Omron CS1W-CT041, CS1W-CT021 Operation Manual
OPERATION MANUAL
High-speed Counter Units
CS1W-CT021
CS1W-CT041
Cat. No. W902-E2-03
CS1W-CT021/CT041
High-speed Counter Units
Operation Manual
Revised August 2004
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Notice:
OMRON products are manufactured for use according to proper procedures by a qualified operator and
only for the purposes described in this manual.
The following conventions are used to indicate and classify precautions in this manual. Always pay attention to the information provided with them. Failure to comply with the precautions can result in injury to people or damage to the product.
!DANGER Indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury.
!WARNING Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
!Caution Indicates an potentially hazardous situation which, if not avoided, may result in
minor or moderate injury, or property damage.
OMRON Product References
All OMRON products are capitalised in this manual. The word “Unit” is also capitalised when it refers to an
OMRON product, regardless of whether or not it appears in the proper name of the product.
The abbreviation “Ch,” which appears in some displays and on some OMRON products, often means
“word” and is abbreviated “Wd” in documentation in this sense.
The abbreviation “PLC” means Programmable Logic Controller and is not used as an abbreviation for anything else.
Visual Aids
The following headings appear in the left column of the manual to help you locate different types of information.
1, 2, 3… Indicates lists of one sort or another, such as procedures, checklists, etc.
OMRON, 2004
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any
form, or by any means, mechanical, electronic, photocopying, recording, or otherwise, without the prior written
permission of OMRON.
No patent liability is assumed with respect to the use of the information contained herein. Moreover, because
OMRON is constantly striving to improve its high-quality products, the information contained in this 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 operation of
the product.
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TABLE OF CONTENTS
PRECAUTIONS ............................................................................................... xi
1 Intended Audience........................................................................................................................................................ xii
2 General Precautions...................................................................................................................................................... xii
3 Safety Precautions ........................................................................................................................................................ xii
4 Operating Environment Precautions............................................................................................................................ xiii
5 Application Precautions............................................................................................................................................... xiv
6 EC Directives............................................................................................................................................................... xvi
SECTION 1
Introduction....................................................................................................... 1
1-1 Features and Functions ............................................................................................................................................ 2
1-2 Basic Configuration................................................................................................................................................. 5
1-3 Specifications and Characteristics........................................................................................................................... 7
1-4 Quick Start Up Reference Guide............................................................................................................................. 14
1-5 Operating Procedure Guidelines.............................................................................................................................. 20
1-6 Application Areas.................................................................................................................................................... 23
SECTION 2
Components, Installation and Wiring............................................................. 25
2-1 Components and Switch Settings ............................................................................................................................ 26
2-2 Installation ............................................................................................................................................................... 30
2-3 Wiring...................................................................................................................................................................... 32
SECTION 3
Operation and Configuration .......................................................................... 45
3-1 Overview ................................................................................................................................................................. 46
3-2 Counter Types.......................................................................................................................................................... 47
3-3 Input Signal Types ................................................................................................................................................... 55
3-4 Digital Input Functions............................................................................................................................................ 58
3-5 Output Control......................................................................................................................................................... 65
3-6 Reset Signals ........................................................................................................................................................... 79
3-7 Extra Functions........................................................................................................................................................ 81
SECTION 4
Exchanging Data with CPU ............................................................................. 91
4-1 Overview ................................................................................................................................................................. 92
4-2 Memory Allocation ................................................................................................................................................. 94
4-3 IOWR-Instruction.................................................................................................................................................... 124
4-4 IORD-Instruction..................................................................................................................................................... 126
4-5 Supported IOWR/IORD-Instructions ...................................................................................................................... 128
4-6 Interrupts.................................................................................................................................................................. 135
SECTION 5
Error Processing, Maintenance and Inspection............................................ 141
5-1 Error Indicators........................................................................................................................................................ 142
5-2 Error codes............................................................................................................................................................... 143
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5-3 Maintenance and Inspection.................................................................................................................................... 149
SECTION 6
Application Examples ...................................................................................... 151
6-1 Flow Control ........................................................................................................................................................... 152
6-2 Length Measurement............................................................................................................................................... 155
6-3 Positioning............................................................................................................................................................... 160
6-4 CAM-positioning .................................................................................................................................................... 164
6-5 Speed Control.......................................................................................................................................................... 169
Appendices
Appendix A Comparison with C200H-CT021 .................................................................................................... 172
Appendix B Using Terminal Block Units with Screw-terminals......................................................................... 175
Appendix C Assigning External Interrupt Tasks to Outputs ............................................................................... 176
Appendix D Description of the Response Time................................................................................................... 178
INDEX ............................................................................................................... 181
Revision History ............................................................................................... 187
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About this Manual:
This manual describes the installation and operation of the CS1W-CT021/CT041 High-speed Counter
Units and includes the sections described below. Both the CS1W-CT021 and the CS1W-CT041 Highspeed Counter Units are identical and differ only in the number of Counters that they are equipped with, 2
and 4 Counters respectively. Remarks are made throughout this manual to indicate the differences
between the CS1W-CT021 and CS1W-CT041 High-speed Counter Units. The word “Unit” in this manual
refers to the corresponding High-speed Counter Unit that you are using (CS1W-CT021 or CS1W-CT041).
Please read this manual carefully and be sure you understand the information provided before attempting
to install and operate the CS1W-CT021/CT041 High-speed Counter Unit. Be sure to read the precau-
tions provided in the following sections.
Section 1 introduces the CS1W-CT021/CT041 High-speed Counter Unit and describes the features,
functions, and specifications. It gives short instructions on how to operate the Units.
Section 2 provides information about components, wiring and installing the CS1W-CT021/CT041 High-
speed Counter Unit.
Section 3 provides information about the configuration and operation of the CS1W-CT021/CT041 High-
speed Counter Unit.
Section 4 provides information on the data-exchange and the communication interface between the
CS1W-CT021/CT041 High-speed Counter Unit and the CPU.
Section 5 provides details of the CS1W-CT021/CT041 High-speed Counter Unit’s errors, error -codes
and indicators and guidelines for troubleshooting.
Section 6 provides sample programs, according to practical applications, that can be used with the
CS1W-CT021/CT041 High-speed Counter Unit.
The Appendices describe a comparison with C200H-CT021 High-speed Counter Unit, the numbering of
Terminal Block Units, the numbering of External Interrupt Tasks to Outputs and a description of the
Response Time.
All through this manual where a double word is defined as for instance “n+2, n+3” this must be interpreted
as follows:
n+3 (MSW) n+2 (LSW)
sign x106x105x104x103x102x101x100 :BCD Double Word
0 = + (positive)
F = - (negative)
n+3 (MSW) n+2 (LSW)
x167x166x165x164x163x162x161x160 :Hexadecimal Double Word
LSW = Least Significant Word
MSW = Most Significant word
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!WARNING Failure to read and understand the information provided in this manual may
result in personal injury or death, damage to the product, or product failure.
Please read each section in its entirety and be sure you understand the information provided in the section and related sections before attempting any of the procedures or operations given.
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PRECAUTIONS
This section provides general precautions for using the Programmable Controller (PLC) and the High-speed Counter Unit.
The information contained in this section is important for the safe and reliable application of the High-speed Counter
Unit. You must read this section and understand the information contained before attempting to set up or operate a
High-speed Counter Unit and PLC system.
1 Intended Audience........................................................................................................................................................ xii
2 General Precautions...................................................................................................................................................... xii
3 Safety Precautions ........................................................................................................................................................ xii
4 Operating Environment Precautions ........................................................................................................................... xiii
5 Application Precautions .............................................................................................................................................. xiv
6 EC Directives .............................................................................................................................................................. xvi
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!"#$%&'()*+ Intended Audience
1 Intended Audience
This manual is intended for the following personnel, who must also have knowledge of electrical systems (an electrical engineer or the equivalent).
• Personnel in charge of installing FA systems.
• Personnel in charge of designing FA systems.
• Personnel in charge of managing FA systems and facilities.
2 General Precautions
The user must operate the product according to the performance specifications
described in the operation manuals.
Before using the product under conditions which are not described in the manual
or applying the product to nuclear control systems, railroad systems, aviation systems, vehicles, combustion systems, medical equipment, amusement machines,
safety equipment, and other systems, machines, and equipment that may have a
serious influence on lives and property if used improperly, consult your OMRON
representative.
Make sure that the ratings and performance characteristics of the product are sufficient for the systems, machines, and equipment, and be sure to provide the systems, machines, and equipment with double safety mechanisms.
This manual provides information for installing and operating OMRON Highspeed Counter Units. Be sure to read this manual before operation and keep this
manual close at hand for reference during operation.
!WARNING It is extremely important that a PLC and all PLC Units be used for the specified
purpose and under the specified conditions, especially in applications that can
directly or indirectly affect human life. You must consult with your OMRON representative before applying a PLC system to the above mentioned applications.
3 Safety Precautions
!WARNING The CPU Unit refreshes I/O even when the program is stopped (i.e., even in
PROGRAM mode). Confirm safety thoroughly in advance before changing the
status of any part of memory allocated to I/O Units, Special I/O Units, or CPU
Bus Units. Any changes to the data allocated to any Unit may result in unexpected operation of the loads connected to the Unit. Any of the following operation may result in changes to memory status.
• Transferring I/O memory data from a Programming Device to the CPU Unit.
• Changing present values in memory with a Programming Device.
• Force-setting/-resetting bits with a Programming Device.
• Transferring I/O memory files from a Memory Card or EM file memory to the
CPU Unit.
• Transferring I/O memory from a host computer or from another PLC on a network.
!WARNING Do not attempt to take any Unit apart while the power is being supplied. Doing so
may result in electric shock.
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!"#$%&'()*+ Operating Environment Precautions
!WARNING Do not touch any of the terminals or terminal blocks while the power is being
supplied. Doing so may result in electric shock.
!WARNING Do not attempt to disassemble, repair, or modify any Units. Any attempt to do so
may result in malfunction, fire, or electric shock.
!Caution Execute online edit only after confirming that no adverse effects will be caused
by extending the cycle time. Otherwise, the Input signals may not be readable.
!Caution Confirm safety at the destination node before transferring a program to another
node or changing contents of the I/O memory area. Doing either of these without
confirming safety may result in injury.
!Caution Tighten the screws on the terminal block of the AC Power Supply Unit to the
torque specified in the operation manual. Loose screws may result in burning or
malfunction.
4 Operating Environment Precautions
!Caution Do not operate the control system in the following locations:
• Locations subject to direct sunlight.
• Locations subject to temperatures or humidity outside the range specified in the
specifications.
• Locations subject to condensation as the result of severe changes in temperature.
• Locations subject to corrosive or flammable gases.
• Locations subject to dust (especially iron dust) or salts.
• Locations subject to exposure to water, oil, or chemicals.
• Locations subject to shock or vibration.
!Caution Take appropriate and sufficient countermeasures when installing systems in the
following locations:
• Locations subject to static electricity or other forms of noise.
• Locations subject to strong electromagnetic fields.
• Locations subject to possible exposure to radioactivity.
• Locations close to power supplies.
!Caution The operating environment of the PLC System can have a large effect on the lon-
gevity and reliability of the system. Improper operating environments can lead to
malfunction, failure, and other unforeseeable problems with the PLC System. Be
sure that the operating environment is within the specified conditions at installation and remains within the specified conditions during the life of the system.
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!"#$%&'()*+ Application Precautions
5 Application Precautions
Observe the following precautions when using the High-speed Counter Unit or the
PLC.
!WARNING Failure to comply with the following precautions could lead to serious or possibly
fatal injury. Always follow these precautions.
• Always ground the system with 100 Ω or less when installing the system, to pro-
tect against electrical shock.
• Always turn OFF the power supply to the PLC before attempting any of the following. Performing any of the following with the power supply turned ON may
lead to electrical shock:
• Mounting or removing any Units (e.g., I/O Units, CPU Unit, etc.) or memory
cassettes.
• Assembling any devices or racks.
• Connecting or disconnecting any connectors, cables or wiring.
• Setting DIP switch or rotary switches.
!Caution Failure to comply with the following precautions could lead to faulty operation of
the PLC or the system, or could damage the PLC or PLC Units. Always follow
these precautions.
• Fail-safe measures must be taken by the customer to ensure safety in the event
of incorrect, missing, or abnormal signals caused by broken signal lines,
momentary power interruptions, or other causes.
• Interlock circuits, limit circuits, and similar safety measures in external circuits
(i.e., not in the Programmable Controller) must be provided by the customer.
• If the IOM Hold Bit is turned ON, the outputs from the PLC will not be turned
OFF and will maintain their previous status when the PLC is switched from RUN
or MONITOR mode to PROGRAM mode. Make sure that the external loads will
not produce dangerous conditions when this occurs. (When operation stops for
a fatal error, including those produced with the FALS instruction, all outputs
from Output Unit will be turned OFF and only the internal output status will be
maintained.)
• Use the Units only with the power supplies and voltages specified in the operation manuals. Other power supplies and voltages may damage the Units.
• Take appropriate measures to ensure that the specified power with the rated
voltage and frequency is supplied. Be particularly careful in places where the
power supply is unstable. An incorrect power supply may result in malfunction.
• Install external breakers and take other safety measures against shortcircuiting in external wiring. Insufficient safety measures against shortcircuiting may result in burning.
• Do not apply voltages to Input sections in excess of the rated Input voltage.
Excess voltages may result in burning.
• Do not apply voltages or connect loads in excess of the maximum switching
capacity to output sections. Excess voltage or loads may result in burning.
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!"#$%&'()*+ Application Precautions
!Caution • Install the Units properly as specified in the operation manuals. Improper
installation of the Units may result in malfunction.
• Be sure that all the mounting screws, terminal screws, and cable connector
screws are tightened to the torque specified in the relevant manuals. Incorrect
tightening torque may result in malfunction.
• Leave the label attached to the Unit when wiring. Removing the label may result
in malfunction if foreign matter enters the Unit.
• Remove the label after the completion of wiring to ensure proper heat dissipation. Leaving the label attached may result in malfunction.
• Use crimp terminals for wiring. Do not connect bare stranded wires directly to
terminals. Connection of bare stranded wires may result in burning.
• Double-check all the wiring and the connectors before turning ON the power
supply. Incorrect wiring or bad connections may result in burning or malfunction.
• Be sure that the terminal blocks, Memory Units, expansion cables, and other
items with locking devices are properly locked into place. Improper locking may
result in malfunction.
• Check switch settings, the contents of the DM Area, and other preparations
before starting operation. Starting operation without the proper settings or data
may result in an unexpected operation.
• Check the user program for proper execution before actually running it on the
Unit. Not checking the program may result in an unexpected operation.
• Confirm that no adverse effect will occur in the system before attempting any of
the following. Not doing so may result in an unexpected operation.
• Changing the operating mode of the PLC.
• Force-setting/force-resetting any bit in memory.
• Changing the present value of any word or any set value in memory.
• Do not pull on the cables or bend the cables beyond their natural limit. Doing
either of these may break the cables.
• Do not place objects on top of the cables or other wiring lines. Doing so may
break the cables.
• When replacing parts, be sure to confirm that the rating of a new part is correct.
Not doing so may result in malfunction or burning.
• Before touching a Unit, be sure to first touch a grounded metallic object in order
to discharge any static built-up. Not doing so may result in malfunction or damage.
• Do not touch circuit boards or the components mounted to them with your bare
hands. There are sharp leads and other parts on the boards that may cause
injury if handled improperly.
• Provide proper shielding when installing in the following locations:
• Locations subject to static electricity or other sources of noise.
• Locations subject to strong electromagnetic fields.
• Locations subject to possible exposure to radiation.
• Locations near power supply lines.
• Do not attempt to take any Units apart, to repair any Units, or to modify any
Units in any way.
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!"#$%&'()*+ EC Directives
6 EC Directives
6-1 Applicable Directives
• EMC Directives
• Low Voltage Directive
6-2 Concepts
EMC Directives
OMRON devices that comply with EC Directives also conform to the related EMC
standards so that they can be more easily built into other devices or the overall
machine. The actual products have been checked for conformity to EMC standards (see the following note). Whether the products conform to the standards in
the system used by the customer, however, must be checked by the customer.
EMC-related performance of the OMRON devices that comply with EC Direc-tives
will vary depending on the configuration, wiring, and other conditions of the equipment or control panel on which the OMRON devices are installed. The customer
must, therefore, perform the final check to confirm that devices and the overall
machine conform to EMC standards.
Note Applicable EMC (Electromagnetic Compatibility) standards are as follows:
EMS (Electromagnetic Susceptibility) :EN61131-2
EMI (Electromagnetic Interference) :EN50081-2
(Radiated emission: 10-m regulations)
Low Voltage Directive
Always ensure that devices operating at voltages of 50 to 1,000 VAC and 75 to
1,500 VDC meet the required safety standards for the PLC (EN61131-2).
6-3 Conformance to EC Directives
CS1-series Units conform to EC Directives. For the system to conform to EC
Directives, however, the following precautions must be adhered to.
1, 2, 3... 1. CS1-series Units must be installed within control panels.
2. Use reinforced insulation or double insulation for the DC power supplies used
for the I/O power supplies.
3. CS1-series Units that meet EC Directives also meet the Common Emission
Standard (EN50081-2). The measure necessary to ensure that standards,
such as the radiated emission standard (10-m), are met, however, will vary
depending on the overall configuration of the control panel, the other devices
connected to the control panel and wiring. You must therefore confirm that EC
Directives are met for the overall machine or device.
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SECTION 1
Introduction
This section gives specifications of the CS1W-CT021/CT041 and a brief description of the functions and features of the Unit
and the areas of application.
1-1 Features and Functions............................................................................................................................................ 2
1-2 Basic Configuration................................................................................................................................................. 5
1-3 Specifications and Characteristics........................................................................................................................... 7
1-3-1 General Specifications ............................................................................................................................... 7
1-3-2 Functional Specifications .......................................................................................................................... 8
1-3-3 Input Specifications ................................................................................................................................... 11
1-3-4 Output Specifications ................................................................................................................................ 13
1-4 Quick Start Up Reference Guide............................................................................................................................. 14
1-4-1 Configuring the High-speed Counter Unit ................................................................................................ 18
1-5 Operating Procedure Guidelines ............................................................................................................................. 20
1-6 Application Areas.................................................................................................................................................... 23
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,#%'&"#+-%*.-,&*$'()*+ Section 1-1
1-1 Features and Functions
The CS1W-CT021 and CT041 High-speed Counter Units are equipped with 2 and
4 Counters respectively, all able to count over a maximum binary range of 32-bits.
Accepting input pulse frequencies of up to 500 kHz allows precise control of fast
motions. The Unit’s bi-directional counting ability enables detecting movement in
either direction. Each Counter of the Unit can be configured independently. The
Unit is equipped with 4 Digital Inputs, 4 Digital Outputs and 28 Soft Outputs. A
maximum response time of 0.5 ms guarantees high-speed closed loop control of
applications.
Freely Configurable The CS1W-CT021/CT041, a Special I/O Unit for CS1-series PLC-systems, is a
freely configurable High-speed Counter Unit. Depending on the requirements of
your application, the specific behaviour of the Unit can be adjusted by changing
the configuration settings.
Counter Type Configuring the Unit starts with choosing one out of 3 Counter Types:
• Simple Counter (refer to 3-2-1 "Simple Counter")
• Circular Counter (refer to 3-2-2 "Circular Counter")
• Linear Counter (refer to 3-2-3 "Linear Counter")
By default all Counters are set to Simple Counter for which no configuration settings have to be made, enabling every Counter to count pulses directly after the
Unit has been powered up. For all Counter Types the full counting range is available. Circular and Linear Counters can be fully (DM-) configured according to the
application that is to be controlled.
Input Signal Type Depending on the type of input signal that your application requires, for every
Counter a choice can be made out of three input signal types:
• Phase Differential Inputs (multiplication by either 1, 2 or 4)
(refer to 3-3-1 "Phase Differential")
• Up/Down Pulse Inputs (refer to 3-3-2 "Up & Down")
• Pulse & Direction Inputs (refer to 3-3-3 "Pulse & Direction")
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,#%'&"#+-%*.-,&*$'()*+ Section 1-1
Digital Input Function The Unit is equipped with 4 Digital Inputs (I0, I1, I2 and I3) that can be freely
assigned to any Counter. To meet the requirements of your application every Digital Input can be configured according to one out of 17 available functions. The
functions make it possible to use a Digital Input with Gate-, Preset-, Reset- or Capture Functionality (among other functions). Refer to 3-4 "Digital Input Functions".
Digital Output Control To control the Outputs the Unit can be configured in one of the two following Out-
put Control Modes:
• Range Mode (refer to 3-5-1 "Range Mode")
• Comparison Mode (refer to 3-5-2 "Comparison Mode")
In Range Mode, a configurable number of up to 32 Ranges can be applied to individual Counters. Every Range can control up to a maximum of 32 Outputs. An
Output is turned ON when the Counter is in the corresponding Range. In Comparison Mode a configurable number of up to 32 Comparison Values can be applied
to individual Counters. Depending on the direction of counting, an Output can be
set or reset (configurable) on reaching the Comparison Value. Every Comparison
Value can control up to maximum 32 Outputs.
Furthermore Outputs can be controlled manually by setting/resetting PLC software bits (refer to 3-5-3 "Manual Output Control"). The Outputs can be configured
to keep their last state or to have a predefined state, in case the PLC-state
changes (RUN/MONITOR → PROGRAM), an I/O Bus error or an Overflow/Underflow error occurs. Additionally Outputs can be configured with an NPN- or PNP
Output driver (refer to 3-5-4 "Output Control Configuration").
Resetting Counter Value Resetting of the Counter Value can be freely configured depending on the appli-
cation needs. The following sources can trigger a reset:
• Software bit in the PLC
• Z-Input
• Digital Input (that is configured as a Reset Input)
To enable resetting a Counter Value, an external Digital Input can be configured as
Enable Reset Input and/or the Software Enable Reset bit can be used (refer to
3-6 "Reset Signals").
Programmable Output
Pulses
Rate Measurement The ability, for every Counter, to measure the Rate of the incoming pulses within
The timing characteristics of the Digital Outputs can be modified, depending on
the requirements of the application as follows (refer to 3-7-1 "Programmable Out-
put Pulses"):
• Output Turn ON Delay [1 ms to 9999 ms], to delay turning ON an Output
• Output Pulse Duration [1 ms to 9999 ms], to generate an Output pulse of the
specified duration
a predefined time-window [1ms to 9999 ms] enables measuring speeds and frequencies. Rate Measurement is executed as background calculation and can be
enabled or disabled. For every Counter up to a maximum of 64 most recent Rate
Values are available as a Rate History Log File (refer to 3-7-2 "Rate Measure-
ment").
Hysteresis For Counters in Range Mode a hysteresis can be configured [1 to 255 counts], to
prevent Outputs from toggling due to unwanted oscillating of encoding equipment
(e.g. rotary incremental encoder). Refer to 3-7-3 "Hysteresis".
&
,#%'&"#+-%*.-,&*$'()*+ Section 1-1
Noise Filtering For the purpose of suppressing noise on the signal lines A and B of every Counter
and on the Digital Input lines noise filters can be used. Noise filters can be configured independently from each other for Counters 1&2, Counters 3&4, Digital
Inputs 0&1 and Digital Inputs 2&3. The cut-off frequencies for the signal lines A
and B can be set to:
• 10 kHz
• 50 kHz (default)
• 500 kHz
For the Digital Inputs 10 kHz and 50 kHz (default) noise filters can be configured.
Refer to 3-7-4 "Noise Filtering".
Run-time Configurable Configuration settings of the Unit can be changed at Run-time by using the IOWR-
instruction to be able to quickly adjust to changing application needs without the
need of restarting the Unit or stopping the Counters.
Interrupt Support All Outputs and the 4 Digital Inputs can be configured to generate interrupts to the
PLC in order to have a minimal response time enabling fast control of applications.
Generating interrupts is only possible when the High-speed Counter Unit is
mounted on a CPU-backplane.
Support Software The Unit can be configured by using CX-Programmer Support Software or a Pro-
gramming Console.
Comparison with
C200H-CT021
Quick Start Up Reference
Guide
For those users who are familiar with the C200H-CT021 High-speed Counter Unit,
the predecessor of the CS1W-CT021/CT041 High-speed Counter Units, there is a
quick comparison overview in the appendix A “Comparison with C200H-CT021”.
For a quick overview of all the features and functions that the High-speed Counter
Unit offers to you, refer to 1-4 "Quick Start Up Reference Guide". This section also
contains references to the particular section(s) in the Manual where you can read
more detailed information about specific features and functions of the High-speed
Counter Unit.
'
/%+($-0)*1(2&"%'()* Section 1-2
1-2 Basic Configuration
Typical applicable Sensors for Digital Inputs:
Photo Electric
Sensor
Push Button
Limit Switch
Proximity Switch
Other Sensors
Typical applicable Pulse Generators for
Counter Inputs:
Incremental
Encoder
Typical applicable Actuators for Digital Outputs:
Relais
Lamp
Motor Interface
ON/OFF
High/Low Speed
Forward/Reverse
Brake ON/OFF
Other Actuators
M
Proximity Sensor
Other Pulse
Generators
(
/%+($-0)*1(2&"%'()* Section 1-2
Mounting Restrictions The CS1W-CT021/CT041 High-speed Counter Unit is a Special I/O Unit belong-
ing to the CS1-Series.
CS1W- CT021/CT041 High-speed Counter Units can be mounted to either CS1
CPU Racks or CS1 Expansion Racks. These High-speed Counter Units cannot be
mounted to C200H Expansion I/O Racks or SYSMAC BUS Slave Racks.
Note If you want the CS1W-CT021/CT041 High-speed Counter Unit to generate inter-
rupts to the CPU, the Unit should be mounted on a CS1 CPU Rack. CS1 Expansion Racks do not support interrupts.
The maximum number of CS1W-CT021/CT041 High-speed Counter Units that
can be mounted to a CS1 CPU Rack or CS1 Expansion Rack is equal to the
number of slots of the Rack. In a configuration with multiple Racks the maximum
number of CS1-CT021/CT041 High-speed Counter Units is limited to 24 because
the Unit is allocated 40 CIO-words and 400 DM-words in the Special I/O Unit Area.
Furthermore, the number of High-speed Counter Units that can be mounted to
one Rack (i.e., a CPU Rack or Expansion Rack) depends on the maximum supply
current from the Power Supply Unit that supplies the Rack and the current consumption of other Units on the Rack.
I/O Connection Methods To connect the In- and Output signal wires to the Unit two methods are available:
1. Directly connecting the wires by soldering them to the external connector.
2. Indirectly connecting the wires by connecting them to screw terminals on a Terminal Block Unit. The Omron Terminal Block Unit (XW2B-40G4 or XW2B40G5) is connected to the Unit via standard available Omron flat-cables
(XW2Z-xxxB).
Refer to 2-3-2 "Connector Wiring Methods" for more details.
)
34#$(1($%'()*+-%*.-05%"%$'#"(+'($+ Section 1-3
1-3 Specifications and Characteristics
1-3-1 General Specifications
Item CS1W-CT021/CT041
Unit type CS1 Special I/O Unit
General Specifications Conform to general specifications for SYSMAC CS1-series
Operating Temperature 0 to +55 °C
Storage Temperature -20 to +75 °C
Humidity 10 to 90% without condensation
Internal Current Consumption 450 mA (CS1W-CT041), 360 mA (CS1W-CT021) (at 5V via backplane)
Dimensions (mm) 35 x 130 x 100 (W x H x D)
Weight 245 g
Mounting Position CS1 CPU Rack or CS1 Expansion Rack
(Cannot be mounted to a C200H Expansion I/O Rack or a SYSMAC BUS Slave
Rack).
Maximum Number of CT021/
CT041 Units per Rack
Maximum Number of CT021/
CT041 Units per basic CS1system
Data Exchange with CPU Unit • I/O Refresh Data Area (CIO-bits 200000 to 295915, CIO-words 2000 to
Note 1. The maximum number of Units per Rack is also depending on the maximum
Equal to the number of slots of the Rack (see Note 1)
24
2959): Note 2)
• Special I/O Unit DM-Area (D-words 20000 to 29599): 400 DM-words per Unit
are transmitted form the CPU to the Unit at Power Up or when the Unit is
restarted (see Note 3)
supply current of the Power Supply Unit and the current consumption of other
Units on the Rack.
2. Both the CS1W-CT021/CT041 Special I/O Units are allocated words for 4 Units
in the Special I/O Unit (CIO) Area (refer to 4-2-3 "CIO-Memory Mapping").
3. Both the CS1W-CT021/CT041 Special I/O Units are allocated words for 4 Units
in the Special I/O Unit DM-Area. From the 400 DM-words that are allocated to
the CT041 only the first 203 words are used to make the DM-settings. The
remaining 197 DM-words can be used as work-words in the PLC Ladder Program. For the CT021 the first 113 words are used to make the DM-settings and
the remaining 287 words can be used as work-words (refer to 4-2-4 "DM-Mem-
ory Mapping").
*
34#$(1($%'()*+-%*.-05%"%$'#"(+'($+ Section 1-3
1-3-2 Functional Specifications
Item CS1W-CT021/CT041
Number of Counters • 2 run-time configurable Counters for the CS1W-CT021
• 4 run-time configurable Counters for the CS1W-CT041
Counter Type • Simple Counter (refer to 3-2-1 "Simple Counter")
• Circular Counter (refer to 3-2-2 "Circular Counter")
• Linear Counter (refer to 3-2-3 "Linear Counter")
The Counter Type can be chosen by DIP switch at the back of the Unit. By
default the Counters are set to Simple Counter (refer to 2-1-3 "Counter Type
Switch").
Maximum Input Frequency 500 kHz, refer to 1-3-3 "Input Specifications" for details
Maximum Response Time 0.5 ms (refer to Appendix D “Description of the Response Time”)
Signals per Counter Phase A, B and Z
Digital I/O • 4 Digital Inputs (I0, I1, I2 and I3):
Every Digital Input can be assigned to a Counter. In this way one Counter
can be controlled by a maximum of 4 Digital Inputs (refer to 3-4 "Digital Input
Functions")
• 4 Digital Outputs (O0, O1, O2 and O3):
The Unit Output Pattern represents the 4 Digital Outputs and 28 Soft
Outputs (refer to 3-5 "Output Control").
Input Signal Types • Phase Differential (multiplication x1), (multiplication x2)* and (multiplication
x4)* (refer to 3-3-1 "Phase Differential")
• Up/Down* (refer to 3-3-2 "Up & Down")
• Pulse & Direction* (refer to 3-3-3 "Pulse & Direction")
Counter Control using CIOsoftware bits
Digital Input Functionality • Gate*
• Open Gate / Start Counter: Counter is enabled to count pulses
• Close Gate / Stop Counter: Counter is disabled to count pulses
• Preset Counter: Preset Value can be set in CIO
• Reset Counter to zero
• Capture Counter Value: Captured Counter Value can be read using IORD-
instruction (refer to 4-5-3-1 "Captured Counter Value")
Refer to 3-4 "Digital Input Functions".
• Reset*
• Preset*
• Capture*
• Stop/Capture-Continue*
• Stop/Capture-Reset/Continue*
• Capture/Reset*
• Enable Reset*
• Disable Reset*
For every Function the corresponding action can be triggered on a rising- or on
a falling edge (refer to 3-4 "Digital Input Functions").
Output Control Mode • Automatic Output Control in:
• Range Mode* (Refer to 3-5-1 "Range Mode")
• Comparison Mode* (Refer to 3-5-2 "Comparison Mode")
• Manual Output Control (Refer to 3-5-3 "Manual Output Control")
+
34#$(1($%'()*+-%*.-05%"%$'#"(+'($+ Section 1-3
Item CS1W-CT021/CT041
Output State Control On changing the Operating Mode of the PLC from RUN/MONITOR
→ PROGRAM, an I/O Bus Error or an Overflow/Underflow
Error, the Digital Outputs can be configured to:
• Continue automatic updating Output States
• Freeze Output States*
• Predefine Output States*
Refer to 3-5-4 "Output Control Configuration".
Output Driver Configuration The Output Driver of every Digital Output can be configured as:
• NPN
• PNP*
Refer to 3-5-4 "Output Control Configuration".
Reset Signals Every Counter can be reset to zero by (a combination of) the following sources:
• Software Counter Reset Bit
• Digital Input*
• Z-Input*
Refer to 3-6 "Reset Signals".
Extra Functions • Programmable Output Pulse*:
To every Digital Output an ON-delay and/or a Pulse Duration [1, 9999 ms]
can be applied (refer to 3-7-1 "Programmable Output Pulses")
• Rate Measurement*: For every Counter the Pulse Rate can be measured by
defining a Time-Window [1, 9999 ms]. Up to a maximum of 64 Rate Values
are stored in the Rate History Log File. Rate Values from the Rate History
Log File can be read using the IORD-instruction. Additionally for every
Counter two Rate Ranges can be defined that control the Outputs according
to the measured Rate Value. Refer to 3-7-2 "Rate Measurement".
• Hysteresis*: To prevent Outputs from being switched On and Off by very
small fluctuations in the Counter Value around Range Limits, for every
Counter an Hysteresis-value [1, 255] can be defined (the Unit must in Range
Mode). Refer to 3-7-3 "Hysteresis".
Noise Filtering Counter Inputs
and Digital Inputs
Initial Counter Value • The Initial Counter Value* is transferred to the Unit when the Unit is Powered
To suppress noise on the signal lines of the Counter Inputs (A and B) and the
Digital Inputs (I0, I1, I2 and I3) a Noise Filter can be configured:
• 10 kHz*
• 50 kHz (default)
• 500 kHz*
For the Digital Inputs the 500 kHz filter can not be selected. The Z-Input
Signals of every Counter are filtered with a fixed Noise Filter of 1 kHz. Refer to
3-7-4 "Noise Filtering".
Up or Restarted. The Initial Counter Value is very useful to overcome
problems in case of power failure. Refer to 3-7-5 "Initial Counter Value".
,
34#$(1($%'()*+-%*.-05%"%$'#"(+'($+ Section 1-3
Item CS1W-CT021/CT041
IORD- and IOWR-instructions Run-time configuration and operation of the High-speed Counter Unit is
possible by using IORD- and IOWR-instructions. The following data can be
read or written:
• DM-configuration data* (refer to 4-5-1 "DM-data")
• Range- and Comparison Data* (refer to 4-5-2 "Range- and Comparison
data")
• Captured Counter Value (refer to 4-5-3-1 "Captured Counter Value")
• Rate History Log File Data* (refer to 4-5-3-2 "Rate History Log File data")
• Counter Value (refer to 4-5-3-3 "Counter Value")
• (Re) Configure High-speed Counter Unit* (refer to 4-5-3-4 "(Re) Configure
Unit")
• Error Clear (refer to 4-5-3-5 "Error Clear Command")
Interrupts of Outputs • The Digital Outputs and the Soft Outputs of the Unit Output Pattern can all
be configured to generate interrupts to the CS1-CPU*. Refer to 4-6-1
"Outputs Generating Interrupts".
Interrupts of Digital Inputs • The Digital Inputs can all be configured to generate interrupts to the CS1-
CPU*. Refer to 4-6-2 "Digital Inputs Generating Interrupts".
Error History Log Function • Stores up to 30 error log records (refer to 5-2 “Error codes”)
* This specification item is only supported for Circular and Linear Counters (not
for Simple Counters). For a complete overview of the differences between Simple and Circular/Linear Counters refer to 1-4 "Quick Start Up Reference Guide".
$-
34#$(1($%'()*+-%*.-05%"%$'#"(+'($+ Section 1-3
1-3-3 Input Specifications
Item Counter Inputs A and B Digital Inputs
(I0, I1, I2 and I3)
Input Voltage 24 VDC
(19.6 to 26.4 V)
Input Current
(typical)
ON Voltage
(min.)
OFF Voltage
(max.)
Item Counter Input Z
Input Voltage 24 VDC
Input Current
(typical)
ON Voltage
(min.)
OFF Voltage
(max.)
8 mA 8 mA 7 mA 11mA
19.6V 9.8V 4.5V 19.6V
4 V 2.5V 1.5V 4 V
(18.6 to 26.4 V)
7.3 mA 6.6 mA 6 mA 11mA
18.6V 9.8V 4.5V
4 V 2.5V 1.5V
12 VDC
(9.8 to 13.2V)
12 VDC
(9.8 to 13.2V)
5 VDC
(4.5 to 5.5V)
5 VDC
(4.5 to 5.5V)
Line Driver 24 VDC
(19.6 to 26.4 V)
7.6 mA
Connectable to
RS-422
compatible Line
Drivers.
Line Driver
Connectable to
RS-422
compatible Line
Drivers.
Note 1. The Counter Inputs (A, B, Z) are insulated from each other and from the Digital
Inputs. The Digital Inputs are also insulated from each other. All Counter Inputs
and Digital Inputs are reverse polarity protected and insulated from the I/O-bus.
2. For every pair of Digital Inputs (I0 & I1, I2 & I3) a noise filter can be configured
(10 kHz or 50 kHz (default)). Every Z-Input has a defined noise filter of 1 kHz.
$$
34#$(1($%'()*+-%*.-05%"%$'#"(+'($+ Section 1-3
Counter Inputs A, B, Z and Digital Inputs
5/12/24V input signals RS-422 Line Driver signals
Counter inputs A and B
Input pulses with a duty factor of 50%
C
BB
On
Counter Inputs A, B and Z
50%
Off
ts A and B
uty factor of 50%
Relationship between A and B phases with phase
Phase A
B
On
50%
Off
Phase B
phases with phase
uts
On
50%
Off
Z
* Maximum allowed frequency of Z-pulses is 1 kHz * Maxim um allowed frequency of Z-pulses is 1 kHz
differential inputs
DDDD
Counter Input Z * / Digital Inputs (24V)
RS-422 Line Driver signalssignals
AA
On
0V
Off
Relationship between A and B phases with phase
On
0V
Off
Phase A
On
E
0V
Off
Counter inputs A and B
Input pulses with a duty factor of 50%
F
GG
differential inputs
H
On
0V
Off
Relationship between A and B phases with phase
On
0V
Off
Phase A
On
0V
Off
Phase B
Counter inputs A and B
Input pulses with a duty factor of 50%
F
GG
differential inputs
H
II
Counter Input Z *
On
0V
Off
Z
I
I
J
$%
Filter
Selection
10 kHz
50 kHz
500 kHz
<3
>50<3
>10<3
>2
>100
>20
>4
Timing requirement [µs]
>1
>10>4.5
>10
>20
>2
>50>100>10>23
>10
>1
>100
>20
>4
>23
>4.5
JIHGFEDCBA
>10
>10
>10>1
Note As a general guideline it can be stated that if you want the timing requirements for
the Counter Inputs to satisfy the above mentioned specifications, you must pay
attention to the type of output driver of the encoder being used, the length of the
encoder cable and the frequency of the count pulses generated. For example, if
you use an E6B2-type Open Collector encoder (e.g. E6B2-CWZ6C) at 24 V with
10 m cable, you can typically generate count pulses up to 20 kHz. Therefore, if you
34#$(1($%'()*+-%*.-05%"%$'#"(+'($+ Section 1-3
want to generate count pulses with higher frequencies, you should use a different
type of encoder (e.g. E6B2-CWZ1X with Line Driver output or a fast push-pull 24
V encoder, e.g. E6C2-CWZ5GH) or reduce the length of the encoder cable.
1-3-4 Output Specifications
Item Specification
Driver Type Open Collector (NPN/PNP selectable)
Operating Voltage Range 12-24V (10.2 to 26.4V)
Maximum Switching Capacity 46 mA at 10.2V to 100 mA at 26.4V (400 mA maximum/common)
(see picture below)
Minimum Switching Current 5 mA
Output ON-delay 100 µs max.
Output OFF-delay 100 µs max.
Leakage Current 0.1 mA max.
Residual Voltage 1.5 V max.
Short Circuit Protection No
Maximum Switching
Capacity
Note 1. Every Digital Output has 2 Output drivers available: NPN and PNP (available
as separate pins on the front connectors). Every Output can be separately (DM-)
configured for NPN or PNP. By default the Outputs are configured as NPN-output
(refer to 3-5-4 "Output Control Configuration").
2. The Digital Outputs are insulated from the I/O-bus but not from each other.
They are not short circuit protected.
3. The Output current must not exceed 400 mA per common (i.e. per 4 Digital Outputs) otherwise the unit will be damaged.
4. The Outputs can be automatically or manually controlled (DM-setting) by using
Force ON/OFF bits in CIO (refer to 3-5 "Output Control").
5. The state control of the 32 Outputs, in case the operating mode of the PLCCPU is changed from RUN/MONITOR → PROGRAM, an I/O Bus error or an
Overflow/Underflow error occurs, can be configured (refer to 3-5-4 "Output
Control Configuration").
The maximum switching current depends upon the power supply voltage, as
shown below.
100
Maximum Switchign Capacity (mA)
46
10.2 20.4 26.4
External Supply Voltage (VDC)
$&
6&($7-3'%"'-84-9#1#"#*$#-:&(.# Section 1-4
Power Supply
Characteristics
The power supplied to the Unit, to feed the Digital Outputs, has to be supplied
externally and should be a double insulated class II (over-voltage) type with ratings from 12 to 24 VDC (10.2 to 26.4 VDC). Characteristics of the Power Supply
Input circuitry are summarized in the following table.
Item Specification
Operating Voltage Range 10.2-26.4 VDC
Current Consumption 30 mA max. (load current excluded)
Internal Fault Protection Two 1A (not replaceable) internal fuses in Power Supply lines
Reverse Polarity Protection Yes
1-4 Quick Start Up Reference Guide
Operation and
Configuration
Every Counter of the High-speed Counter Unit can be configured as Simple, Circular or Linear Counter (refer to the next section 1-5 "Operating Procedure Guide-
lines" for quick start up information).
Counters configured as Circular/Linear Counter can use all the functions and features that the Unit offers to you, while Counters configured as Simple Counter only
offer you a limited subset instead. The diagram below shows you all the functional
blocks that the Unit has available to you to operate and configure the Unit (refer to
"Operation and Configuration"). The numbers in grey refer to the table on page 16
to indicate which functions are supported for Simple Counters and which functions
for Circular/Linear Counters.
Capture
2, 3 2, 3
Register
Counter Inputs
1
(A, B, Z)
Simple
Counter*
1, 2, 3, 4
Counter
Start/Stop
9
Measurement
Circular
Linear
Rate
I0
Digital Inputs
3
(I0, I1, I2, I3)
11
Noise Filter
Time-Window
* Diagram is valid for every Counter 1, 2, 3 and 4
I1
I2
I3
2, 3 2, 3, 7
Preset
Register
Counter
Reset
8
Output State
5
Automatic
4
Output Control
4
Output Control
10
Rate History
Log File
Programmable
Output Pulse
Control
Manual
Hysteresis
NPN/PNP
Digital Outputs
6
(O0, O1, O2, O3)
$'
6&($7-3'%"'-84-9#1#"#*$#-:&(.# Section 1-4
Exchanging data with CPU The diagram below shows you all the functional blocks that the Unit has available
to you to exchange data with the CS1-CPU (refer to "Exchanging Data with
CPU").
CS1-CPU
13
13
14
15
IOWR
IORD
Interrupts
Interrupts
CS1W-CT021/
CT041
Unit Output Pattern
O3
O2
O1
O0
I0
I1
I2
I3
$(
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