SYSMAC CS-series High-speed Counter Units CS1W-CT021/041 CSM_CS1W-CT_DS_E_2_1 High-Speed, Flexible Control With A Wide Array of Features • Equipped with 2 or 4 Counters and counts 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 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. CS1W-CT021 CS1W-CT041 Features • • • • • • • • • • • Input frequencies to 500 kHz (with line driver input). 32-bit counting range. 2 or 4 axes operation available. 5, 12, 24 V line driver inputs available. (5 and 12 V line driver input is only available for 1 axis with the CS1W-CT021 and 2 axes with the CS1WCT041). Supports simple, ring, and linear counting modes. Supports offset phase input, up and down pulse input, and pulse + direction input. Supports 4 external control outputs and a total of 16 functions can be set including open gate, close gate, preset, reset, capture, stop/capture/ reset combinations, and reset enable. One Module supports 4 external outputs and 28 internal outputs with counter value zone comparisons, target comparisons, delays, holds, programmable outputs, and hysteresis settings. Pulse rate measurement function and data logging. Counter outputs and external control inputs can be used to trigger interrupt tasks in the CPU. Settings can be changed during Module operation. 1 CS1W-CT021/041 System Configuration High-speed Counter Unit CS1W-CT041 C T 041 RUN ERC CH1 A CH2 A CH3 A CH4 A B B B B P ow er ERH I0 I1 I2 I3 Z Z Z Z P S204S O0 O1 O2 O3 MACH N o. X 10 1 X 10 0 1 1 CN 2 CN 1 20 20 A Counter Inputs Encoder B A B Typical applicable Sensors for Digital Inputs: Photoelectric Sensor Push Button Typical applicable Actuators for Digital Outputs: Relays Lamp Proximity Switch Limit Switch Proximity Switch Motor Interface ON/OFF High/Low Speed Forward/Reverse Brake ON/OFF Other Actuators 2 CS1W-CT021/041 Ordering Information International Standards • The standards are abbreviated as follows: U: UL, U1: UL (Class I Division 2 Products for Hazardous Locations), C: CSA, UC: cULus, UC1: cULus (Class I Division 2 Products for Hazardous Locations), CU: cUL, N: NK, L: Lloyd, and CE: EC Directives. • Contact your OMRON representative for further details and applicable conditions for these standards. Specifications Unit type Product name Countable channels 2 HighCS1 speed Special I/O Counter Unit Units Max. counting rate Encoder A and B inputs, pulse input Z signals 4 Open collector Input voltage: 5 V DC, 12 V DC, or 24 V DC (only 1 axis for 5 V or 12 V input) 50kHz RS-422 line driver 500kHz Open collector Input voltage: 5 V DC, 12 V DC, or 24 V DC (up to 2 axes for 5 V or 12 V input) 50kHz RS-422 line driver 500kHz No. of unitnumbers allocated Current consumption (A) Model 5V 26 V 0.36 − Standards CS1W-CT021 UC, N, L, CE 4 0.45 − CS1W-CT041 Accessories The High-Speed Counter Unit includes the 40-pin solder-type connectors C500-CE404 (socket: Fujitsu FCN-361J040-AU, cover: Fujitsu FCN360C040-J2). Applicable Connectors Name Connection Soldered Crimped 40-pin Connectors Specifications Model FCN-361J040-AU Connector FCN-360C040-J2 Connector Cover Right angle type, included with Unit C500-CE404 FCN-363J040 Housing FCN-363J-AU Contactor FCN-360C040-J2 Connector Cover Right angle type C500-CE405 FCN-367J040-AU/F, w/o connector cover C500-CE403 40-pin, soldered, w/connector cover C500-CE401 40-pin, crimped w/connector cover C500-CE402 Pressure welded Soldered Crimped Connector-Terminal Conversion Unit and Connection Cables Product Name Specifications Connecting Cables Normal wiring For Connecting with Terminal Block Connector-Terminal Conversion Unit Through Slim Model Cable length: 0.5m XW2Z-050B Cable length: 1.0m XW2Z-100B Cable length: 1.5m XW2Z-150B Cable length: 2.0m XW2Z-200B Cable length: 3.0m XW2Z-300B Cable length: 5.0m XW2Z-500B 40-pin M2.4 screw terminals XW2B-40G4 40-pin M3.5 screw terminals XW2B-40G5 40-pin M3 screw terminals XW2D-40G6 Mountable Racks CS1 System Model CS1W-CT021 CS1W-CT041 CS1D System CPU Rack Expansion Backplane Long-distance Expansion Racks CPU Rack Expansion Backplane Yes Yes Yes Yes Yes 3 CS1W-CT021/041 Specifications General Specifications Item CS1W-CT021/CT041 Unit type CS1 Special I/O Unit General Specifications Conform to general specifications for SYSMAC CS1-series Ambient Operating Temperature 0 to 55 °C Ambient Storage Temperature −20 to 75 °C Ambient Operating Humidity 10 to 90% without condensation Internal Current Consumption 450 mA (CS1W-CT041), 360 mA (CS1W-CT021) (at 5V via backplane) Dimensions 35 × 130 × 100 mm (W × H × 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 Equal to the number of slots of the Rack (see Note 1) Maximum Number of CT021/CT041 Units per basic CS1-system 24 Data Exchange with CPU Unit • I/O Refresh Data Area (CIO-bits 200000 to 295915, CIO-words 2000 to 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) Note: 1. The maximum number of Units per Rack is also depending on the maximum 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. 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. 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 • Circular Counter • 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. Maximum Input Frequency 500 kHz Maximum Response Time 0.5 ms (refer to High-speed Counter Units Operation Manual (Cat. No. W902)) 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. • 4 Digital Outputs (O0, O1, O2 and O3): The Unit Output Pattern represents the 4 Digital Outputs and 28 Soft Outputs. Input Signal Types • Phase Differential (multiplication ×1), (multiplication ×2) ∗ and (multiplication ×4) ∗ • Up/Down ∗ • Pulse & Direction ∗ Counter Control using CIOsoftware bits • 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 Digital Input Functionality • Gate ∗ • 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. Output Control Mode • Automatic Output Control in: • Range Mode ∗ • Comparison Mode ∗ • Rate Range • Manual Output Control 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 ∗ The Output Driver of every Digital Output can be configured as: Output Driver Configuration • NPN • PNP ∗ 4 CS1W-CT021/041 Item CS1W-CT021/CT041 Reset Signals Every Counter can be reset to zero by (a combination of) the following sources: • Software Counter Reset Bit • Digital Input ∗ • Z-Input ∗ Extra Functions • Programmable Output Pulse ∗ : To every Digital Output an ON-delay and/or a Pulse Duration [1 to 9999 ms] can be applied. • Rate Measurement ∗ : For every Counter the Pulse Rate can be measured by defining a Time-Window [1 to 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. • 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 to 255] can be defined (the Unit must in Range Mode). Noise Filtering Counter Inputs and Digital Inputs 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. Initial Counter Value • The Initial Counter Value ∗ is transferred to the Unit when the Unit is Powered Up or Restarted. The Initial Counter Value is very useful to overcome problems in case of power failure. 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 ∗ • Range- and Comparison Data ∗ • Captured Counter Value • Rate History Log File Data ∗ • Counter Value • (Re) Configure High-speed Counter Unit ∗ • Error Clear 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 ∗ . Interrupts of Digital Inputs • The Digital Inputs can all be configured to generate interrupts to the CS1-CPU ∗ . Error History Log Function • Stores up to 30 error log records ∗1. 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 High-speed Counter Units Operation Manual (Cat. No. W902). ∗2. If an IOWR- or IORD-instruction is used during operation, comparison will stop during instruction execution. Care must be taken, therefore, with the timing of executing instructions. Input Specifications Item Digital Inputs (I0, I1, I2 and I3) Counter Inputs A and B Input Voltage 24 VDC (19.6 to 26.4 V) 12 VDC (9.8 to 13.2V) 5 VDC (4.5 to 5.5V) Input Current (typical) 8 mA 8 mA 7 mA ON Voltage (min.) 19.6 V 9.8 V 4.5 V OFF Voltage (max.) 4V 2.5 V 1.5 V Input Voltage 24 VDC (18.6 to 26.4 V) 12 VDC (9.8 to 13.2V) 5 VDC (4.5 to 5.5V) Input Current (typical) 7.3 mA 6.6 mA 6 mA ON Voltage (min.) 18.6V 9.8V 4.5V OFF Voltage (max.) 4V 2.5V 1.5V Item Line Driver 24 VDC (19.6 to 26.4 V) 7.6 mA 11mA Connectable to RS-422 compatible Line Drivers. 19.6 V 4V Counter Input Z Line Driver 11mA 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. 5 CS1W-CT021/041 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% Counter inputs A and B Input pulses with a duty factor of 50% C F B B G G On On 50% 0V Off Off A A Relationship between A and B phases with phase differential inputs Relationship between A and B phases with phase differential inputs H Phase A On On 50% 0V Off Off Phase A On 0V Phase B Off D D D Phase B D I Counter Input Z ∗ / Digital Inputs (24 V) On On 50% 0V Off Off Z I I I Counter Input Z ∗ Z E J ∗ Maximum allowed frequency of Z-pulses is 1 kHz ∗ Maximum allowed frequency of Z-pulses is 1 kHz Timing requirement (µs) Filter Selection A B C D E F G H I J 10 kHz <3 >50 >100 >23 >10 >100 >50 >100 >23 >10 50 kHz <3 >10 >20 >4.5 >10 >20 >10 >20 >4.5 >10 500 kHz − − − − − >2 >1 >4 >1 >10 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 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. E6C3-CWZ5GH (Complementary output)) or reduce the length of the encoder cable. 6 CS1W-CT021/041 Output Specifications Item Specification Driver Type Open Collector (NPN/PNP selectable) Operating Voltage Range 12 to 24V (10.2 to 26.4V) 30 mA max. at 26.4 VDC (for PNP output, without load current) 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 None 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. 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 Out-puts) otherwise the unit will be damaged. 4. The Outputs can be automatically or manually controlled (DM-setting) by using Manual Output Control in CIO. 5. The state control of the 32 Outputs, in case the operating mode of the PLC-CPU is changed from RUN/MONITOR → PROGRAM, an I/ O Bus error or an Overflow/Underflow error occurs, can be configured. Maximum Switching Capacity Maximum Switchign Capacity (mA) The maximum switching current depends upon the power supply voltage, as shown below. 100 46 10.2 20.4 26.4 External Supply Voltage (VDC) 7 CS1W-CT021/041 External Interface CT021 RUN Indicators ERC CH1 A CH2 A B B ERH Z Z I0 O0 I1 I2 I3 O1 O2 O3 MACH No. Machine Number Switch CT041 RUN CH1 CH2 CH3 CH4 A A A A ERC B B B B ERH Z Z Z Z I0 O0 I1 I2 I3 O1 O2 O3 Counter Mode Switch MACH No. X101 X101 X100 1 1 CN2 CN1 X100 1 1 CN2 CN1 Bus Connector 20 20 A B A 20 20 A B B A B Indicators CT021 RUN ERC CH1 A B CH2 A B Z Z CS ERH I0 O0 I1 I2 I3 O1 O2 O3 CT041 RUN ERC CH1 CH2 CH3 CH4 A A A A B B B B Z Z Z Z CS ERH I0 O0 I1 I2 I3 O1 O2 O3 The indicators on the LED-display show the operating status of the Unit. The following table shows the meaning of the indicators. LED RUN ERC ERH Color Red Red Green A/B/Z Yellow O0/O1/O2/O3 Yellow Yellow Description ON Unit is in operation (i.e. Unit has initialised normally after (re-) starting the Unit). OFF Unit is not in operation (i.e. Unit was not able to initialise normally after (re-) starting the Unit or the power to the Unit is switched OFF). ON Unit has operational failure due to a detected error. Green CH1/2/3/4 I0/I1/I2/I3 State OFF Unit has no operational failure. ON CPU Unit has operational failure. OFF CPU Unit has no operational failure. ON Channel 1/2/3/4 (i.e. Counter 1/2/3/4) is ready to count (the corresponding counting gate is open). OFF Counter 1/2/3/4 is not ready to count (the corresponding counting gate is closed). ON Physical Input A/B/Z has turned ON. (Every Counter is characterised by the signals A/B/Z.) OFF Physical Input A/B/Z is turned OFF. ON Digital Input (I0/I1/I2/I3) is turned ON. OFF Digital Input (I0/I1/I2/I3) is turned OFF. ON Digital Output (O0/O1/O2/O3) is turned ON. OFF Digital Output (O0/O1/O2/O3) is turned OFF. 8 CS1W-CT021/041 Using Connector-Terminal Conversion Unit Wiring requires the dedicated connection cables. Connector-Terminal Conversion Unit and Connection Cables are sold separately. Model B 00906 A A Connection Cable Connector-Terminal Conversion Unit B CS1W-CT021 XW2Z-B XW2B-40G4 (40-pin M2.4 screw terminals) XW2B-40G5 (40-pin M3.5 screw terminals) B 00906 A A B CS1W-CT041 XW2Z-B XW2D-40G6 (40-pin M3 screw terminals) Note: 2 units are required for 4 axes control. 9 CS1W-CT021/041 Dimensions (Unit : mm) CS1W-CT021 CS1W-CT041 CT041 RUN CH1 CH2 CH3 CH4 A A A A ERC B B B B ERH Z Z Z Z I0 O0 I1 I2 I3 O1 O2 O3 MACH No. X101 X100 1 1 130 mm CN2 CN1 20 20 A B A B 35 mm 35 mm 130 mm 100 mm Related Manuals Cat. No. English W902 Japanese SBCC-829 Model CS1W-CT021 CS1W-CT041 Name High-speed Counter Units Operation Manual Contents Provides information on operating and installing High-speed Counter Units, including details. On basic settings, memory operation, direct operation from CPU and other functions. 10 Read and Understand This Catalog Please read and understand this catalog before purchasing the products. Please consult your OMRON representative if you have any questions or comments. Warranty and Limitations of Liability WARRANTY OMRON's exclusive warranty is that the products are free from defects in materials and workmanship for a period of one year (or other period if specified) from date of sale by OMRON. OMRON MAKES NO WARRANTY OR REPRESENTATION, EXPRESS OR IMPLIED, REGARDING NON-INFRINGEMENT, MERCHANTABILITY, OR FITNESS FOR PARTICULAR PURPOSE OF THE PRODUCTS. ANY BUYER OR USER ACKNOWLEDGES THAT THE BUYER OR USER ALONE HAS DETERMINED THAT THE PRODUCTS WILL SUITABLY MEET THE REQUIREMENTS OF THEIR INTENDED USE. OMRON DISCLAIMS ALL OTHER WARRANTIES, EXPRESS OR IMPLIED. LIMITATIONS OF LIABILITY OMRON SHALL NOT BE RESPONSIBLE FOR SPECIAL, INDIRECT, OR CONSEQUENTIAL DAMAGES, LOSS OF PROFITS OR COMMERCIAL LOSS IN ANY WAY CONNECTED WITH THE PRODUCTS, WHETHER SUCH CLAIM IS BASED ON CONTRACT, WARRANTY, NEGLIGENCE, OR STRICT LIABILITY. In no event shall the responsibility of OMRON for any act exceed the individual price of the product on which liability is asserted. IN NO EVENT SHALL OMRON BE RESPONSIBLE FOR WARRANTY, REPAIR, OR OTHER CLAIMS REGARDING THE PRODUCTS UNLESS OMRON'S ANALYSIS CONFIRMS THAT THE PRODUCTS WERE PROPERLY HANDLED, STORED, INSTALLED, AND MAINTAINED AND NOT SUBJECT TO CONTAMINATION, ABUSE, MISUSE, OR INAPPROPRIATE MODIFICATION OR REPAIR. Application Considerations SUITABILITY FOR USE OMRON shall not be responsible for conformity with any standards, codes, or regulations that apply to the combination of products in the customer's application or use of the products. At the customer's request, OMRON will provide applicable third party certification documents identifying ratings and limitations of use that apply to the products. This information by itself is not sufficient for a complete determination of the suitability of the products in combination with the end product, machine, system, or other application or use. The following are some examples of applications for which particular attention must be given. This is not intended to be an exhaustive list of all possible uses of the products, nor is it intended to imply that the uses listed may be suitable for the products: Outdoor use, uses involving potential chemical contamination or electrical interference, or conditions or uses not described in this catalog. Nuclear energy control systems, combustion systems, railroad systems, aviation systems, medical equipment, amusement machines, vehicles, safety equipment, and installations subject to separate industry or government regulations. Systems, machines, and equipment that could present a risk to life or property. Please know and observe all prohibitions of use applicable to the products. NEVER USE THE PRODUCTS FOR AN APPLICATION INVOLVING SERIOUS RISK TO LIFE OR PROPERTY WITHOUT ENSURING THAT THE SYSTEM AS A WHOLE HAS BEEN DESIGNED TO ADDRESS THE RISKS, AND THAT THE OMRON PRODUCTS ARE PROPERLY RATED AND INSTALLED FOR THE INTENDED USE WITHIN THE OVERALL EQUIPMENT OR SYSTEM. PROGRAMMABLE PRODUCTS OMRON shall not be responsible for the user's programming of a programmable product, or any consequence thereof. Disclaimers CHANGE IN SPECIFICATIONS Product specifications and accessories may be changed at any time based on improvements and other reasons. It is our practice to change model numbers when published ratings or features are changed, or when significant construction changes are made. However, some specifications of the products may be changed without any notice. When in doubt, special model numbers may be assigned to fix or establish key specifications for your application on your request. Please consult with your OMRON representative at any time to confirm actual specifications of purchased products. DIMENSIONS AND WEIGHTS Dimensions and weights are nominal and are not to be used for manufacturing purposes, even when tolerances are shown. PERFORMANCE DATA Performance data given in this catalog is provided as a guide for the user in determining suitability and does not constitute a warranty. It may represent the result of OMRON’s test conditions, and the users must correlate it to actual application requirements. Actual performance is subject to the OMRON Warranty and Limitations of Liability. ERRORS AND OMISSIONS The information in this document has been carefully checked and is believed to be accurate; however, no responsibility is assumed for clerical, typographical, or proofreading errors, or omissions. 2011.9 In the interest of product improvement, specifications are subject to change without notice. OMRON Corporation Industrial Automation Company http://www.ia.omron.com/ (c)Copyright OMRON Corporation 2011 All Right Reserved.