CJ1 SERIES Contents Smallest, Most Powerful Solution for Tomorrow's Advanced Production Systems We shrank our most powerful programmable controller by 40% to fit industry's most space-confined cabinets. All of Omron's outstanding performance was retained in the process: That includes the mix of standard and special I/O available, options for system expansion, and standardized programming across CJ1G/H . . . . . . . . . . . . . . . . . B-11 CJ1M . . . . . . . . . . . . . . . . . . B-12 Basic I/O . . . . . . . . . . . . . . . B-35 Special I/O . . . . . . . . . . . . . . B-61 Networking and Communications . . . . . . B-74 System Power and Expansion . . . . . . . . . . B-108 Ordering Guide . . . . . . . . . . B-118 Reference Information . . . . B-131 all Omron controller platforms. High-Speed Processing Seamless Communications Cost and Space Savings With separate communications and processing bus structures, the CJ1 delivers the fastest throughput for both advanced and basic instructions for reliable sequential action. Simultaneously, data queries of various sizes and in locations across the entire network can be processed without delaying the cycle time. The CJ1 delivers transparent communications across a variety of network types and protocols: Ethernet, DeviceNet, Controller Link and Serial communications. This capability can allow a user to load programs or acquire data from any location in the facility. With no rack to purchase and slim modules that are easy to configure and assemble, the CJ1 lowers overall system cost, takes up little space and leaves you room for future growth. B-1 F E AT U R E S Five Reasons to Design CJ1 PLCs into Your Application Ultra-compact Size Approx. 40% smaller than mid-size controllers such as CS1 and C200H Measures just 90 mm H x 65 mm D; width depends on modules selected. Modules are either 20 mm or 31 mm wide Shallow 65 mm depth allows thinner control panels Modules lock together to create a flexible "through plane" eliminating the need for a backplane Speed Three CJ1 PLC part numbers combine to form a powerful 4-axis motion controller that can fit in the palm of your hand Control up to 2560 local I/O, plus 32,000 DeviceNet I/O using multiple DeviceNet masters Instructions to facilitate every application PID with auto-tuning ideal for multi-loop temperature control and analog process I/O Floating-point decimal math operations ensure precise positioning with X-Y tables Conversion between floating-point decimal and ASCII character string data allows measuring device data to be used in operations High-resolution line approximation allows conversion from a level measurement in mm to tank capacity in liters according to the shape of the tank Built-in flash memory backup protects user program and parameter areas Optional Omron flash memory cards hold up to 64 MB of data to transfer program modifications, load recipes for quick production changeover or store logged data values from the CPU One Platform Can Meet All Your Control Needs Standardizing on the CJ1 platform means that you have chosen a control solution that can be scaled for systems from simple to the most sophisticated. It all starts with choosing the CPU to fit your needs. From there every application will use the same Communications, Specialty, and Basic I/O modules. This versatility preserves your hardware and training investment while delivering the same look and programming feel for every application. B-2 Basic instruction processing time from 20 nanoseconds Executes 38K steps of basic instructions or 22K of basic and special instructions in a cycle time of 1 ms Fast processing of 20 most-frequently-used data manipulation instructions, including compares, transfers, moves, jumps, subroutine/reset call and more Parallel program execution shortens peripheral processing time by about half Large amounts of data can be exchanged with the host without dependence on the program size in the CPU Data can be refreshed smoothly with uniform timing for data exchanges with SCADA software No effect on cycle time in the event of future network expansions 32 MHz system bus transfer speed between CPU and Special I/O impacts overall performance Immediate refresh available for Data Links, DeviceNet, Remote I/O communications from the ladder program Increased number of cyclic tasks (from 32 to 288) improves efficiency by breaking long programs into sections by function or by developer Huge Capabilities Ultra-fast cycle time any way you measure it Communications Easy to set up network communications from device level to controller level to enterprise (information) level Using a common data memory area and routing tables, Omron's networked PLCs and computers can exchange data regardless of DeviceNet, Profibus-DP, Ethernet or Controller Link formatting Omron networks transparently break down barriers to expansion and change in data collection by eliminating the need for rigid block transfers of data Simple connections to general-purpose serial components Built-in Protocol Macros contain handshaking scripts for most Omron temperature controllers and other serial devices for automatic communications CX-Protocol software quickly sets up script and transmission data for serial devices from any manufacturer Maintenance can be performed from remote locations Ethernet Module can send e-mail to alert personnel Perform diagnostics and corrective actions locally using CX-Simulator, then implement those corrections and restart the system by modem, using CX-Programmer CPU SELECTION Which CPU is Right for You? CPU selection CJ1G-H/CJ1H-H CJ1M Application High-end, sophisticated applications with critical response times and large memory requirements * Execution time per basic instruction from: 0.02 s * Program Memory from 10 to 120K steps * Data memory from 64 to 256K words (Includes Extended Memory) Simpler applications with fewer I/O and memory requirements: faster processing than most micro controllers * Execution time per basic instruction from: 0.1 s * Program Memory from 10 to 20K steps * Data memory up to 32K words (No Extended Memory) Effective system size I/O counts up to 2560 points I/O counts up to 640 points PLC to PLC communications Uses a Controller Link Communications Module Built-in serial PLC Link function communicates exclusively between CJ1M CPUs Built-in basic input/output signals Uses Basic Input and Output Modules CPU22 and CPU23 have built-in general purpose I/O: 10 inputs/6 outputs Interrupt inputs Uses Interrupt Input I/O Module CJ1W-INT01 Four of the 10 inputs on CPU22 and CPU23 can be designated as interrupt inputs Pulse catch input Uses separate Pulse Catch Input Module CJ1W-IDP01 Four of the 10 inputs on CPU22 and CPU23 can be designated as quick-response inputs High-speed counters Uses High-speed Counter Module CJ1W-CT021 CPU22 and CPU23 have two built-in high-speed counter inputs rated 50 kHz for phase differential input; 100 kHz for single-phase input from highspeed line driver. Pulse train for position control Uses a Position Control Module CJ1W-NC, depending on the number of axes (1, 2, or 4) CPU22 and CPU23 have 2 pulse outputs for 1 or 2-axis positioning applications Program storage/exchange medium Flash memory cards Flash memory cards Serial PLC Link Communications Built-In I/O with Extra Capabilities For CJ1M CPUs, this low-cost serial link is simple to use and helps integrate processes or coordinate activities with a master PLC, depending on the application. Capabilities: 10 words per CPU can be allocated to PLC Link in a master/slave arrangement Network size: 1 Master and 1 to 8 Slaves (total of 9 CJ1M PLCs) can exchange data Medium: RS-232C, using port built into each CPU Hardware: CJ1W-CIF11 RS-232C to RS-422/485 converter for multi-drop The CJ1M-22/-23 CPUs have 10 inputs and six outputs that provide exceptional versatility for handling most control applications. Four interrupt inputs update the CPU with signal changes that take place faster than the scan cycle Two high-speed counter inputs for phase differential or single phase input Two pulse outputs that can be used for two-axis position control or two single-axis control applications, speed control up to 100 kHz or pulse width modulated (PWM) output B-3 C J 1 C O N F I G U R AT I O N CPUs Memory Card PAGE PAGE PAGE B-11 B-12 B-12 PAGE CJ1H-CPU66H/65H CJ1G-CPU45H/44H/43H/42H CJ1H-CPU66H/65H Models with Built-in I/O CJ1M-CPU21 (5K steps) CJ1M-CPU22 (10K steps) CJ1M-CPU23 (20K steps) CJ1M-CPU11 (5K steps) CJ1M-CPU12 (10K steps) CJ1M-CPU13 (2K steps) End Cover Power Supply B-20 HMC-EF172/372/672 /RS-422A Converte RS-232C to RS-422/485 Converter End Plate CJ1W-CIF11 (non-isolated converter for converting RS-232C to RS-422/485) PAGE B-114 PFP-M (included with CPU) CJ1W-PA202 (14 W, AC) CJ1W-PA205R (25 W, AC) CJ1W-PD025 (25 W, DC) CJ1W-TER01 (included with CPU) PAGE B-14 d converter for converting RS CPU I/O Control Module DIN Rail PAGE B-116 PFP-50N/100N/100N2 PFP-50N/100N/100N2 CJ1W-IC101 (required for expansion) I/O Connecting Cable PAGE B-117 I/O Interface Module Power Supply CS1W-CN3 (30 cm, 70 cm, 2 m, 3 m, 5 m, 10 m, 12 m) PAGE PAGE B-114 B-117 Expansion CJ1W-PA205R CJ1W-PA202 (14 W, AC) CJ1W-PA205R (25 W, AC) CJ1W-PD025 (25 W, DC) CJ1W-II101 (required for expansion) End Cover over Refer to End Plate CJ1W-TER01 (included with I/O Interface Module) B-4 PFP-M (included with I/O Interface Module) DIN Rail PFP-50N/100N/100N2 PAGE B-108 for expansion information. C J 1 C O N F I G U R AT I O N Basic I/O Modules (Allocated words: CIO 0000 to CIO 0039. Allocated in word units (16 bits) according to the mounting position, starting from the left.) * Input Modules PAGE PAGE PAGE PAGE PAGE PAGE PAGE B-37 B-37 B-37 B-37 B-37 B-37 B-37 8-point DC Input CJ1W-ID201 16-point DC Input CJ1W-ID211 32-point DC Input CJ1W-ID231 32-point DC Input CJ1W-ID232 64-point DC Input CJ1W-ID261 64-point DC Input CJ1W-ID262 8/16-point AC Input CJ1W-IA111/201 * Output Modules PAGE PAGE PAGE PAGE PAGE PAGE B-44 B-44 B-44 B-44 B-44 B-44 8-point Transistor Output CJ1W-OD201/202/203/204 16-point Transistor Output CJ1W-OD211/212 32-point Transistor Output CJ1W-OD231 32-point Transistor Output CJ1W-OD232/233 64-point Transistor Output CJ1W-OD261 Interrupt Input 64-point Transistor Output CJ1W-OD262/OD263 Pulse Catch Input PAGE PAGE PAGE PAGE PAGE B-44 B-44 B-44 B-42 B-43 8-point (independent-contact) Relay Output CJ1W-OC201 16-point Relay Output CJ1W-OC211 8-point Triac Output CJ1W-OA201 16-point Interrupt Input CJ1W-INT01 16-point Pulse Catch Input CJ1W-IDP01 * I/O Modules * B7A Interface Modules PAGE PAGE PAGE PAGE PAGE PAGE B-54 B-54 B-54 B-54 B-54 B-60 32-point DC Input/Transistor Output CJ1W-MD231 32-point DC Input/Transistor Output CJ1W-MD232/MD233 64-point DC Input/Transistor Output CJ1W-MD261 64-point DC Input/Transistor Output CJ1W-MD263 64-point TTL I/O CJ1W-MD563 64-point Interface CJ1W-B7A Special I/O Modules (Allocated words: CIO 2000 to CIO 2959, 10-40 words per Module. Allocated according to unit number.) PAGE PAGE PAGE PAGE B-63 B-64 B-67 B-68 Analog Input CJ1W-AD081-V1 CJ1W-AD041-V1 (4 or 8 inputs) High-speed Counter CJ1W-CT021 (2 axes) Temperature Control CJ1W-TC (2 or 4 temperature inputs) Analog Output CJ1W-DA041/021 CJ1W-DA08V/DA08C (2, 4, or 8 outputs) PAGE PAGE PAGE PAGE PAGE B-69 B-97 B-66 B-72 B-96 Position Control CJ1W-NC43 (1 to 4 axes) CompoBus/S Master CJ1W-SRM21 Note: for I/O allocation follow special I/O rules Analog I/0 CJ1W-MAD42 (4 inputs, 2 outputs) ID Sensor CJ1W-V600C1 (For 1 or 2 heads) Profibus-DP Slave CJ1W-PRT21 CPU Bus Modules (Allocated words: CIO 1500 to CIO 1899, 25 words per Module. Allocated according to unit number.) PAGE PAGE PAGE PAGE B-79 B-83 B-89 B-101 Ethernet CJ1W-ETN21 Controller Link CJ1W-CLK21-V1 DeviceNet CJ1W-DRM21 Serial Communications CJ1W-SCU41 (one RS-232C port and one RS-422/485 port) CJ1W-SCU21 (two RS-232C ports) B-5 C J 1 A P P L I C AT I O N S Vacuum-Packing Foods Omron's CJ1M packs high-speed control and maximum versatility into the industry's most space-efficient package. * Built-in high speed counter for encoders feedback * Pulse control for stepper motors * Built-in I/O available * Uses CJ1 special I/O for temperature control and analog input for pressure * Built-in serial port exchanges data with operator interface terminal for parameter and data setting Operator Interface terminal Weighing and Form-Fill-Seal Packaging Equipment Multi-pouch weighing unit Personal computer Inspection, sealing and marking unit Case forming unit Filler/bagger unit 2 Filler/bagger unit 1 B-6 The CJ1 controllers let you scale control capability to match the needs of each machine unit for flexible reconfiguration. Manage production using data transferred via network from the PLCs on each machine to a personal computer. * Use CJ1 in the multi-pouch weighing unit to handle high-speed load cell weight measurements and coordinate transfer operations. * Form-fill-seal machines 1 and 2 use CJ1 or CJ1M controllers to create two different colored bags of product then transfer it to the case packaging unit. * The small box packager machine forms flat stock into a box that holds multiple bags of product. CJ1M coordinates fabrication and gluing activities. * Inspection, sealing and date/lot code marking equipment are controlled by CJ1. Data transferred to the PC for finished packages gets archived for production optimization and regulatory record keeping. CJ1 - BUILDING YOUR SYSTEM When selecting the CPU for your system you'll need to consider... How many I/O points Program memory storage Page B-10 Data memory storage Portable program storage options For local Input Modules, consider... What input voltage How many points Input current requirements Are Terminal Blocks and connection cables necessary Page B-35 For local Output Modules, consider... How many points What type of output Are Terminal Blocks and connection cables necessary Page B-36 Analog input Analog output Analog Mixed I/O Temperature controllers High-speed counters Position control Page B-61 Ethernet Controller Link Profibus-DP DeviceNet CompoBus/S distributed I/O Serial Page B-74 CX-Programmer CX-Simulator CX-Protocol Hand-held programmers Page E-2 CX-Supervisor CX-ServerLITE CX-ServerOPC Page E-2 Using serial port Using peripheral port Page E-2 If Special I/O capabilities are required, consider... For networked communications at information, controller and device levels, consider... For software and programming tools to simplify setup and maintenance you'll need to consider... For PC-based HMI solutions, consider... For communications and programming cables, consider... Determine power supply and expansion requirements by considering... Basic CJ1 configuration Expansion I/O racks Calculating overall current consumption Power supply selection Maximum system expansion Page B-108 B-7 C J 1 S Y S T E M C O N F I G U R AT I O N Configuring a CJ1 System This section provides tools to configure a CJ1G/H or CJ1M system. Included in this section are: Basic Configuration A CJ1 Series basic configuration consists of a CPU, power supply unit, and up to 10 basic I/O, special I/O and bus units, and an end cover. Add up the current consumption for all the modules and the CPU according to the chart shown on page B-9, then select the power supply unit suitable for the application. CPU Rack Power supply unit CPU and Expansion Racks Configuration modules (basic I/O modules, special I/O modules, CPU bus modules) Power supply Memory unit card CPU CPU Memory card If the number of modules per rack exceeds 10 or the current consumption is greater than the capacity of the power supply units, use the CPU and expansion rack configuration. This divides the load from the modules across two power supply units. To allow communication and automatic channel assignment in programming, order an I/O control module for the CPU rack and an I/O interface module on each expansion rack. Expansion Rack (up to 3 expansion racks allowed Power supply unit I/O connecting cable End cover Configuration modules (basic I/O modules, special I/O modules, CPU bus modules) End cover Configuration modules I/O (basic I/O modules, interface special I/O modules, module CPU bus modules) End cover I/O control module Select the CPU then determine how many expansion racks. Depending on the CPU chosen, the system can be expanded with up to three additional racks of basic I/O, special I/O and CPU bus units. CPU Models CJ1M-CPU11 CJ1M-CPU21 CJ1M-CPU12 CJ1M-CPU22 CJ1M-CPU13 CJ1M-CPU23 CJ1G-CPU42H CJ1G-CPU43H CJ1G-CPU44H CJ1G-CPU45H CJ1H-CPU65H CJ1H-CPU66H Number of I/O 160 points 320 points 640 points 960 points 1280 points 2560 points Program memory size 5K words 10K words 10K words 10K words (42) 30K words (44) 20K words (43) 60K words (45) 60K words (65) 120K words (66) Data memory storage 32K words 32K words 32K words 64K words 64K words (44) 128K words (45) 128K words (65) 256K words (66) Maximum I/O modules per CPU 10 10 20 30 40 40 Maximum I/O expansion racks per CPU 0 0 1 2 3 3 See page B-12 B-12 B-11 B-11 B-11 B-12 Note: Order one CJ1W-IC101 I/O control module for the CPU rack and one CJ1W-II101 I/O interface module for each I/O expansion rack. Connect the modules with a cable of the appropriate length. Second and third I/O expansion racks connect between I/O interface modules. See page B-117 for details. B-8 C J 1 S Y S T E M C O N F I G U R AT I O N Where are ratings to calculate overall current consumption? All the current consumption ratings for the CPU, basic I/O, special and CPU bus units are collected in tables on pages B-110 to B-111. Which power supply is right? Compare the current consumption total of basic I/O and special I/O modules, and CPU bus units to determine which power supply to use. If more than 10 modules are required or the current consumption exceeds the output capacity of the power supplies, configure the system using CPU and I/O expansion racks. Input Voltage 100 to 240 VAC 24 VDC Output rating 5 A, 5 VDC with 2 A RUN output 2.8 A, 5 VDC 5 A, 5 VDC Output capacity 25 W max. 14 W max. 25 W max. Power supply model CJ1W-PA205R CJ1W-PA202 CJ1W-PD025 See page B-110 B-110 B-110 I/O Allocations In CJ1 PLC systems, part of the I/O memory is allocated to basic, special I/O unit and CJ1 CPU bus units. This summarizes how each of these units is allocated in the memory. Module type Allocated words Unit of allocation Method of allocation Basic I/O CIO 0000 to CIO 0039 1 word (8 or 16 I/O pts) 2 words (32 I/O pts) 4 words (64 I/O pts) According to mounting position, starting from the left Special I/O CIO 2000 to CIO 2959 10 words per module According to unit number CPU bus CIO 1500 to CIO 1899 25 words per module According to unit number B-9 CJ1 CPU OVERVIEW CPU Selection This section describes the CPUs and memory cards for a CJ1 system. How many I/O points are needed? Number of I/O 160 320 640 960 1280 2560 CPU models CJ1M-CPU11 CJ1M-CPU12 CJ1M-CPU13 CJ1G-CPU42H CJ1G-CPU44H CJ1H-CPU65H CJ1M-CPU21 CJ1M-CPU22 CJ1M-CPU23 CJ1G-CPU43H CJ1G-CPU45H CJ1H-CPU66H B-12 B-12 B-12 B-11 B-11 B-11 See page How much program memory storage is required? Program Memory Size CPU Models See page 5K words CJ1M-CPU11, CJ1M-CPU21 B-12 10K words CJ1G-CPU42H, CJ1M-CPU12, CJ1M-CPU22 B-11, B-12 20K words CJ1G-CPU43H, CJ1M-CPU13, CJ1M-CPU23 B-11, B-12 30K words CJ1G-CPU44H B-11 60K words CJ1G-CPU45H, CJ1H-CPU65H B-11 120K words CJ1H-CPU66H B-11 How much data memory storage is required? Data memory size 32K Words 64K Words 128K Words 256K Words CPU models CJ1M-CPU1 CJ1G-CPU42H CJ1G-CPU45H CJ1H-CPU66H CJ1M-CPU2 CJ1G-CPU43H CJ1H-CPU65H CJ1M-CPU3 B-12 CJ1G-CPU44H See page B-11 B-11 B-11 Selecting program storage options Memory card uses: * Download recipes * Replace PLC program while operating * Auto-boot the PLC upon power up Memory Size 15 MB 30 MB Memory card HMC-EF172 HMC-EF372 HMC-EF672 See page B-20 B-20 B-20 Note: An adapter is available to insert the flash memory card into a computer. Go to page B-20 for details. B-10 64 MB