. OK: Supported, ---: Not supported

2. The Removal/Addition of Units without a Programming Device function is
supported only by CS1D CPU Units with unit version 1.3 or later and a Du­plex CPU, Dual I/O Expansion System.
If the Removal/Addition of Units without a Programming Device function is
selected in a Duplex CPU, Single I/O Expansion System, the function will
operate as the earlier Unit Removal without a Programming Device func-
tion.

3. Basic I/O Units and Special I/O Units can be added for the Online Addition
of Units and Backplanes function. CPU Units cannot be added.

4. Expansion Backplanes cannot be added with a Duplex CPU, Single I/O Ex­pansion System.

Unit Versions and Programming Devices

CX-Programmer version 7.0 or higher is required to use the functions added
to the CS1D-CPU@@H CPU Units in unit version 1.3 (Duplex CPU Systems).
CX-Programmer version 4.0 or higher is required to use the functions added
to the CS1D-CPU@@S CPU Units in unit version 2.0 (Single CPU Systems).
The following tables show the relationship between unit versions and CX-Pro­grammer versions.

x

Unit Versions and Programming Devices

CPU Unit Functions CX-Programmer Program-

CJ1M CPU Units,
low-end models, Unit
Ver. 2.0

CS1-H, CJ1-H, and
CJ1M CPU Units
except low-end
models, Unit Ver. 2.0

CS1D CPU Units for
Single CPU Systems,
Unit Ver. 2.0

CS1D CPU Units for
Duplex CPU
Systems, Unit Ver.1

CS1D Duplex CPU
Unit Ver. 1.2

CS1D Duplex CPU
Unit Ver. 1.3

Functions
added for unit
version 2.0

Functions
added for unit
version 2.0

Functions
added for unit
version 2.0

Functions
added for unit
version 1.1

Functions
upgraded in
Unit Ver. 1.2

Functions
upgraded in
Unit Ver. 1.3

Ver. 3.2

or

lower

Using new functions --- --- OK OK OK No
Not using new functions --- OK OK OK OK

Using new functions --- --- OK OK OK
Not using new functions OK OK OK OK OK

Using new functions --- --- OK OK OK
Not using new functions

Using new functions --- --- OK OK OK
Not using new functions OK OK OK OK OK

Using new functions --- --- --- OK OK
Not using new functions OK OK OK OK OK

Using new functions --- --- --- --- OK

Not using new functions OK OK OK OK OK

Ver.

3.3

Ver. 4. 0

to

Ver. 6.0

Ver.6.1 Ver.7.0

(See
note.)

ming

Console

restrictions

Online
addition of
Units is not
supported.

Note With CX-Programmer version 7.0, the auto update function can be used to

expand the Unit’s functions.

Device Type Setting The unit version does not affect the setting made for the device type on the

CX-Programmer. Select the device type as shown in the following table
regardless of the unit version of the CPU Unit.

Series CPU Unit group CPU Unit model Device type setting on

CX-Programmer Ver. 4.0 or higher

CS Series CS1-H CPU Units CS1G-CPU@@H CS1G-H

CS1H-CPU@@H CS1H-H
CS1D CPU Units for Duplex CPU Systems CS1D-CPU@@H CS1D-H (or CS1H-H)
CS1D CPU Units for Single CPU Systems CS1D-CPU@@S CS1D-S

CJ Series CJ1-H CPU Units CJ1G-CPU@@H CJ1G-H

CJ1H-CPU@@H CJ1H-H
CJ1M CPU Units CJ1M-CPU@@ CJ1M

xi

Troubleshooting Problems with Unit Versions on the CX-Programmer

Problem Cause Solution

After the above message is displayed, a compiling
error will be displayed on the Compile Tab Page in the
Output Window.

“????” is displayed in a program transferred from the
PLC to the CX-Programmer.

An attempt was made using CX­Programmer version 4.0 or higher
to download a program contain­ing instructions supported only by
CPU Units Ver. 2.0 or later to a
Pre-Ver. 2.0 CPU Units.

An attempt was made using CX­Programmer version 4.0 or higher
to download a PLC Setup con­taining settings supported only by
CPU Units Ver. 2.0 or later (i.e.,
not set to their default values) to a
Pre-Ver. 2.0 CPU Units.

CX-Programmer version 3.3 or
lower was used to upload a pro­gram containing instructions sup­ported only by CPU Units Ver. 2.0
or later from a CPU Unit Ver. 2.0
or later.

Check the program or change
the CPU Unit being down­loaded to a CPU Unit Ver. 2.0
or later.

Check the settings in the PLC
Setup or change the CPU Unit
being downloaded to a CPU
Unit Ver. 2.0 or later.

The new instructions cannot
be uploaded using CX-Pro­grammer version 3.3 or lower.
Use CX-Programmer version

4.0 or higher.

xii

TABLE OF CONTENTS

PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxiii

1 Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxiv

2 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxiv

3 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxiv

4 Operating Environment Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxvi

5 Application Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxvii

6 Conformance to EC Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxxiii

SECTION 1

Features and System Configuration . . . . . . . . . . . . . . . . . . . 1

1-1 CS1D Duplex System Overview and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1-2 System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SECTION 2

Specifications, Nomenclature, and Functions . . . . . . . . . . . 15

2-1 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2-2 Configuration Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2-3 Duplex Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

2-4 CPU Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

2-5 File Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

2-6 Programming Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

2-7 Power Supply Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

2-8 Backplanes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

2-9 Units for Duplex CPU, Dual I/O Expansion Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

2-10 Units on CS1D Long-distance Expansion Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

2-11 Basic I/O Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

2-12 Unit Current Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104

2-13 CPU Bus Unit Setting Area Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

2-14 I/O Table Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

SECTION 3

Duplex Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

3-1 Duplex CPU Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

3-2 Duplex Power Supply Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

3-3 Duplex Communications Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

3-4 Duplex Connecting Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

SECTION 4

Operating Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

4-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

4-2 Basic Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

xiii

TABLE OF CONTENTS

SECTION 5

Installation and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

5-1 Fail-safe Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

5-2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

5-3 Power Supply Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

5-4 Wiring Methods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

SECTION 6

PLC Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

6-1 Overview of PLC Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188

6-2 Specific PLC Setup Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191

SECTION 7

I/O Allocations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

7-1 I/O Allocations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

7-2 I/O Allocation Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

7-3 Allocating First Words to Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

7-4 Allocating First Words to Slots (Single CPU Systems Only) . . . . . . . . . . . . . . . . . . . . . . . . 237

7-5 Detailed Information on I/O Table Creation Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

7-6 Data Exchange with CPU Bus Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

7-7 Online Addition of Units and Backplanes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

SECTION 8

Memory Areas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

8-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252

8-2 I/O Memory Areas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

8-3 I/O Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

8-4 CS-series DeviceNet Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .266

8-5 Data Link Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

8-6 CPU Bus Unit Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

8-7 Inner Board Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

8-8 Special I/O Unit Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

8-9 Work Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272

8-10 Holding Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

8-11 Auxiliary Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

8-12 TR (Temporary Relay) Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304

8-13 Timer Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

8-14 Counter Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

8-15 Data Memory (DM) Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

8-16 Extended Data Memory (EM) Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310

8-17 Index Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

8-18 Data Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317

xiv

TABLE OF CONTENTS

8-19 Task Flags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318

8-20 Condition Flags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319

8-21 Clock Pulses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322

8-22 Parameter Areas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323

SECTION 9

CPU Unit Operation and the Cycle Time. . . . . . . . . . . . . . . 327

9-1 CPU Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329

9-2 CPU Unit Operating Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336

9-3 Power OFF Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338

9-4 Computing the Cycle Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342

9-5 Instruction Execution Times and Number of Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358

SECTION 10

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387

10-1 Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388

10-2 Error Processing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389

10-3 Troubleshooting Racks and Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416

10-4 Troubleshooting Errors in Duplex Connecting Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419

SECTION 11

Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 423

11-1 Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424

11-2 Replacing User-serviceable Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426

11-3 Replacing a CPU Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432

11-4 Online Replacement of I/O Units, Special I/O Units, and CPU Bus Units . . . . . . . . . . . . . . 435

11-5 Replacing Power Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455

11-6 Replacement of Expansion Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455

11-7 Replacing the Duplex Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .457

Appendices

A Specifications of Basic I/O Units and High-density I/O Units . . . . . . . . . . . . . . . . . . . . . . . 461

B Auxiliary Area Allocations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501

C Memory Map of PLC Memory Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549

D PLC Setup Coding Sheets for Programming Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 551

E Precautions in Replacing CS1-H PLCs with CS1D PLCs . . . . . . . . . . . . . . . . . . . . . . . . . . 565

F Connecting to the RS-232C Port on the CPU Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 573

G CJ1W-CIF11 RS-422A Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583

Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 589

Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597

xv

TABLE OF CONTENTS

xvi

About this Manual:

This manual describes the installation and operation of the CS1D Duplex Programmable Controllers
(PLCs) and includes the sections described below. The CS Series and CJ Series are subdivided as
shown in the following table.

Unit CS Series CJ Series

CPU Units CS1-H CPU Units: CS1H-CPU@@H

CS1 CPU Units: CS1H-CPU@@-EV1

CS1D CPU Units: CS1D-CPU@@H

CS1D Process-control CPU Units:

Basic I/O Units CS-series Basic I/O Units CJ-series Basic I/O Units
Special I/O Units CS-series Special I/O Units CJ-series Special I/O Units
CPU Bus Units CS-series CPU Bus Units CJ-series CPU Bus Units
Power Supply Units CS-series Power Supply Units

CS1D Power Supply Units

Please read this manual and all related manuals listed in the table on the next page and be sure you
understand information provided before attempting to install or use CS1D-CPU@@H/S CPU Units in a
PLC System.

Process-control CPU Units refer to CPU Units with the models CS1D-CPU@@P. Each Process-control
CPU Unit consists of a CS1D-CPU@@H CS1D CPU Unit and a CS1D-LCB05D Loop Control Board as
a set.

Precautions provides general precautions for using the CS1D Programmable Controllers (PLCs) and
related devices, including the CS1D-CPU@@H CPU Units for Duplex CPU Systems, CS1D-CPU@@S
CPU Units for Single CPU Systems, CS1D-DPL01 Duplex Unit, and CS1D-PA/PD@@@ Power Supply
Unit.

Section 1 introduces the special features and functions of the CS1D Duplex PLCs and describes the
differences between these PLCs and other PLCs.

Section 2 provides the specifications, defines the nomenclature, and describes the functions of CS1D
PLCs.

Section 3 describes the basic operation of a Duplex System.
Section 4 outlines the steps required to assemble and operate a CS1D Duplex PLC system.
Section 5 describes how to install a PLC System, including mounting the various Units and wiring the

System. Be sure to follow the instructions carefully. Improper installation can cause the PLC to mal­function, resulting in very dangerous situations.

Section 6 describes the settings in the PLC Setup and how they are used to control CPU Unit opera­tion.

Section 7 describes I/O allocations to Basic I/O Units, Special I/O Units, and CPU Bus Units, and data
exchange with Units.

Section 8 describes the structure and functions of the I/O Memory Areas and Parameter Areas.
Section 9 describes the internal operation of the CPU Unit and the cycle used to perform internal pro-

cessing.

Section 10 provides information on hardware and software errors that occur during PLC operation.
Section 11 provides inspection and maintenance information.

The Appendices provide Unit specifications, Auxiliary Area words and bits, a memory map of internal
addresses, and PLC Setup coding sheets, RS-232C port connection information, and precautions
when upgrading a system to duplex operation with CS1D PLCs

CS1G-CPU@@H

CS1G-CPU@@-EV1

CS1D-CPU@@S

CS1D-CPU@@P

CJ1-H CPU Units: CJ1H-CPU@@H

CJ1G-CPU@@H

CJ1-H Loop-control CPU Units:

CJ1G-CPU@@H

CJ1 CPU Units: CJ1G-CPU@@-EV1

CJ1M CPU Units: CJ1M-CPU@@

CJ-series Power Supply Units

xvii

About this Manual, Continued

Name Cat. No. Contents

SYSMAC CS Series
CS1D-CPU@@H CPU Units
CS1D-CPU@@S CPU Units
CS1D-DPL01/02D Duplex Unit
CS1D-PA/PD@@@ Power Supply Unit
Duplex System Operation Manual

SYSMAC CS/CJ/NSJ Series
CS1G/H-CPU@@-EV1, CS1G/H-CPU@@H,
CS1D-CPU@@H, CS1D-CPU@@S, CJ1G-CPU@@,
CJ1M-CPU@@, CJ1G-CPU@@P, CJ1G/H-CPU@@H,
NSJ@-@@@@(B)-G5D, NSJ@-@@@@(B)-M3D
Programmable Controllers Programming Manual

SYSMAC CS/CJ/NSJ Series
CS1G/H-CPU@@-EV1, CS1G/H-CPU@@H,
CS1D-CPU@@H, CS1D-CPU@@S, CJ1G-CPU@@,
CJ1M-CPU@@, CJ1G-CPU@@P, CJ1G/H-CPU@@H,
NSJ@-@@@@(B)-G5D, NSJ@-@@@@(B)-M3D
Programmable Controllers Instructions Reference Manual

SYSMAC CS/CJ Series
CQM1H-PRO01-E, C200H-PRO27-E, CQM1-PRO01-E
Programming Consoles Operation Manual

SYSMAC CS/CJ/CP/NSJ Series
CS1G/H-CPU@@-EV1, CS1G/H-CPU@@H, CS1D-CPU@@H,
CS1D-CPU@@S, CJ1G-CPU@@, CJ1M-CPU@@, CJ1G­CPU@@P, C J1 G/ H- CP U@@H, CS1W-SCU@@-V1, CS1W­SCB@@-V1, CJ1W-SCU@@-V1, CP1H-X@@@@-@, CP1H­XA@@@@-@, CP1H-Y@@@@-@,
NSJ@-@@@@(B)-G5D, NSJ@-@@@@(B)-M3D
Communications Commands Reference Manual

SYSMAC
WS02-CXPC1-E-V70
CX-Programmer Ver. 7.0 Operation Manual

SYSMAC CX-Programmer Ver. 7.0
WS02-CXPC1-E-V7, CS1-H, CJ1-H, CJ1M, CP1H CPU Units,
NSJ, FQM1
Operation Manual: Function Blocks

SYSMAC WS02-PSTC1-E
CX-Protocol Operation Manual

SYSMAC CS/CJ Series Loop Control Boards/Process-control
CPU Units/Loop-control CPU Units
CS1W-LCB01/LCB05, CS1D-CPU@@P, CJ1G-CPU42P,
CJ1G-CPU43P/44P/45P
Operation Manual

CS1D-ETN21D
Ethernet Unit Operation Manual

W405 Provides an outline of and describes the design,

installation, maintenance, and other basic operations
for a Duplex System based on CS1D CPU Units.
(This manual)

W394 This manual describes programming and other meth-

ods to use the functions of the CS/CJ-series PLCs
and NSJ Controllers.

W340 Describes the ladder diagram programming instruc-

tions supported by CS/CJ-series PLCs and NSJ Con­trollers.

W341 Provides information on how to program and operate

CS/CJ-series PLCs using a Programming Console.

W342 Describes the communications commands used with

CS-series, CJ-series, and CP-series PLCs and NSJ
Controllers.

W446 Describes operating procedures for the CX-Program-

mer Support Software running on a Windows com­puter.

W447 Describes specifications and procedures required to

use function blocks.

W344 Describes the use of the CX-Protocol to create proto-

col macros as communications sequences to com­municate with external devices.

W406 Provides information on how to operate CS1 Loop

Control Boards, including descriptions of the installa­tion, maintenance, and other basic operations.

W430 Provides information on how to operateCS1D Ether-

net Units, including descriptions of the installation,
maintenance, and other basic operations.

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

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

xviii

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.

xix

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.

xx

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.

xxi

xxii

PRECAUTIONS

This section provides general precautions for using the CS1D Programmable Controllers (PLCs) and related devices,
including the CS1D-CPU@@H CPU Units for Duplex CPU Systems, CS1D-CPU@@S CPU Units for Single CPU
Systems, CS1D-DPL01 Duplex Unit, and CS1D-PA/PD@@@ Power Supply Unit.

The information contained in this section is important for the safe and reliable application of Programmable
Controllers. You must read this section and understand the information contained before attempting to set up or
operate a PLC system.

1 Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxiv

2 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxiv

3 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxiv

4 Operating Environment Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxvi

5 Application Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxvii

6 Conformance to EC Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxxiii

6-1 Applicable Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxxiii

6-2 Concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxxiii

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

6-4 Relay Output Noise Reduction Methods . . . . . . . . . . . . . . . . . . . . . xxxiv

xxiii

Intended Audience 1

1 Intended Audience

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

• Personnel in charge of installing FA systems.

• Personnel in charge of designing FA systems.

• Personnel in charge of managing FA systems and facilities.

2 General Precautions

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

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

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

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

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

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

3 Safety Precautions

!WARNING 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 to the CPU Unit from a Programming
Device.

• Changing present values in memory from a Programming Device.

• Force-setting/-resetting bits from 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.

xxiv

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

so may result in electric shock.

Safety Precautions 3

!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.

!WARNING Do not touch the Power Supply Unit while power is being supplied or immedi-

ately after power has been turned OFF. Doing so may result in electric shock.

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

Controller), including the following items, to ensure safety in the system if an
abnormality occurs due to malfunction of the PLC or another external factor
affecting the PLC operation. Not doing so may result in serious accidents.

With a CS1D System operating in Duplex Mode, operation will be stopped
and all outputs will be turned OFF in the following circumstances.

• When self-diagnosis simultaneously detects an error in both the active
and standby CPU Units.

• When a severe failure alarm (FALS) instruction is simultaneously exe­cuted in both the active and standby CPU Units.

• When self-diagnosis detects an error in Simplex Mode or when it detects
an error during duplex initialization for Duplex Mode.

• When a severe failure alarm (FALS) instruction is executed in Simplex
Mode or during duplex initialization for Duplex Mode.

Unexpected operation, however, may still occur for errors in the I/O control
section, errors in I/O memory, and other errors that cannot be detected by the
self-diagnosis function. As a countermeasure for all such errors, external
safety measures must be provided to ensure safety in the system.

!WARNING 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.

!WARNING When the 24-V DC 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.

!Caution Confirm safety before transferring data files stored in the file memory (Mem-

ory 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.

!Caution 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.

xxv

Operating Environment Precautions 4

!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 The CS1D 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 HR Areas), however, is not written to flash mem­ory. The DM, EM, and HR 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 HR
Areas are used to control external outputs, prevent inappropriate outputs from
being made whenever the Battery Error Flag (A40204) is ON.

!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. The loose screws may result in
burning or malfunction.

!Caution Caution is required when connecting peripheral devices, such as a personal

computer, to the PLC when Units with non-isolated power supplies, such as
the CS1W-CLK12/CLK52(-V1), that are connected to an external power sup­ply are mounted to the PLC. If the 24-V side is grounded on the external
power supply, a short will be created if the 0-V side of the peripheral device is
grounded. When connecting peripheral devices, either ground the 0-V side of
the external power supply or do not ground the external power supply at all.

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.

xxvi

!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.

Application Precautions 5

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

longevity and reliability of the system. Improper operating environments can
lead to malfunction, failure, and other unforeseeable problems with the PLC
System. 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.

5 Application Precautions

Observe the following precautions when using the PLC System.

• Do not use the C200H/CS-series Power Supply Units (C200H-P@@@@)
in a CS1D PLC. System operation will not be dependable and may stop.

• Do not use a CS1D Power Supply Unit (CS1D-PA/PD@@@) for any PLC
other than a CS1D PLC. Operational errors and burning will result.

• If duplex Power Supply Units are to be used, calculate the current con­sumption so that the system will be able to operate with a single Power
Supply Unit in case an error occurs in the other Power Supply Unit. If two
different kinds of Power Supply Units are to be used, calculate the current
consumption using the output of the smaller-capacity Power Supply Unit.

• In a CS1D Duplex CPU System, always mount the CS1D-CPU@@H/P
CPU Units for Duplex CPU Systems to the CS1D-BC052/BC042D CPU
Backplane. Faulty operation will occur if any other CPU Unit is mounted.

• In a CS1D Single CPU System, always mount a CS1D-CPU@@S CPU
Unit for Single CPU Systems to the CS1D-BC82S CPU Backplane. Faulty
operation will occur if any other CPU Unit is mounted.

• Do not mount a CS1D-CPU@@H/P/S CPU Unit to a CS1W-BC@@ (non­CS1D) CPU Backplane. Otherwise, faulty operation will occur.

• The cycle time will be increased over the normal cycle time whenever
duplex operation is initialized, including when power is turned ON, when
the initialization button is pressed, when operation is started, and when
data is transferred. The increase will be a maximum of 190 ms for the
CS1D-CPU65H and 520 ms for the CS1D-CPU67H. Set the monitoring
time (10 to 40,000 ms, default: 1 s) for the cycle time high enough to allow
for this increase. Also, confirm that the system will operate correctly and
safely even for the maximum cycle time, including the increase for duplex
initialization.

• If operation switches from Duplex Mode to Simplex Mode, processing to
synchronize the active and standby CPU Units will no longer be per­formed, resulting in a shorter cycle time. The more instructions requiring
synchronization (such as IORF, DLNK, IORD, IOWR, PID, RXD, FREAD,
and FWRIT) are used, the greater the difference between Duplex Mode
and Simplex Mode operation will be (with Duplex Mode having the longer
cycle time). Confirm that the system will operate correctly and safely even
for the cycle time in both Simplex and Duplex Modes.

• If the active CPU Unit is switched when PTs or host computers are con­nected to the RS-232C port on both the active and standby CPU Units,
communications may be interrupted momentarily. Always enable retry
process in communications programs at the PTs or host computers.

• Before replacing a Unit online, always disable the operation of all con­nected external devices before starting the replacement procedure. Unex­pected outputs from the Unit being replaced may result in unexpected
operation of controlled devices or systems.

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Application Precautions 5

• Always following the procedures provided in the operation manual when
performing online replacement.

• When replacing a Unit online, always replace it with a Unit that has the
same specifications.

• When replacing a Duplex Unit online in a Duplex CPU, Dual I/O Expan­sion System, always follow the procedure provided in this operation man­ual.

• When replacing a Connecting Cable or Expansion Unit online in a Duplex
CPU, Dual I/O Expansion System, always follow the procedure provided
in this operation manual.

• When using duplex Connecting Cables in a Duplex CPU, Dual I/O Expan­sion System, always use cables that are the same length.

• In a Duplex CPU, Dual I/O Expansion System, do not connect two Con­necting Cables to Expansion Backplanes that are in different operating
levels. Doing so may cause improper operation.

• Before removing a Unit during operation without a PLC Programming
Device (CX-Programmer or a Programming Console), always confirm that
the Removal of a Unit without a Programming Device or Removal/Addition
of Units without a Programming Device function is enabled in the PLC
Setup. If a Unit is removed while the PLC Setup is not set to enable Unit
removal without a Programming Device, an I/O bus error will occur and
the PLC (CPU Unit) will stop operating.

• When a Unit has been removed during operation without a PLC Program­ming Device (CX-Programmer or a Programming Console), data trans­ferred from the removed Unit to the CPU Unit may be invalid. If an invalid
data transfer will adversely affect the system, use a Programming Device
to replace the Unit online.

• When the Removal of a Unit without a Programming Device or Removal/
Addition of Units without a Programming Device function is enabled in the
PLC Setup and a Special I/O Unit has been removed, the Special I/O Unit
Area words allocated to that Unit for data transfer (to and from the CPU
Unit) will be cleared. If the loss of the Special I/O Unit Area data will
adversely affect the system, disable these functions in the PLC Setup and
use a Programming Device to replace the Unit online. (When a Program­ming Device is used to replace the Unit online, the data in the Special I/O
Unit Area is retained while the Unit is removed.)

• An I/O bus error, which can be caused by a Unit malfunction, is normally a
fatal error that stops operation. When he Removal of a Unit without a Pro­gramming Device or Removal/Addition of Units without a Programming
Device function is enabled in the PLC Setup, the I/O bus error will be
treated as a non-fatal error and PLC (CPU Unit) will not stop operating. If
there are any Units that will adversely affect the system if an I/O bus error
occurs, do not enable these functions in the PLC Setup.

• Do not turn ON the Maintenance Start Bit (A80015) continuously from the
ladder program. As long as the Maintenance Start Bit is ON, errors will
not be generated even if there are Unit malfunctions, so the system may
be adversely affected.

Note The Maintenance Start Bit is provided to prevent non-fatal errors

from occurring during Unit removal without a Programming Device.

• Do not turn ON the Online Replacement Completed Bit (A80215) continu­ously from the ladder program. If the Unit is mounted while the Online
Replacement Completed Bit is ON, the PLC (CPU Unit) may stop operat­ing.

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Application Precautions 5

Note The Online Replacement Completed Bit is provided to restart the

data exchange between the replaced Unit and CPU Unit. After a
Unit has been replaced without a Programming Device, turn ON the
Online Replacement Completed Bit to restart the data exchange.

• Always turn OFF the reserved pin (RSV) of the Duplex Unit's Communica­tions Setting DIP Switch.

• 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, CJ1W-CIF11 Adapter, or
NV3W-M@20L Programmable Terminal. The external device or the CPU
Unit may be damaged.

• You must use the CX-Programmer (programming software that runs on
Windows) if you need to program more than one task. A Programming
Console can be used to program only one cyclic task. A Programming
Console can, however, be used to edit multitask programs originally cre­ated with the CX-Programmer.

!WARNING Always heed these precautions. Failure to abide by the following precautions

could lead to serious or possibly fatal injury.

• 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.

• 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, In­ner Boards, or any other Units.

• Assembling the Units.

• Setting DIP switches or rotary switches.

• Connecting cables or wiring the system.

• Connecting or disconnecting the connectors.

!Caution Failure to abide by the following precautions could lead to faulty operation of

the PLC or the system, or could damage the PLC or PLC Units. Always heed
these precautions.

• The user program and parameter area data in the 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.

• The PLC Setup is set to specify using the mode set on the Programming
Console and a Programming Console is not connected, the CPU Unit will
start in RUN mode. This is the default setting in the PLC Setup. (A CS1
CPU Unit will start in PROGRAM mode under the same conditions.)

• 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

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Application Precautions 5

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. Refer to information on file operations in
the CS/CJ Series Programming Manual for details.

• 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.

• 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.

• Do not turn OFF the power supply to the PLC when data is being trans­ferred. In particular, do not turn OFF the power supply when reading or
writing a Memory Card. Also, do not remove the Memory Card when the
BUSY indicator is lit. 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.

• 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.)

• The contents of the DM, EM, and HR Areas in the CPU Unit are backed
up by a Battery. If the Battery voltage drops, this data may be lost. Provide
countermeasures in the program using the Battery Error Flag (A40204) to
re-initialize data or take other actions if the Battery voltage drops.

• When supplying power at 200 to 240 V AC, always remove the metal
jumper from the voltage selector terminals on the Power Supply Unit
(except for Power Supply Units with wide-range specifications). The prod­uct will be destroyed and must be replaced if 200 to 240 V AC is supplied
while the metal jumper is attached. Refer to 5-4 Wiring Methods for
details.

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

• 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.

• Install the Units as far away as possible from devices that generate
strong, high-frequency noise.

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