C102971 0 SERVICE PLC

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DOC-1017-1

Control Unit PLC A1

Service Manual

Revision history:

REV. DATE MODIFIER DESCRIPTION

0 2.4.2008

AaNi Created

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DOC-1017-1

CONTROL SYSTEM LOGICS A1 ...................................................................................................... 3

PLC UNIT A1 INSTALLATION .......................................................................................................... 4

PLC CPU UNIT DESCRIPTION ......................................................................................................... 6

3.1

ATTERY

.......................................................................................................................................... 7

3.2

EMORY CARD

................................................................................................................................ 8

3.3

PLC

CPU

DIP

SWITCH SETTINGS

..................................................................................................... 9

3.4

PLC

CPU

INDICATORS

....................................................................................................................11

3.4.1

Indicator Status and Error Conditions .......................................................................................12

CPU RACKS AND STANDARD EXPANSION RACKS ERRORS ................................................13

4.1

NPUT

RRORS

................................................................................................................................14

4.2

UTPUT

RRORS

............................................................................................................................16

ANALOQUE UNIT ...............................................................................................................................18

5.1

NALOGUE UNIT

MAD42

SETTING

.................................................................................................18

5.2

NALOGUE UNIT

ADO81

SETTING

..................................................................................................19

5.3

NALOGUE UNIT INDICATORS

.........................................................................................................20

5.3.1

Indication combinations .............................................................................................................21

SPECIAL I/O UNITS ERRORS ..........................................................................................................22

6.1

AULT FINDING

...............................................................................................................................23

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1 C

ONTROL SYSTEM LOGICS

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DOC-1017-1

2 PLC

NIT

INSTALLATION

CONNECTION

The Units that make up a PLC can be connected
simply by pressing the Units together and locking
the sliders by moving them toward the back of
the Units. The End Cover is connected in the
same way to the Unit on the far right side of the
PLC. Follow the procedure listed below to
connect PLC components.

The following diagram shows the connection of

two Units that make up a PLC. Join the Units so
that the connectors fit exactly.

The yellow sliders at the top and bottom of each
Unit lock the Units together. Move the sliders

toward the back of the Units as shown below
until they click into place.

Note If the locking tabs are not secured properly,
the may not function properly. Be sure to slide
the locking tabs until they are securely in place.
Attach the End Cover to the Unit on the far right
side of the Rack.

There is no Backplane. The PLC is constructed

by connecting Units together using the
connectors on the sides.

Attach the End Cover to the Unit on the far right
side of the Rack. An I/O bus error will occur and

the PLC will not operate in either RUN or
MONITOR mode if the End Cover is not

connected.

◊ NOTE

Always turn OFF the power supply before
connecting Units to each other.

Always turn OFF the power supply to the entire

system before replacing a Unit.

A maximum of 10 I/O Units can be connected to

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DOC-1017-1

a CPU Rack or an Expansion Rack.

DIN TRACK INSTALLATION

Use the following procedure to install a PLC on DIN
Track.

Release the pins on the backs of the Units.

Fit the back of the PLC onto the DIN Track by
inserting the top of the track and then pressing in

at the bottom of the PLC

Lock the pins on the backs of the Units.

Install a DIN Track End Plate on each end of the
PLC. To install an End Plate, hook the bottom on the
bottom of the track, rotate the Plate to hook the top of
the Plate on the top of the track, and then tighten the
screw to lock the Plate in place.

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3 PLC

CPU

NIT DESCRIPTION

1. CPU DIP switch
2. Built-in I/O MIL connector (40 pins)

3. I/O Indicator Indicates ON/OFF status

of signals to actual built-in inputs and

outputs.

4. Slider Secures the neighboring Unit.
5. Memory Card Indicators MCPWR

(green): Lit when power is supplied to
the Memory Card. BUSY (orange): Lit
when Memory Card is being accessed.

6. Indicators
7. Peripheral Port The peripheral port is

connected to Programming Devices,
such as Programming Consoles, or host

computers.

8. RS-232C Port The RS-232C port is

connected to Programming Devices
other than Programming Consoles, host

computers, general purpose external
devices, or Programmable Terminals.

9. Memory Card Connector
10. Memory Card
11. Memory Card Eject Button Press the

eject button to remove the Memory Card
from the CPU Unit.

12. Connector Connect to neighboring Unit

by joining Connectors.

13. 13. Memory Card Power Supply

Switch Press the power supply switch to
disconnect power before removing the

Memory Card. Also, press the Memory
Card Power Supply Switch to perform an
easy backup operation.

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DOC-1017-1

3.1 B

ATTERY

ATTERY FREE OPERATION

When the user program or data in the parameter areas is transferred to the CPU Unit, it
is now automatically backed up in the flash memory built into the CPU Unit. At startup,
this data is automatically restored from the flash memory to the operating memory,
enabling battery-free operation without a Memory Card.

NTERNAL BATTERY

This makes sure, that when voltage of the internal battery of the logic goes below the
alarm limit, the logic continue to operate.

ATTERY REPLACEMENT

Keep the power on during the battery replacement
procedure.

If the power disappears accidentally, the capacitor
that backs up memory will keep the memory alive 5
minutes.

Open the compartment on the upper left of the

CPU (A1) unit and carefully draw out the battery.

Insert a small flat-blade screwdriver into the

opening at the bottom of the battery compartment
cover and lift open the cover.

Check, that the new battery is same as the old one.

Remove the battery connector.

Connect the battery,

place it into compartment

Place the cable so that it is at an angle to the upper
right and close the cover.

Disconnect the logic power supply and restore it.

If you should change batteries often than once in three years, you should check,
if the control unit temperature is too high.

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3.2 M

EMORY CARD

Never turn OFF the PLC while the CPU is accessing the Memory Card.

INSTALLING THE MEMORY CARD

Never insert the Memory Card facing the
wrong way. If the Memory Card is inserted

forcibly, it may become unusable.

Pull the top end of the Memory Card cover

forward and remove from the Unit.

Insert the Memory Card with the label facing to
the right. (Insert with the arrow on the Memory

Card label and the arrow on the CPU Unit
facing each other.)

Push the Memory Card securely into the
compartment. If the Memory Card is inserted

correctly, the Memory Card eject button will be
pushed out.

REMOVING THE MEMORY CARD

Press the Memory Card power supply switch.

Press the Memory Card eject button after the

BUSY indicator is no longer Lit.

The Memory Card will eject from the

compartment.

Remove the Memory Card cover when a

Memory Card is not being used.

Never remove the Memory Card while the CPU is
accessing the Memory Card. Press the Memory
Card power supply switch and wait for the BUSY
indicator to go OFF before removing the Memory
Card. In the worst case, the Memory Card may
become unusable if the PLC is turned OFF or the
Memory Card is removed while the Card is being

accessed by the CPU.

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DOC-1017-1

3.3 PLC

CPU

DIP

SWITCH SETTINGS

The CPU Unit has an 8-pin DIP switch that is used to set basic operational parameters
for the CPU Unit. The DIP switch is located under the cover of the battery
compartment.

The DIP switch settings are described in the circuit diagrams. In this manual given
values are “basic” values, which could be different as in circuit diagrams.

PERATION MODE

Normal operation mode is “MONITOR” mode set by program device.

The CPU Unit will not enter any mode except PROGRAM mode after backing up data
to a Memory Card using DIP switch pin 7. To enter RUN or MONITOR mode, turn OFF
the power supply, turn OFF pin 7, and then restart the PLC. This will enable changing
the operating mode as normal.

DIP POS FUNCTION

USAGE

ON Writing disabled for user program

memory.
(See note.)

OFF Writing enabled for user program

memory.

Used to prevent programs from being
accidentally overwritten from Programming
Devices (including Programming Console).
The following data cannot be overwritten when
pin 1 is ON:

All parts of the user program (programs in

all tasks)

All data in the parameter area (such as the

PLC Setup and I/O table)

When pin 1 is ON, the user program and

parameter area will not be cleared when the
memory clear operation is performed from a
Programming Device.

ON The user program is automatically

transferred from the Memory Card
when power is turned ON.

OFF The user program is not

automatically transferred from the
Memory Card when power is
turned ON.

Used to store the programs in the Memory

Card to switch operations, or to automatically
transfer programs at power-up (Memory Card

ROM operation).
Note When pin 7 is ON and pin 8 is OFF, easy

backup reading from the Memory Card is given
priority, so even if pin 2 is ON, the user
program is not automatically transferred from
the Memory Card when power is turned ON.

Not used.

4 ON

Peripheral

port

communications

parameters

set in the PLC Setup are used.

OFF

Peripheral

port

communications

parameters
set using Programming Console
or CX-Programmer (Peripheral
bus only) are used.

Turn ON to use the peripheral port for a device
other than Programming Console or CX-

Programmer (Peripheral bus only).

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DOC-1017-1

DIP POS FUNCTION

USAGE

ON Turn ON to use the peripheral

port for a
device other than Programming
Console or
CX-Programmer (Peripheral bus

only).

OFF RS-232C port communications

parameters

set in the PLC Setup are used.

Turn ON to use the RS-232C port for a
Programming Device.

ON User-defined pin. Turns OFF the

User DIP
Switch Pin Flag (A39512).

OFF User-defined pin. Turns ON the

User DIP
Switch Pin Flag (A39512).

Set pin 6 to ON or OFF and use A39512 in
the program to create a user-defined condition
without using an I/O Unit.

ON Writing from the CPU Unit to the

Memory
Card.

Press and hold the Memory Card Power

Supply Switch for three seconds.

ON Restoring from the Memory Card

to the CPU Unit.

To read from the Memory Card to the CPU
Unit, turn ON the PLC power. This operation is

given priority over automatic
transfer (pin 2 is ON) when power is ON.

OFF Verifying contents of Memory

Card.

Press and hold the Memory Card Power

Supply Switch for three seconds.

8 OFF

Always

OFF.

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DOC-1017-1

3.4 PLC

CPU

INDICATORS

The PLC CPU unit has some indication LED, which indicates the status of PLC. The
indication is also depending of the indication lamp HI17 at remote control panel.

IND COLOR

STATUS

MEANING

HI17

PLC is operating normally.

OFF

Flashing System download mode error or DIP switch setting

error

OFF

RUN Green

OFF

PLC has stopped operating while in PROGRAM
mode, or has stopped operating due to a fatal error,
or is downloading data from the system.

OFF

PLC has stopped operating due to a fatal error, or a
hardware error (watchdog) has occurred. The PLC

turns all outputs OFF.

OFF

Flashing A non-fatal error has occurred. The PLC will continue

operating.

OFF

Flashing Battery voltage is below the monitoring level. You

should change the battery. This has no influence to
the operation of the PLC. The PLC software is
designed so, that it start from "Flash" memory after

black-out.

ERR/ALARM Red

OFF

PLC is operating normally.

OFF

Output OFF Bit (A50015) has been turned ON. The
outputs from all Output Units will turn OFF.

OFF

INH Orange

OFF

Output OFF bit (A50015) has been turned OFF.

Flashing CPU unit is communicating (sending or receiving) via

peripheral port.

PRPHL Orange

OFF

CPU unit is not communicating via the peripheral
port.

Flashing CPU Unit is communicating via RS232C port

COMM Orange

OFF

CPU Unit is not communicating via RS232C port

User program and parameter area dat is being
backed up to flash memory in the CPU Unit or being

restored from flash memory. Do not turn OFF the
power supply to the PLC while this indicator is lit.

BKUP Orange

OFF

Data is not being written to flash memory.

Power is being supplied to the Memory Card.

Flashing Flashes once: Easy backup read, write, or verify

normal

Flashes five times: Easy backup write malfunction
Flashes three times: Easy backup write warning
Flashes continuously: Easy backup read or verify
malfunction

MCPWR Green

OFF

Power is not being supplied to the Memory Card.

Flashing Memory Card is being accessed.

BUSY Orange

OFF

Memory Card is not being accessed.

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DOC-1017-1

3.4.1 I

NDICATOR

TATUS AND

RROR

ONDITIONS

COMMUNICATION
ERROR

IND. CPU

ERROR

CPU
STANDBY

FATAL
ERROR

NON-FATAL
ERROR

PERIPH RS232

OUTPUT
OFF BIT

RUN OFF

OFF OFF ON ON

ERR/ALARM ON

OFF

Flashing

INH OFF

PRPHL

OFF

COMM

OFF

OPERATION CPU

will
stop

The CPU

Unit will not
start

operation in
RUN or

MONITOR
mode.

The CPU

Unit will stop
operating in

RUN or
MONITOR

mode.

The CPU

Unit will
continue

operating in
RUN or

MONITOR
mode.

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DOC-1017-1

4 CPU

ACKS AND

TANDARD

XPANSION

ACKS

RRORS

SYMPTOM CAUSE REMEDY

PCB short-circuited or
damaged.

Replace Power Supply Unit.

Error in program.

Correct program

POWER indicator is not lit.

Power line is faulty.

Replace Power Supply Unit.

RUN output* does not turn

ON., RUN indicator lit.

Internal circuitry of Power

Supply Unit
is faulty.

Replace Power Supply Unit.

Serial Communications Unit or
CPU

Bus Unit does not operate or
malfunctions.
Bits do not operate past a

certain point.
Error occurs in units of 8
points.
I/O bit turns ON
All bits in one Unit do not turn
ON.

The I/O Connecting Cable is
faulty.

The I/O bus is faulty.

Replace the I/O Connecting
Cable

Replace the I/O Control Unit
or I/O

Interface Unit.

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DOC-1017-1

4.1 I

NPUT

RRORS

SYMPTOM CAUSE REMEDY

Power is not supplied to Input

Unit.

Supply power

Supply voltage is low.

Adjust supply voltage to within
rated range.

Terminal block mounting
screws are loose.

Tighten screws.

Not all inputs turn ON or

indicators are not lit.

Faulty contact of terminal

block connector.

Replace terminal block

connector.

Not all inputs turn ON
(indicator lit).

Input circuit is faulty. (There is
a short at the load or
something else that caused an
overcurrent to flow.)

Replace Unit.

Not all inputs turn OFF.

Input circuit is faulty.

Replace Unit.

Input device is faulty.

Replace input devices.

Input wiring disconnected.

Check input wiring

Terminal block screws are
loose.

Tighten screws.

Faulty terminal block
connector contact.

Replace terminal block
connector.

Too short ON time of external
input.

Adjust input device

Faulty input circuit

Replace Unit.

Specific bit does not turn ON.

Input bit number is used for
output instruction.

Correct program.

Input circuit is faulty.

Replace Unit.

Specific bit does not turn OFF.

Input bit number is used for

output instruction.

Correct program.

External input voltage is low or

unstable.

Adjust external input voltage

to within rated range.

Malfunction due to noise.

Take protective measures
against noise,

such as:
(1) Increase input response

time
(2) Install surge suppressor.
(3) Install insulation
transformer.
(4) Install shielded cables
between the Input Unit and the

loads.

Terminal block screws are
loose.

Tighten screws.

Input irregularly turns ON

/OFF.

Faulty terminal block
connector contact.

Replace terminal block
connector.

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DOC-1017-1

Common terminal screws are
loose.

Tighten screws.

Faulty terminal block

connector contact.

Replace terminal block

connector.

Faulty data bus

Replace Unit.

Error occurs in units of 8
points or 16 points, i.e., for

the same common.

Faulty CPU

Replace CPU.

Input indicator is not lit in
normal operation.

Faulty indicator or indicator
circuit.

Replace Unit.

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4.2 O

UTPUT

RRORS

SYMPTOM CAUSE REMEDY

Load is not supplied with

power.

Supply power

Load voltage is low.

Adjust voltage to within rated
range.

Terminal block screws are
loose.

Tighten screws.

Faulty terminal block

connector contact.

Replace terminal block

connector.

An overcurrent (possibly
caused by a short at the load)
resulted in a blown fuse in the
Output Unit. (Some Output
Units provide an indicator for

blown fuses.)

Replace fuse or Unit.

Faulty I/O bus connector
contact.

Replace Unit.

Output circuit is faulty.

Replace Unit.

Not all outputs turn ON

If the INH indicator is lit, the
Output OFF Bit (A50015) is
ON.

Turn A50015 OFF.

Not all outputs turn OFF

Output circuit is faulty.

Replace Unit.

Output ON time too short
because of a
mistake in programming.

Correct program.

Bit status controlled by
multiple instructions.

Correct program.

Output of a specific bit number
does not turn ON or indicator
is not lit

Output circuit is faulty.

Replace Unit.

Faulty output device.

Replace output device.

Break in output wiring.

Check output wiring.

Terminal block screws are
loose.

Tighten screws.

Faulty terminal block

connector contact.

Replace terminal block

connector.

Faulty output bit.

Replace relay or Unit.

Output of a specific bit number
does not turn ON (indicator lit).

Output circuit is faulty.

Replace Unit.

Faulty output bit.

Replace relay or Unit.

Output of a specific bit number

does not turn OFF (indicator is
not lit).

Bit does not turn OFF due to

leakage current or residual
voltage.

Replace external load or add

dummy resistor.

Bit status controlled by
multiple instructions.

Correct program.

Output of a specific bit number
does not turn OFF (indicator
lit).

Output circuit is faulty.

Replace Unit.

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DOC-1017-1

SYMPTOM CAUSE REMEDY

Low or unstable load voltage. Adjust load voltage to within

rated range

Bit status controlled by
multiple instructions.

Correct program.

Malfunction due to noise.

Protective measures against
noise:
(1) Install surge suppressor.
(2) Install insulation
transformer.
(3) Use shielded cables
between the Output
Unit and the loads.

Terminal block screws are

loose.

Tighten screws.

Output irregularly turns ON/
OFF.

Faulty terminal block
connector contact.

Replace terminal block
connector.

Terminal block screws are
loose.

Tighten screws.

Faulty terminal block

connector contact.

Replace terminal block

connector.

An overcurrent (possibly
caused by a short at the load)

resulted in a blown fuse in the
Output Unit.

Replace fuse or Unit.

Faulty data bus.

Replace Unit.

Error occurs in units of 8
points or 16 points, i.e., for the

same common.

Faulty CPU.

Replace CPU.

Output indicator is not lit
(operation is normal).

Faulty indicator.

Replace Unit.

ERR led is lit in output unit

Short circuit at output circuit

Check and repair output wiring
or component

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DOC-1017-1

5 A

NALOQUE UNIT

5.1 A

NALOGUE UNIT

MAD42

SETTING

SET THE VOLTAGE / CURRENT SWITCH.

The analogue conversion input can be
switched from voltage input to current input
by changing the pin settings on the voltage /
current switch located on the back of the
terminal block. At the unused input should
the switch be at voltage set.

SET THE UNIT NUMBER SWITCH.

The Special I/O Unit Area and Special I/O

Unit DM Area word addresses that each
Analogue Input Unit occupies are set by the

unit number switch on the front panel of the
Unit. The user number is identified at circuit

diagram.

INSTRUMENT GROUND AG

CONNECTIONS

The instrument ground AG is to connected
to the signal ground or 0. The ground is
connected to terminals B7 and A7, which are
internally connected together. The
connection is shown at circuit diagrams. The
right connection is very important with
voltage signals.

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5.2 A

NALOGUE UNIT

ADO81

SETTING

SET THE OPERATION MODE SWITCH ON

THE FRONT PANEL OF THE UNIT.

The operation mode switch on the front

panel of the Unit is set to normal mode
(OFF).

SET THE VOLTAGE / CURRENT SWITCH.

The analogue conversion input can be
switched from voltage input to current input
by changing the pin settings on the voltage /
current switch located on the back of the
terminal block.

SET THE UNIT NUMBER SWITCH.

The CPU Unit and Analogue Input Unit

exchange data via the Special I/O Unit Area
and the Special I/O Unit DM Area.

The Special I/O Unit Area and Special I/O
Unit DM Area word addresses that each

Analogue Input Unit occupies are set by the
unit number switch on the front panel of the
Unit. The user number is identified at circuit
diagram. Analogue units have their own
number series. It is not depending of number
of other units.

INSTRUMENT GROUND AG
CONNECTIONS

The instrument ground AG is to connected
to the signal ground or 0. The ground is

connected to terminals B7 and A7, which are
internally connected together. The

connection is shown at circuit diagrams. The
right connection is very important with

voltage signals.

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5.3 A

NALOGUE UNIT INDICATORS

LED IND MEANING

CPU

RUN

POSSIBLE REASON

Operating in normal mode.

RUN

OFF Unit has stopped exchanging data with

the CPU Unit.

Alarm has occurred (such as
disconnection detection) or initial
settings are incorrect.

ON Alarm has occurred at the

Analogue Input Unit.

Alarm has occurred (such as
disconnection detection) or initial
settings are incorrect.

OFF Check whether the initial settings

for the Analogue Input Unit are
set correctly.

ERC

OFF Operating

normally.

Error has occurred during data
exchange with the CPU Unit.

ON Error detected by CPU Unit

Error has occurred during data
exchange with the CPU Unit.

OFF Check whether the unit number is

set correctly.

ERH

OFF Operating

normally.

Flash Operating in offset/gain adjustment

mode.

ADJ

OFF Other than the above.

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5.3.1 I

NDICATION COMBINATIONS

RUN ERC ERH ADJ MEANING

ON ON

The output setting range has been exceeded.

A disconnection was detected. (1 to 5 V or 4 to 20 mA).

An EEPROM writing error has occurred while in adjustment
mode.

ON ON Flash

In adjustment mode, offset or gain cannot be adjusted because
input value is out of the permissible range for adjustment.

In adjustment mode, adjustment cannot be performed because
the specified input or output number is not set for use or because
the wrong input or output number is specified.

The PLC is in either MONITOR or RUN mode while the Analog

I/O Unit is operating in adjustment mode.

When a PLC error occurs in the adjustment mode, Unit

operations will stop operating. (The input and output values
immediately prior to the error will be held.)

The I/O number for the ratio conversion function has been set to

be not used.

There is a mistake in the upper or lower limit setting when scaling
is used. The set value is exceeded, the upper limit equals the
lower limit (not 0000), etc. A number outside of the 0 to 9999
BCD range has been specified for the ratio set value.

The wrong output status for when conversion is stopped has
been specified. The wrong number of samplings has been
specified for mean processing. The conversion time/resolution

setting or operation mode setting is incorrect.

ON ON

Error has occurred during data exchange with the CPU Unit.

No response from CPU Unit during fixed period.

Error has been generated in CPU Unit.

No error will be detected by the CPU Unit or displayed on the
Programming Console, because the CPU Unit is continuing

operation.

The same unit number has been assigned to more than one Unit
or the unit number was set to a value other than 00 to 95. The

Special I/O Units registered in the I/O table are different from the
ones actually mounted.

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DOC-1017-1

6 S

PECIAL

I/O

NITS

RRORS

SYMPTOM CAUSE

REMEDY

The ERH and RUN

indicators on the Special
I/O Unit are lit.

I/O refreshing is not being

performed for the Unit from the CPU
Unit (CPU Unit monitoring error). It’s

possible that cyclic refreshing has
been disabled for the Special I/O
Unit in the Cyclic Refresh Disable
Setting in the PLC Setup (i.e., the bit
corresponding to the unit number
has been set to 1).

Change the bit corresponding

to the unit number to 0 to
enable cyclic refreshing, or

make sure that the Unit is
refreshed from the program
using IORF at least once
every 11 s.

SET THE LINE TERMINATING RESISTOR

RS-422 is the standard for a point-to-point

connection between two devices. The line
terminating resistor on both sides of the RS-422

transmission link must be switched on. Þ "Terminate"
slide switch always in "ON" position.

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DOC-1017-1

6.1 F

AULT FINDING

FAULT EFFECT

TEMPORARY

ACTION

CAUSE REMEDY

Short circuit at
output circuits

Find the reason. If the
external failure has
caused the failure of the

PLC, find it out and
repair, because the

failure can happen
again.

Vibration

Isolate the unit from

vibration source.

High

temperature at
control unit

Lower temperature

PLC failure

Main control is
not working

Use back-up
control

Component

failure

Replace the component

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