Inovance AM403 Series User manual

User Guide
AM403 Series PLC (NPN)
Suzhou Inovance Technology Co,.Ltd
Address: No.16 Youxiang Road, Yuexi, Wuzhong District, Suzhou 215104
Customer service hotline: [phone]
Website: http://www.inovance.com
Document DownloadTechnical support APP

2
Thank you for purchasing the AM400 series PLC developed and manufactured
independently by Inovance.
The AM400 series PLC is a CoDeSys-based medium-sized PLC, which fully
󶍾
cam synchronous motion control. It has a unique high-speed IO port adapted for
high-speed applications.
󶍾
AM400 series PLC. Read this guide carefully before using to fully understand the
product and ensure safety. Visit our website (www.inovance.com) for the latest
version of the guide.
1 Safety Instructions
1.1 Safety Precautions
1. Before installing, using, and maintaining this equipment, read the safety
information and precautions thoroughly, and comply with them during
operations.
2. To ensure the safety of humans and equipment, follow the signs on the
equipment and all the safety instructions in this user guide.
3. The “CAUTION”, “WARNING” and “DANGER” signs are only supplements
to the safety instructions.
4. Use this equipment according to the designated environment requirements.
Damage caused by improper usage is not covered by warranty.
5. Inovance shall take no responsibility for any personal injuries or property
damage caused by improper usage.
1.2 Safety Levels and De󶍾nitions
=GXTOTM
: Indicates that failure to comply with the notice may result in severe
personal injuries or even death.
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: The “CAUTION” sign indicates that failure to comply with the notice
may result in minor or moderate personal injury or damage to the equipment.
Keep this guide well so that it can be read when necessary and forward this guide
to the end user.

3
During control system design
=GXTOTM
Provide a safety circuit outside the PLC so that the control system can still work safely once
external power failure or PLC fault occurs.
 󶍾
overcurrent caused by operation above rated current or load short-circuit.
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An emergency stop circuit, a protection circuit, a forward/reverse operation interlocked
circuit, and an upper position limit and lower position limit interlocked circuit must be set in
the external circuits of PLC to prevent damage to the machine.
To ensure safe operation, for the output signals that may cause critical accidents, design
external protection circuit and safety mechanism;
Once PLC CPU detects abnormality in the system , all outputs may be closed; however, when
a fault occurs in the controller circuit, the output may not be under control. Therefore, it is
necessary to design an appropriate external control circuit to ensure normal operation;
If the PLC output units such as relays or transistors are damaged, the output may fail to switch
between ON and OFF states according to the commands;
The PLC is designed to be used in indoor electrical environment (overvoltage category II). The
power supply must have a system-level lightning protection device, assuring that overvoltage
due to lightning shock cannot be applied to the PLC power supply input terminals, signal
input terminals and output terminals and so forth, so as to avoid damage to the equipment.
Installation
=GXTOTM
Installation must be carried out by the specialists who have received the necessary
electrical training and understood enough electrical knowledge.
Disconnect all external power supplies of the system before removing/installing the
module. Failure to do so may result in electric shock, module fault or malfunction.
Do not use the PLC where there are dust, oil smoke, conductive dust, corrosive or
combustible gases, or exposed to high temperature, condensation, wind & rain, or
󶍾
damage or deterioration to the product.
The PLC is open-type equipment that must be installed in a control cabinet with
󶏣 
necessary electrical training and understood enough electrical knowledge can open
the cabinet.

4
)G[ZOUT
 󶍾
󶍾
Ensure there are no foreign matters on ventilation surface. Failure to comply may result in
󶍾
Ensure the module is connected to the respective connector securely and hook the module
󶍾󶍽
Wiring
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M
Wiring must be carried out by personnel who have received the necessary electrical training
and understood enough electrical knowledge.
Disconnect all external power supplies of the system before wiring. Failure to comply may
result in electric shock, module fault or malfunction.
Install the terminal cover attached to the product before power-on or operation after wiring is
completed. Failure to comply may result in electric shock
Perform good insulation on terminals so that insulation distance between cables will not
reduce after cables are connected to terminals. Failure to comply may result in electric shock
or damage to the equipment.
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 󶍾
󶍾
 󶍾
For details, see the wiring section in this guide.
 󶎀
the cables to ground reliably.
Ensure that all cables are connected to the correct interface. Failure to comply may result in
module and external equipment fault.
 󶍾
󶍾󶍽
󶍾
If the connector is used to connect with external equipment, perform correct crimping or
󶍾
󶍾
A label on the top of the module is to prevent foreign matters entering the module. Do not remove
the label during wiring. Remember to remove it before system operation, facilitating ventilation.
Do not bundle control wires, communication wires and power cables together. They must be
run with distance of more than 100 mm. Otherwise, noise may result in malfunction.
Select shielded cable for high-frequency signal input/output in applications with serious
interference so as to enhance system anti-interference ability.

5
Operation and Maintenance
=GXTOT
M
◆Maintenance & inspection must be carried out by personnel who have the necessary
electrical training and experience.
◆Do not touch the terminals while the power is on. Failure to comply may result in
electric shock or malfunction.
◆Disconnect all external power supplies of the system before cleaning the module or re-
tightening screws on the terminal block or screws of the connector. Failure to comply
may result in electric shock.
◆Disconnect all external power supplies of the system before removing the module or
connecting/removing the communication wirings. Failure to comply may result in
electric shock or malfunction.
)G[ZOUT
◆󶍾
RUN/STOP operation.
◆Disconnect the power supply before installing/removing the extension card.
Disposal
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◆Treat scrapped module as industrial waste. Dispose the battery according to local laws
and regulations.

6
2 Product Information
2.1 Model Number and Nameplate
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Model Category Description
AM403-CPU1608TN CPU
module
10 M program storage space; 20 M data storage
space;
2 RS485 ports, 1 CANopen/CANlink port, and 1
LAN port;
Support for EtherCAT bus; built-in 16-in-8-
out high-speed I/O; supports up to 16 DSP402
slaves; sink-type output.

7
2.2 External Interface
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Figure 1 Diagram of CPU module interfaces
Interface Name Function
DB9 (CN1)/(receptacle) 2 RS485 ports, supporting MODBUS protocol
DB9 (CN2)/(receptacle) 1 CANopen/CANlink port
Network port (CN4) EtherCAT protocol
Network port (CN3)
1. MODBUS TCP protocol
2. Standard Ethernet functions
3. System program commissioning
4. User program download and commissioning (IPv4 only)

8
Interface Name Function
USB Program download and commissioning
High-speed IO 16-point high-speed input
8-point high-speed output
I/O indicator 󶍽
DIP switch RUN/STOP DIP switch
SD card interface Stores user programs and user data
MFK key Multi-functional key
Indicator
Operation indicator (RUN)
CPU module error indicator (ERR)
System error indicator (SF)
Bus error indicator (BF)
LED display Displays alarm information, and information for the MFK key
Local expansion bus
interface
Supports up to 16 local modules. The actual number
󶍾
consumption. Hot plugging is not supported
24 V power input
terminal DC 24 V voltage input, used with an AM600 power module
Grounding switch
For system digital GND and housing GND. Not used by
default. To ensure system stability, it should be only used
when the digital GND is used as a reference plane.
Termination resistor
DIP switch
ON means a resistor is
connected (the default is
OFF); 1 and 2 are for CAN, 3,
4, 7 and 8 are reserved, and 5
and 6 are for COM0 (RS485):
0/
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2.3 General Speci󶍾cations
Item 󶍾
Programming
method
IEC 61131-3 programming languages (LD, FBD, IL, ST, SFC,
CFC)
Program execution
mode Compile and run
User program
storage space 10 MB
Flash space for
power failure
memory
512 KB

9
Item 󶍾
SD card capacity Up to 32 G
Program power
failure memory
Flash or SD card retention (only available when power is on
for more than 35s before going out)
Internal 5 V power
output current 1500 mA (rated value)
Interrupt mode 8-point input interrupt (CPU module high-speed DI), supports
rising edge and falling edge interrupts
■󶍾
Item 󶍾
Signal Name
󶍽

High-speed input (

XF)
24 V input 󶍽
input 24 V input
Rated input
voltage
24 VDC (-15% to +20%,
rippling within 5%) EIA RS-422-A
compliant
󶍽
line drive level
(equivalent to
AM26LS31)
24 VDC (-15% to
+20%, rippling
within 5%)
Rated input
current 7.3 mA@24 VDC (typical) 7.3 mA (typical)
(@24 VDC)
ON current More than 5 mA More than 5 mA
OFF current Less than 1.5 mA Less than 1.5 mA
Input resistance  
Max. counting
speed
800 Kpps (two-phase quadruplicated frequency), 200 kHz (single
input)
Least ideal duty
cycle of 2-phase
input

Common
terminal
Each point has a separate
common terminal -- 5 points share 1 common terminal
■Output
Item 󶍾
Signal Name Output (Y0-Y7)
Output polarity Sink

10
Item 󶍾
Voltage of the control
circuit 
Rated load current 0.1 A/point, 0.5 A/COM
Max. voltage drop at ON 0.2 V (typical)
Leakage current at OFF Less than 0.1 mA
Output frequency 200 kHz (an external equivalent load above 12 mA is
required)
Common terminal 4 points share 1 common terminal
●The total length of the high-speed I/O cables should be within 3.0 m;
●When the high-speed input is A or B phase, the single-phase pulse duty cycle
must be greater than 40%.
3 Electrical Design Reference
3.1 Terminal Layout
II
I
0 1 2 3 7654
30 1 4 5 6 72
4 5 6 73210
RUN
ERR
SF
BF
RUN STOP
CN4 EtherCATCN3 EtherNET
CN1 RS485
CN5
MFK
AM600-CPU1608TN
CN2 CAN
3536
2 1
3536
2 1
CANERR
CANRUN
Figure 2 Terminal layout of CPU module

11
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ended input.

12
󶍾
a High-Speed I/O Wiring User Guide.
■Equivalent internal circuit:
圫圶圃圕圗圹圃坌坑坓坘块圃
˄Xn2-24V˅
圫圶圃圧圬圩圩圃坌坑坓坘块圃
˄Xn2-DIFF˅
圫圶圃坌坑坓坘块圃圦圲地
˄Xn2-COM˅
3.3k
Ω
200Ω
圶块坄坑均坄坕均圃坌坑坓坘块圃
˄I7˅
圬坑坓坘块圃圦圲地
˄SS1˅
3.3k Ω
3.3k Ω
圶块坄坑均坄坕均圃坌坑坓坘块圃
˄I5˅
* 1 For 24 V single-ended
signals, Xn-24V and Xn-
COM are used;
󶍽
signals, Xn- DIFF and Xn-
COM are used.
3.2 Wiring Precautions
1) The total length of the high-speed I/O cables should be within 3.0 m.
2) Do not bundle the extension cable together with power cables (high voltage,
large current) which produce strong interference signals. Separate it from other
cables and avoid cabling in parallel.
3) Select recommended cables and pinboards for connection. It is recommended
that shielded cables be used as extension cables to enhance capacity of resisting
interference.
4) When laying the extension cable, make sure that the minimum bending radius
of the cable is more than 76 mm. When the bending radius is 76 mm, malfunction
may occur due to poor performance or disconnection.
■Application example
󶍾󶍽
pay special attention during wiring. The following table is an application example
where Xn0 is used.
Example Wiring
(1) PNP 24 V
level input
36
34
32
圬坑块圑圃圦坌坕坆坘坌块
圱坒圑
A/B/Z
在坛块圑圃场坌坕坌坑坊 圶坌坊坑坄坏圃圱坄坐坈
圫圶圃24V 坌坑坓坘块圃
˄Xn0-24 V˅
圫圶圃圧圬圩圩圃坌坑坓坘块圃
˄Xn0-DIFF˅
圫圶圃坌坑坓坘块圃圦圲地
˄Xn0-CO M˅
3.3kΩ
20 0Ω
0V
24 V
圬坑坓坘块圃
圷坜坓坈
PNP圃
坆坒坏坏坈坆块坒坕
國24 V 坏坈坙坈坏圌

13
Example Wiring
(2) NPN 24 V
level input
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4 Mechanical Design Reference
4.1 Dimensions
BF
SF
ERR
RUN
01 2 3 765
4
4 5 6 732
10
I
II
RUN/STOP
MFK
2 765410 3
80.0
90.0
3.9
4.0
7.0
CN3 EtherNET CN4 EtherCAT
CN1 RS485
AM600-CPU1608TN
CN2 CAN
35
36
2 1
CANERR
CANRUN
95.0
Figure 3 Dimensions of CPU module (in mm)

14
5 Communication Connection
5.1 Cabling of CPU module and communication module
󶏎RJ45 cable connection
●Insert the cable connector into the RJ45 port of the communication module until
you hear a click sound.
Figure 4 Cable connection diagram
●Removal: press the release tab of the connector to pull out the connector and
module horizontally.
󶏎Requirements for securing communication cable
To protect the communication cable from any tension and to ensure
󶍾
communication, as shown below:

15
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o
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5
Figure 5 Fix the cable end that near the device
5.2 EtherCAT bus connection
󶏎󶍾
Item 󶍾
Communication
protocol EtherCAT protocol
Service supported CoE (PDO, SDO)
Max. synchronous
jitter 120 us (typical)
Synchronization
mode
The servo adopts a DC-distributed clock and input and output
synchronization
Physical layer 100BASE-TX
Baud rate 100 Mbit/s (100Base-TX)
Duplex mode Full duplex
Topology Linear
Transmission
medium Network cables, see the Wring section
Transmission
distance Less than 100 m between two nodes
Number of slaves Up to 16 DSP402 slaves

16
EtherCAT frame
length 
Process data Max. 1486 bytes per Ethernet frame
󶏎Wiring
The CPU module provides a CN4 port for EtherCAT bus communication. An ECT
communication network cable that meets the following requirements is a must:




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Figure 6 Requirements on the EtherCAT cable
■Signal pins
Pin Signal Signal Direction Signal Description
1 TD+ Output Data transmission+
2 TD- Output Data transmission-
3 RD+ Input Data reception+
4 -- -- Not used
5 -- -- Not used
6 RD- Input 
7 -- -- Not used
8 -- -- Not used
■Length requirements:
According to FastEthernet technology, when an EtherCAT bus is used, the length
of the cable between the devices must not exceed 100 meters. Exceeding this
󶍽

17
■Technical requirements:
100% continuity test, no short circuit, open circuit, misalignment and poor
contact. It is recommended to use the following cables:
Item 󶍾
Cable type Flexible crossover cable, S-FTP, Cat 5e
Complied standards: EIA/TIA568A, EN50173, ISO/IEC11801
EIA/TI Abulletin TSB, EIA/TIA SB40-A&TSB36
Conductor type Twisted pair
Pair 4
5.3 Connection through CANopen/CANlink bus
󶏎Networking diagram
CAN bus topology is shown below. Using shielded twisted cables to connect CAN

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shield.
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Figure 7 CANopen/CANlink communication connection
󶏎Communication interfaces
The CPU module provides a CN2 terminal for CANopen communication and a
DB9 connector for data transmission.
CANopen/CANlink bus

18
RUN
ERR
SF
II
I
0 1 2 3 7654
30 1 4 5 6 72
4 5 6 73210
BF
RUN STOP
CN4 EtherCATCN3 EtherNET
CN1 RS485
MFK
AM600-CPU1608TN
CN2 CAN
C N5
3536
2 1
CANRUN
CANERR
5
4
1
2
3
9
8
7
6
Figure 8 CANopen terminal on CPU module
󶏎Wiring
CANopen requires a DB9 connector for data transmission. DB9 connector pins are
󶍾
Diagram Pin 󶍾
5
94
1
2
3
8
7
6
PIN2 CANL
PIN7 CANH
PIN3 GND

󶍿
single-point grounding is often used for shield. Do not bind the cable together
with DC cable, high voltage cable, and so forth, so that communication signal will
not be interfered.
5.4 Serial communication connection through RS485
The CPU module provides a CN1 terminal as the RS485 port, as shown in the
󶍾

19
RUN
ERR
SF
II
I
0 1 2 3 7654
30 1 4 5 6 72
4 5 6 73210
BF
RUN STOP
CN4 EtherCATCN3 EtherNET
CN1 RS485
MFK
5
4
1
2
3
6
7
8
9
AM600-CPU1608TN
CN2 CAN
C N5
3536
2 1
CANRUN
CANERR
Figure 9 RS485 communication terminal on CPU module
󶍾
Channel Pin 󶍾 Function
COM0 (RS485)
1 RS485- 󶍽
2 RS485+ 󶍽
5 GND0 COM0 power GND
COM1 (RS485)
6 RS485- 󶍽
9 RS485+ 󶍽
3 GND1 COM1 power GND
5.5 Ethernet Connection for Monitoring
󶏎Networking diagram
With the Ethernet port, the CPU module can be connected point-to-point with
devices such as a computer and HMI through an Ethernet cable:
.',
36/4501
$/34 $/ $"/
$/ &UIFS/&5 $/&UIFS$"5
#'
4'
&33
36/  

 * **
&UIFSOFUDBCMF

".$165/
$/



$"/36/
$"/&33
Figure 10 Connection between CPU module and PC
The CPU module can also be connected to a hub or switch, which is further
connected with other network devices, through an Ethernet cable to achieve
multi-point connection.

20
MF·K
RUN/STOP
CN1RS485
CN3 EtherNET CN4 EtherCAT
BF
SF
ERR
RUN 0123 7654
27654103
45673210
I
II
在块坋坈坕坑坈块圃坆坄坅坏坈
圳圦 HMI
LAN
圦坒坐坓坘块坈坕
在块坋坈坕坑坈块圃坆坄坅坏坈
圶坚坌块坆坋
AM600-CPU1608TN
CN2CAN
CN5
3536
21
CANRUN
CANERR
Figure 11 Connection between CPU module and other devices through a switch
󶏎Wiring
To improve communication reliability, the Ethernet cable must be injection-
molded Cat5 shielded twisted pair and with an injection molded and iron shelled
connector.
6 Programming Tool
6.1 Programming tool download
Inovance provides InoProShop as the user programming tool for AM403 medium-
sized PLCs. It is free and you can obtain a DVD copy from our distributors or
download it from our website www.inovance.com, where you can also download
documents about AM403 PLC products and their applications.
Due to the continuous improvement of products and information by the