Cat. No. W195-E1-5
SYSMAC CV-series
CV500/CV1000/CV2000/CVM1
Programmable Controllers
SYSMAC CV-series
CV500/CV1000/CV2000/CVM1
Programmable Controllers
Installation Guide
Revised October 1999
iv
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 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.
! WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
! 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 “PC” means Programmable 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.
Note Indicates information of particular interest for efficient and convenient operation
of the product.
1, 2, 3...
1. Indicates lists of one sort or another, such as procedures, checklists, etc.
© OMRON, 1992
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.
v
vi
TABLE OF CONTENTS
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Operating Environment Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Application Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 Conformance to EC Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1-2
1-3
1-4
1-5
1-6
1-7
1-8
1-9
Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Role of the PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PC Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CV-series Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-series–CV-series System Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Networks and Remote I/O Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
New CPUs and Related Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CPU Comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Improved Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2
System Configuration and Components . . . . . . . . . . . . . .
2-1
2-2
2-3
System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rack Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
3-2
3-3
3-4
3-5
3-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring I/O Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compliance with EC Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4
Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . .
4-1
4-2
4-3
4-4
CPU Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Memory Card Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output Unit Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output Unit Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
5-2
5-3
Error Messages and Alarm Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Flowcharts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Error Processing and Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendices
A Standard Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
vii
About this Manual:
This manual describes the installation of the SYSMAC CV-series Programmable Controllers (CV500,
CV1000, CV2000, and CVM1). This manual is designed to be used together with three CV-series PC operation manuals. The entire set of CV-series PC manuals is listed below. Only the basic portions of the
catalog numbers are given; be sure you have the most recent version for your area.
Manual
Cat. No.
CV-series PC Installation Guide
W195
CV-series PC Operation Manual: SFC
W194
CV-series PC Operation Manual: Ladder Diagrams
W202
CV-series PC Operation Manual: Host Interface
W205
Programming and operating CV-series PCs are performed with the CV Support Software (CVSS), the
SYSMAC Support Software (SSS), and the CV-series Programming Console for which the following manuals are available.
Product
Manuals
CVSS
The CV Series Getting Started Guidebook (W203) and the CV Support Software
Operation Manuals: Basics (W196), Offline (W201), and Online (W200).
SSS
SYSMAC Support Software Operation Manuals: Basics (W247), C-series PC Operations (W248), and CVM1 Operations (W249)
CV-series Programming
Console
CVM1-PRS21-E Programming Console Operation Manual (W222)
Note The CVSS does not support new instructions added for version-2 CVM1 PCs. The SSS does not
support SFC programming (CV500, CV1000, or CV2000).
Section 1 introduces programmable controllers in general and provides tables of the Units the can be
used with CV-series PCs and operation manuals available for CV-series products. Special products used
to create networks, enable remote I/O, or provide additional programming capabilities are also provided.
Tables are also provided of new products included for the first time in this version of the manual, along with
a comparison of CPU capabilities, and a list of improvements made in recent CPU versions.
Section 2 describes the overall configuration that the PC System can take and introduces the main Units
used in the system configuration.
Section 3 provides procedures on installing and wiring.
Section 4 provides information on ongoing maintenance.
Section 5 describes general troubleshoot and provides troubleshooting flowcharts.
Appendix A provides tables of C- and CV-series products that can be used with CV-series PCs.
Appendix B provides general PC specifications, dimensions, and I/O Unit specifications (including internal circuit configurations and wiring diagrams).
! 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.
ix
PRECAUTIONS
This section provides general precautions for using the Programmable Controller (PC) and related devices.
The information contained in this section is important for the safe and reliable application of the Programmable Controller. You must read this section and understand the information contained before attempting to set up or operate a
PC system.
1 Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Operating Environment Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Application Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 Conformance to EC Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
xi
3
Safety Precautions
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 PC and all PC 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 PC System to the above-mentioned
applications.
3
Safety Precautions
! WARNING Do not attempt to take any Unit apart while the power is being supplied. Doing so
may result in electric shock.
! WARNING Do not touch any of the terminals or terminal blocks while the power is being
supplied. Doing so may result in electric shock.
! WARNING Do not attempt to disassemble, repair. or modify any Units. Any attempt to do so
may result in malfunction, fire, or electric shock.
! WARNING There is a lithium battery built into the SRAM Memory Cards. Do not short the
positive and negative terminals of the battery, charge the battery, attempt to take
it apart, subject it to pressures that would deform it, incinerate it, or otherwise
mistreat it. Doing any of these could cause the battery to erupt, ignite, or leak.
! Caution
xii
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.
5
Application Precautions
4
Operating Environment Precautions
! Caution
Do not operate the control system in the following places:
• 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
5
The operating environment of the PC 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 PC 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.
Application Precautions
Observe the following precautions when using the PC System.
! WARNING Always heed these precautions. Failure to abide by the following precautions
could lead to serious or possibly fatal injury.
• Always ground the system to 100 Ω or less when installing the Units. Not connecting to a ground of 100 Ω or less may result in electric shock.
• Always turn OFF the power supply to the PC before attempting any of the following. Not turning OFF the power supply may result in malfunction or electric
shock.
• Mounting or dismounting I/O Units, Memory Cassettes, or any other Units.
• Setting 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
PC or the system, or could damage the PC or PC Units. Always heed 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.
xiii
Conformance to EC Directives
6
• Interlock circuits, limit circuits, and similar safety measures in external circuits
(i.e., not in the Programmable Controller) must be provided by the customer.
• Always use the power supply voltage 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.
• Do not apply voltages to the Input Units in excess of the rated input voltage.
Excess voltages may result in burning.
• Do not apply voltages or connect loads to the Output Units in excess of the
maximum switching capacity. Excess voltages or loads may result in burning.
• Disconnect the functional ground terminal when performing withstand voltage
tests. Not disconnecting the functional ground terminal may result in burning.
• Install the Unit properly as specified in the operation manual. Improper installation of the Unit 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.
• 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 before turning on the power supply. Incorrect wiring may result in burning.
• 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 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 PC.
• Force-setting/force-resetting any bit in memory.
• Changing the present value of any word or any set value in memory.
• Resume operation only after transferring to the new CPU Unit the contents of
the DM Area, HR Area, and other data required for resuming operation. Not
doing so may result in an unexpected operation.
• 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. Doing so may break the cables.
6
Conformance to EC Directives
The CV-series PCs that comply with EC Directives must be installed as follows:
1, 2, 3...
xiv
1. The CV-series PCs are designed for installation inside control panels. The
PC must be installed within a control panel.
2. Use reinforced insulation or double insulation for the DC power supplies to
be connected to the DC I/O Units for CV500-PS211. Use separate power
supplies as the external power supplies for the Relay Output Units and the
power supplies for the DC I/O Units.
3. To meet the EC Directives (Low Voltage Directive), the maximum switching
capacity while the CV500-PS211 is being operated is 24 VDC/2 A.
6
Conformance to EC Directives
4. PCs complying with EC Directives also conform to the Common Emission
Standard (EN50081-2). When a PC is built into a machine, however, noise
can be generated by switching devices using relay outputs and cause the
overall machine to fail to meet the Standards. If this occurs, surge killers
must be connected or other measures taken external to the PC.
The following methods represent typical methods for reducing noise, and
may not be sufficient in all cases. Required countermeasures will vary
depending on the devices connected to the control panel, wiring, the configuration of the system, and other conditions.
Countermeasures
Refer to EN50081-2 for more details.
Countermeasures are not required if the frequency of load switching for the
whole system including the PC is less than 5 times per minute.
Countermeasures are required if the frequency of load switching for the whole
system including the PC is 5 or more times per minute.
Countermeasure Examples
When switching an inductive load, connect a surge protector, diodes, etc., in parallel with the load or contact as shown below.
Circuit
Current
AC
Power
supply
Yes
No
Power
supply
Yes
Inductive
load
Varistor method
Required element
If the load is a relay or solenoid, there
is a time lag between the moment the
circuit is opened and the moment the
load is reset.
The capacitance of the capacitor must
be 1 to 0.5 μF per contact current of
1 A and resistance of the resistor must
be 0.5 to 1 Ω per contact voltage of
1 V. These values, however, vary with
the load and the characteristics of the
relay. Decide these values from
testing, and take into consideration
that the capacitance suppresses spark
discharge when the contacts are
separated and the resistance limits
the current that flows into the load
when the circuit is closed again.
If the supply voltage is 24 or 48 V,
insert the surge protector in parallel
with the load. If the supply voltage is
100 to 200 V, insert the surge
protector between the contacts.
Yes
Inductive
load
Diode method
Power
supply
Yes
Inductive
load
CR method
Characteristic
DC
Yes
The diode connected in parallel with
the load changes energy accumulated
by the coil into a current, which then
flows into the coil so that the current
will be converted into Joule heat by
the resistance of the inductive load.
The dielectric strength of the capacitor
must be 200 to 300 V. If the circuit is
an AC circuit, use a capacitor with no
polarity.
The reversed dielectric strength value
of the diode must be at least 10 times
as large as the circuit voltage value.
The forward current of the diode must
be the same as or larger than the load
current.
This time lag, between the moment
the circuit is opened and the moment
the load is reset, caused by this
method is longer than that caused by
the CR method.
The reversed dielectric strength value
of the diode may be two to three times
larger than the supply voltage if the
surge protector is applied to electronic
circuits with low circuit voltages.
The varistor method prevents the
imposition of high voltage between the
contacts by using the constant voltage
characteristic of the varistor. There is
time lag between the moment the
circuit is opened and the moment the
load is reset.
---
If the supply voltage is 24 or 48 V,
insert the varistor in parallel with the
load. If the supply voltage is 100 to
200 V, insert the varistor between the
contacts.
xv
6
Conformance to EC Directives
When switching a load with a high inrush current such as an incandescent lamp,
suppress the inrush current as shown below.
Countermeasure 1
Countermeasure 2
R
OUT
OUT
R
COM
Providing a dark current of approx.
one-third of the rated value through
an incandescent lamp
xvi
COM
Providing a limiting resistor
SECTION 1
Introduction
This section provides general information about Programmable Controllers and how they fit into a Control System. It also list
the C-series products that can be used with the CV-series PCs and operation manuals available for CV-series products. Finally,
this section introduces Systems that can be used to create networks and enable remote I/O.
1-1
1-2
1-3
1-4
1-5
1-6
1-7
1-8
1-9
Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Role of the PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2-1 Input Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2-2 Output Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PC Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CV-series Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-series–CV-series System Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Networks and Remote I/O Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
New CPUs and Related Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CPU Comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Improved Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-9-1 Upgraded Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-9-2 Version-1 CPUs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-9-3 Version-2 CVM1 PCs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
Section 1-2
The Role of the PC
1-1
Control Systems
A Control System is the electronic equipment needed to control a particular process. It may include everything from a process control computer, to the factory
computer, down through the PCs, and then on down through the network to the
I/O devices: control components like the switches, stepping motors, solenoids,
and sensors which monitor and control mechanical operations.
Process Control Computer
Factory Computer
PCs
PC
PC
PC
I/O devices
A Control System can involve very large applications where many different models of PC are networked together or it could be an application as small as a single
PC controlling a number of output devices.
1-2
The Role of the PC
The PC is the part of the Control System that directly controls the manufacturing
process. According to the program stored in its memory, the PC accepts data
from the input devices connected to it and uses this data to monitor the controlled system. When the program calls for some action to take place, the PC
sends data to the output devices connected to it to cause that action to take
place. The PC may be used to control a simple, repetitive task, or it may be connected to other PCs or to a host computer in order to integrate the control of a
complex process.
2
Section 1-2
The Role of the PC
1-2-1 Input Devices
PCs can receive inputs from either automated or manual devices. The PC could
receive data from the user via a pushbutton switch, keyboard, or similar device.
Automated inputs could come from a variety of devices: micro-switches, timers,
encoders, photoelectric sensors, and so on. Some devices, like the limit switch
shown below, turn ON or OFF when the equipment actually makes contact with
them. Other devices, like the photoelectric sensor and proximity sensor shown
below, use other means, such as light or inductance, in order to get information
about the equipment being monitored.
Photoelectric Sensor
Proximity Sensor
Limit Switch
1-2-2 Output Devices
A PC can output to a myriad of devices for use in automated control. Almost anything that you can think of could be controlled by a PC. Some of the most common devices are motors, solenoids, servomotors, stepping motors, valves,
switches, indicator lights, buzzers, and alarms. Some of these output devices,
such as the motors, solenoids, servomotors, stepping motors, and valves, affect
the controlled system directly. Others, such as the indicator lights, buzzers, and
alarms, provide outputs to notify personnel operating or monitoring the system.
Solenoid
Servomotor
Stepping Motor
3
Section 1-3
PC Operation
1-3
PC Operation
PCs operate by monitoring input signals and providing output signals. When
changes are detected in input signals, the PC reacts through the user-programmed internal logic to produce output signals. The PC continually executes
the program in its memory to achieve this control.
Block Diagram of PC
Power Supply
Memory
Signals
from
switches,
sensors,
etc.
Input
CPU
Output
Signals to
Solenoids,
motors,
etc.
Programming
Device
A program for your applications must be designed and stored in the PC. This
program is then executed as part of the cycle of internal operations of the PC.
Execution Cycle
When a PC operates, i.e., when it executes its program to control an external
system, a series of operations are performed inside the PC. These internal operations can be broadly classified into the following four categories. Refer to the
CV-series PCs Operation Manual: Ladder Diagrams for details.
1, 2, 3...
1. Common (or overseeing) processes, such as watchdog timer operation and
testing the program memory.
2. Data input and output.
3. Program execution.
4. Peripheral device servicing.
Cycle Time
The total time required for a PC to perform all these internal operations is called
the cycle time.
Timing is one of the most important factors in designing a Control System. For
accurate operations, it is necessary to have answers to such questions as these:
• How long does it take for the PC to execute all the instructions in its memory?
• How long does it take for the PC to produce a control output in response to a
given input signal?
4
Section 1-4
CV-series Manuals
The cycle time of the PC can be automatically calculated and monitored, but it is
necessary to have an understanding of the timing relationships within the PC for
effective System design and programming. Refer to the CV-series PCs Operation Manual: Ladder Diagrams for details on internal PC processing and to the
CVSS Operation Manuals for details on monitoring the cycle time.
1-4
CV-series Manuals
The following manuals are available for the various CV-series products. Other
manuals are also available for compatible C-series products (see next section).
Catalog number suffixes have been omitted; be sure you have the most recent
version for your region.
Product
CV-series PCs
CV Support Software ((CVSS))
SYSMAC Support Software (SSS)
Manual
Cat. No.
CV-series PCs Installation Guide
W195
CV-series PCs Operation Manual: SFC
W194
CV-series PCs Operation Manual: Ladder Diagrams
W202
CV-series PCs Operation Manual: Host Link System,
CV500-LK201 Host Link Unit
W205
The CV Series Getting Started Guidebook
CV Support Software Operation Manual: Basics
CV Support Software Operation Manual: Offline
W203
W196
W201
CV Support Software Operation Manual: Online
W200
SYSMAC Support Software Operation Manual: Basics
W247
SYSMAC Support Software Operation Manual: CVM1 PCs
W249
Graphic Programming Console (GPC)
CV500-MP311-E Graphic Programming Console Operation Manual
W216
Programming Console
CVM1-PRS21-E Programming Console Operation Manual
W222
SYSMAC NET Link System
SYSMAC NET Link System Manual
W213
SYSMAC LINK System
SYSMAC LINK System Manual
W212
SYSMAC BUS/2 Remote I/O System
SYSMAC BUS/2 Remote I/O System Manual
W204
CompoBus/D (DeviceNet)
CompoBus/D (DeviceNet) Operation Manual
W267
CV-series Ethernet Unit
CV-series Ethernet System Manual
W242
BASIC Unit
BASIC Unit Reference Manual
W207
BASIC Unit Operation Manual
W206
Temperature Controller Data Link Unit
Personal Computer Unit Operation Manual
Personal Computer Unit Technical Manual
Motion Control Unit Operation Manual: Introduction
Motion Control Unit Operation Manual: Details
CV500-TDL21 Temperature Controller Data Link Unit
W251
W252
W254
W255
W244
Memory Card Writer
CV500-MCW01-E Memory Card Writer Operation Manual
W214
Optical Fiber Cable
Optical Fiber Cable Installation Guide
W156
Personal Computer Unit
Motion Control Unit
5
Section 1-5
C-series–CV-series System Compatibility
1-5
C-series–CV-series System Compatibility
The following table shows when C-series Units can be used and when CV-series
Units must be used. Any C-series Unit or Peripheral Device not listed in this table
cannot be used with the CV-series PCs.
Unit
CPU Rack
C Series
CV Series
Remarks
CPU
No
Yes
CV500-CPU01-EV1, CV1000-CPU01-EV1,
CV2000-CPU01-EV1, CVM1-CPU01-EV2,
CVM1-CPU11-EV2, and CVM1-CPU21-EV2
Power Supply
No
Yes
CV500-PS221, CV500-PS211, and
CVM1-PA208
CPU Backplane
No
Yes
CV500-BC031, CV500-BC051, CV500-BC101,
CVM1-BC103, and CVM1-BC053
I/O Control Unit
No
Yes
CV500-ICj01
Expansion CPU Backplane
No
Yes
CV500-BI111
Expansion I/O Backplane
No
Yes
16-/32-/64-point I/O Units
Yes
Yes
CV500-BI042, CV500-BI062, CV500-BI112,
CVM1-BI114, and CVM1-BI064 (C500
Expansion I/O Racks can be used with certain
limitations.)
---
Special I/O Units
Yes
Yes
Applicable Units include Analog Input, Analog
Output, High-speed Counter, PID, Position
Control, Magnetic Card, ASCII, ID Sensor, and
Ladder Program I/O Units (The C500-ASC03
cannot be used.)
BASIC Unit
No
Yes
CV500-BSCj1
Personal Computer Unit
No
Yes
CV500-VP213-E/217-E/223-E/227-E
Temperature Control Data Link Unit
Link
SYSMAC NET
S
Systems
SYSMAC LINK
No
Yes
CV500-TDL21
Host Link Unit
No
No
No
Yes
Yes
Yes
CV500-SNT31
CV500-SLK11 and CV500-SLK21
CV500-LK201
Ethernet Unit
No
Yes
CV500-ETN01
SYSMAC BUS Units
SYSMAC BUS/2
CV Support Software
Yes
No
No
Yes
Yes
Yes
(See note.)
--CV500-RM211/221 and CV500-RT211/221
CV500-ZS3AT1-EV2 (3 1/2” floppy disks) and
CV500-ZS5AT1-EV2 (5 1/4” floppy disks) for
IBM PC/AT compatible
SYSMAC Support
Software (SSS)
Yes
Yes
(See note.)
C500-ZL3AT1-E (3.5” floppy disks) for IBM
PC/AT compatible
Graphic Programming
Console
Yes (Main
unit only)
GPC: 3G2C5-GPC03-E
Programming Console
No
Yes
(System
Cassette)
(See note.)
Yes
(See note.)
Remote I/O
S
Systems
Peripheral
Devices
System Cassette: CV500-MP311-E
CVM1-PRS21-EV1 (set)
Note The CVSS does not support new instructions added for version-2 CVM1 PCs.
The SSS does not support SFC programming (CV500, CV1000, and CV2000).
New instructions added for version-2 CVM1 PCs are also supported by version-1 CV-series Programming Consoles.
6
Section 1-6
Networks and Remote I/O Systems
1-6
Networks and Remote I/O Systems
Systems that can be used to create networks and enable remote I/O are introduced in this section. Refer to the operation manuals for the Systems for details.
SYSMAC NET Link System
The SYSMAC NET Link System is a LAN (local area network) for use in factory
automation systems. The SYSMAC NET Link System can consist of up to 128
nodes among which communications may be accomplished via datagrams,
data transfers, or automatic data links.
Datagrams transmit and receive data using a command/response format. Commands can be issued from the user program by the DELIVER COMMAND instruction (CMND(194)).
Data can also be transmitted and received using the NETWORK SEND and
NETWORK RECEIVE (SEND(192)/RECV(193)) instructions in the user program. Up to 256 words of data can be transferred for each instruction.
Automatic data links allow PCs and computers to create common data areas.
SYSMAC NET Link Unit
CV500-SNT31
Up to 4 Units can
be mounted.
CV-series
CPU Rack/Expansion CPU Rack
Line Server
Center Power
Feeder
Personal
computer
C200H
C500
C1000H
C2000H
Note Up to four SYSMAC NET Link Units (CV500-SNT31) can be mounted to the
CPU Rack and/or Expansion CPU Rack of each CV-series PC.
7
Section 1-6
Networks and Remote I/O Systems
SYSMAC LINK System
Networks can also be created using SYSMAC LINK Systems. A SYSMAC LINK
System can consist of up to 62 PCs, including the CV500, CV1000, CV2000,
CVM1, C200H, C1000H, and C2000H. Communications between the PCs is accomplished via datagrams, data transfers, or automatic data links in ways similar to the SYSMAC NET Link System.
The main differences between SYSMAC NET Link and SYSMAC LINK Systems
is in the structure of automatic data links and in the system configuration, e.g.,
only PCs can be linked in SYSMAC LINK Systems, whereas other devices can
form nodes in SYSMAC NET Link Systems.
Datagrams transmit and receive data using a command/response format. Commands can be issued from the user program by the DELIVER COMMAND instruction (CMND(194)).
Data can also be transmitted and received using the NETWORK SEND and
NETWORK RECEIVE (SEND(192)/RECV(193)) instructions in the user program. Up to 256 words of data can be transferred for each instruction.
Automatic data links allow PCs and computers to create common data areas.
SYSMAC LINK Unit
CV500-SLK11 (optical)
CV500-SLK21 (wired)
Up to 4 Units can
be mounted.
CV-series
CPU Rack/Expansion CPU Rack
CV500/CV1000/
CV2000/CVM1
C200H/C1000H/
C2000H
Note Up to four SYSMAC LINK Units (CV500-SLK11/21) can be mounted the CPU
Rack and/or Expansion CPU Rack of each CV-series PC.
8
Section 1-6
Networks and Remote I/O Systems
SYSMAC BUS/2 Remote I/O
System
Remote I/O can be enabled by adding a SYSMAC BUS/2 Remote I/O System to
the PC. The SYSMAC BUS/2 Remote I/O System is available in two types: optical and wired.
Two Remote I/O Master Units, optical or wired, can be mounted to the CV500 or
CVM1-CPU01-EV2 CPU Rack or Expansion CPU Rack. Four Remote I/O Master Units can be mounted to the CV1000, CV2000, or CVM1-CPU11/21-EV2
CPU Rack or Expansion CPU Rack.
Up to eight Remote I/O Slave Racks can be connected per PC.
Slaves can be used to provide up to 1,024 remote I/O points for the CV500 or
CVM1-CPU01-EV2; up to 2,048 remote I/O points for the CV1000, CV2000, or
CVM1-CPU11/21-EV2. These limits are the totals for all Slaves control by one
PC.
A Programming Device (such as the CVSS) can be connected to up to two Remote I/O Slave Units for each Remote I/O Master Unit as long as a total of no
more than four Programming Devices are connected per PC.
Remote I/O Master Unit
CV500-RM211 (optical)
CV500-RM221 (wired)
CV500, CVM1-CPU01-EV2:
4 Masters max. can be mounted
CV1000, CV2000, CVM1-CPU11/21-EV2: 8 Masters max. can be mounted
CV-series
CPU Rack/Expansion CPU Rack
Remote I/O Slave
Up to 8 Slave can be connected per PC for 58M
Slaves; 4 Slaves for 122M
or 54MH Slaves.
Remote I/O Slave Unit
CV500-RT211 (optical)
CV500-RT221 (wired)
9
Section 1-6
Networks and Remote I/O Systems
SYSMAC BUS Remote I/O
System
Remote I/O can also be enabled by using the C-series SYSMAC BUS Remote
I/O System with CV-series PC.
Remote I/O Master Units can be mounted on any slot of the CPU Rack, Expansion CPU Rack, or Expansion I/O Rack. Up to four Masters can be mounted for
the CV500 or CVM1-CPU01-EV2, up to eight Masters for the CV1000, CV2000,
or CVM1-CPU11/21-EV2.
For each Master, up to two Slave Racks can be connected for the CV500 or
CVM1-CPU01-EV2; up to eight Slave Racks for the CV1000, CV2000, or
CVM1-CPU11/21-EV2. No more than 16 Slave Racks can be connected per PC.
Slaves can be used to provide up to 512 remote I/O points for the CV500 or
CVM1-CPU01-EV2; up to 1,024 remote I/O points for the CV1000, CV2000, or
CVM1-CPU11-EV2; up to 2,048 remote I/O points for the CVM1-CPU21-EV2.
These limits are the totals for all Slaves control by one PC.
Programming Devices cannot be connected to SYSMAC BUS Slave Racks.
Remote I/O Master Unit
3G2A5-RM001-(P)EV1 (optical)
C500-RM201 (wired)
CV500, CVM1-CPU01-EV2:
2 Masters max. can be mounted
CV1000, CV2000, CVM1-CPU11/21-EV2: 4 Masters max. can be mounted
Up to 8 Units
CV-series
CPU Rack/Expansion CPU
Rack/Expansion I/O Rack
C-series
Remote I/O Slave Rack
Host Link System
(SYSMAC WAY)
The CV-series PCs can be connected to a host computer with the host link connector via the CPU or a CV500-LK201 Host Link Unit mounted to a Rack.
RS-232C or RS-422 communications can be used depending on the switch setting. When RS-422 is selected, up to 32 PCs can be connected to a single host.
Data is transmitted and received by commands and responses.
Host
computer
Host link connector
10
Section 1-7
New CPUs and Related Units
BASIC Unit
The BASIC Unit can be connected to a personal computer to enable communications with the PC using the BASIC programming language. Up to 512 bytes
(256 words) of data can be transferred between the BASIC Unit and the CPU by
the PC READ/WRITE command without using the PC program.
Up to 256 words of data can also be transferred between the BASIC Unit and the
PC’s CPU by using the NETWORK SEND and NETWORK RECEIVE
(SEND(192)/RECV(193)) instructions in the PC program.
Data can also be transferred to other BASIC Units mounted on the same PC, or
to BASIC Units mounted to other PCs connected by networks formed using a
SYSMAC NET Link or SYSMAC LINK System. RS-232C, RS-422, Centronics,
and GPIB interfaces are available.
BASIC Unit
CV500-BSCj1
CV-series
CPU Rack/Expansion
CPU Rack
Personal computer
Personal Computer Unit
1-7
The Personal Computer Unit is a full-fledged IBM PC/AT compatible that can be
used to run independent programming directly on a Rack to eliminate the need
for separate installation space. It can run along or connected to any of the normal
peripherals supported by IBM PC/AT compatibles (mice, keyboards, monitors,
data storage devices, etc.), and as a CPU Bus Unit, the Personal Computer Unit
interfaces directly to the PC’s CPU though the CPU bus to eliminate the need for
special interface hardware, protocols, or programming.
New CPUs and Related Units
The following new CV-series CPUs and related Units are included in this version
of the manual for the first time. Refer to relevant sections of this manual or the
CV-series PC Operation Manual: Ladder Diagrams for further details.
Unit
CPU
Temperature Controller
Data Link Unit
Model number
CVM1-CPU01-EV2
CVM1-CPU11-EV2
CVM1-CPU21-EV2
CV500-CPU01-EV1
CV1000-CPU01-EV1
CV2000-CPU01-EV1
CV500-TDL21
Main specifications
I/O capacity: 512 pts; Ladder diagrams only
I/O capacity: 1,024 pts; Ladder diagrams only
I/O capacity: 2,048 pts; Ladder diagrams only
I/O capacity: 512 pts; Ladder diagrams or SFC + ladder diagrams
I/O capacity: 1,024 pts; Ladder diagrams or SFC + ladder diagrams
I/O capacity: 2,048 pts; Ladder diagrams or SFC + ladder diagrams
Connects up to 64 temperature control devices via 2 ports.
11
Section 1-9
Improved Specifications
1-8
CPU Comparison
The following table shows differences between the various CV-series CPUs.
CVM1CPU01-EV2
CPU
Ladder diagrams
Program- SFC
P
ming
Instructions
CVM1CPU11-EV2
CVM1CPU21-EV2
CV500CPU01-EV1
CV1000CPU01-EV1
CV2000CPU01-EV1
Supported
Supported
Supported
Supported
Supported
Supported
Not supported
Not supported
Not supported
Supported
Supported
Supported
284
284
285
169
170
170
Basic
instructions (ms)
0.15 to 0.45
0.125 to 0.375
0.125 to 0.375
0.15 to 0.45
0.125 to 0.375
0.125 to 0.375
Other
instructions (ms)
0.6 to 9.9
0.5 to 8.25
0.5 to 8.25
0.6 to 9.9
0.5 to 8.25
0.5 to 8.25
Program capacity (see note)
30K words
30K words
62K words
30K words
62K words
62K words
Local I/O capacity
512 pts
1,024 pts
2,048 pts
512 pts
1,024 pts
2,048 pts
Remote
I/O
capacity
SYSMAC BUS/2
1,024 pts
2,048 pts
2,048 pts
1,024 pts
2,048 pts
2,048 pts
SYSMAC BUS
512 pts
1,024 pts
2,048 pts
512 pts
1,024 pts
1,024 pts
8K words
24K words
24K words
8K words
24K words
24K words
Not supported
32K words
each for 8
banks
32K words
each for 8
banks
Speed
DM Area
Expansion DM Area
Not supported
Not supported
32K words
each for 8
banks
Timers
512
1,024
1,024
512
1,024
1,024
Counters
512
1,024
1,024
512
1,024
1,024
SFC steps
None
None
None
512
1,024
1,024
Step Flags
None
None
None
512
1,024
1,024
Transition Flags
None
None
None
512
1,024
1,024
Note The useable program capacity is 28K words or 60K words.
1-9
Improved Specifications
1-9-1 Upgraded Specifications
The following improvements are applicable to all CV500-CPU01-E and
CV1000-CPU01-E CPUs with lot numbers in which the rightmost digit is 3
(jjj3) or higher.
1, 2, 3...
1. The MLPX(110) (4-TO-16 DECODER) instruction has been improved to
also function as a 8-to-256 decoder and the DMPX(111) (16-TO-4 ENCODER) instruction has been improved to also function as a 256-to-8 encoder.
To enable this improvement, the digit designator (Di) has been changed as
shown below.
Digit number:
3 2 1 0
0
Specifies the first digit to be converted
4-to-16/16-to-4: 0 to 3
8-to-256/256-to-8: 0 or 1
Number of digits to be converted
4-to-16/16-to-4: 0 to 3 (1 to 4 digits)
8-to-256/256-to-8: 0 or 1 (1 or 2 digits)
Process
0: 4-to-16/16-to-4
1: 8-to-256/256-to-8
2. The following operating parameter has been added to the PC Setup.
JMP(004) 0000 Processing
Y: Enable multiple usage (default)
N: Disable multiple usage
12
Section 1-9
Improved Specifications
3. The operation of Completion Flags for timers has been changed so that the
Completion Flag for a timer turns ON only when the timer instruction is
executed with a PV of 0000 and not when the timer’s PV is refreshed to a PV
value of 0000, as was previously done.
Only the timing of the activation of the Completion Flag has been changed,
and the timer’s PV is still refreshed at the same times (i.e., when the timer
instruction is executed, at the end of user program execution, and every
80 ms if the cycle time exceeds 80 ms).
4. The READ(190) (I/O READ) and WRIT(191) (I/O WRITE) instructions have
been improved so that they can be used for Special I/O Units on Slave
Racks under the following conditions.
a) The lot number of the Remote I/O Master Unit and Remote I/O Slave Unit
must be the same as or latter than the following.
01
X
2
1992
October (Y: November; Z: December)
1st
b) The DIP switch on the Remote I/O Slave Unit must be set to “54MH.”
c) The Special I/O Unit must be one of the following: AD101, CT012,
CT021, CT041, ASC04, IDS01-V1, IDS02, IDS21, IDS22, or LDP01-V1.
(The NC221-E, NC222, CP131, and FZ001 cannot be mounted to Slave
Racks.)
1-9-2 Version-1 CPUs
CV-series CPUs were changed to version 1 from December 1993. The new
model numbers are as follows: CVM1-CPU01-EV1, CVM1-CPU11-EV1,
CV500-CPU-EV1, CV1000-CPU-EV1, and CV2000-CPU-EV1. (Of these, all
CVM1 CPUs were changed to version 2 from December 1994; refer to the next
sections for details.)
The following additions and improvements were made to create the version-1
CPUs.
PT Link Function
The host link interface on the CPU can be used to connect directly to Programmable Terminals (PTs) to create high-speed data links. To use the PT links, turn
ON pin 3 of the DIP switch on the CPU. Pin 3 must be turned OFF for host link
connections.
EEPROM Writes
With the new CPUs, you can write to EEPROM Memory Cards mounted to the
CPU by using the file write operation from a Peripheral Device. A Memory Card
Writer is no longer required for this write operation. Writing is possible in PROGRAM mode only.
New Command
A new I/O REGISTER command (QQ) has been added so that words from different data areas can be read at the same time.
Faster Host Links
The communications response time for the built-in host link interface on the CPU
has been improved by a factor of approximately 1.2.
Faster Searches
The search speed from Peripheral Devices for instructions and operands has
been nearly doubled.
1-9-3 Version-2 CVM1 PCs
CVM1 CPUs were changed to version 2 and a new CPU was added from December 1994. The new model numbers are as follows: CVM1-CPU01-EV2,
CVM1-CPU11-EV2, and CVM1-CPU21-EV2.
13
Section 1-9
Improved Specifications
The following additions and improvements were made to create the version-2
CPUs.
CMP/CMPL
New versions of the CMP(020) and CMPL(021) have been added that are not
intermediate instructions. The new instructions are CMP(028) and CMPL(029)
and are programs as right-hand (final) instructions. A total of 24 other new comparison instructions have also been added with symbol mnemonics (e.g., >, +,
and