Mitsubishi Electric MELSEC-A Series User manual

User's Manual
It _
•
type A2CCPU (P21/R21)
•MITSUBISHI
.... ELECTRIC

I
•

I
•
REVISIONS
*The manual number is given on the bottom left of the back cover.
Print Date *Manual Number Revision
Nov, 1990 IB (NA) 66267-A First edition

•

I
•
INTRODUCTION
Thank you for choosing the Mitsubishi MELSEC-ASeries of General Purpose Programmable Control-
lers. Please read this manual carefully so that the equipment is used to its optimum. A
copy of this
manual should be forwarded to the end user.

1
CONTENTS
INTRODUCTION •...••...•••••....••.•••••••••••....•••••.••••••••••••• 1-1 -1-11
1.1 General Description of Operation 1-2
1.1.1 ON/OFF data communication between the A2C and the remote I/O module •. . . .. 1 - 2
1.1.2 Data communication between the A2CCPU and the remote terminal module
..... 1 - 4
1.2 Features. ................................................................. .. 1 - 5
1.3 General Terms and Abbreviations 1 - 9
1.4 Reference Manuals
.........................................................• 1- 11
I
2SYSTEM CONFIGURATION 2-1 -2-16
2.1 Overall Configuration ..........................................................2 - 1
2.2 Notes on System Construction 2 - 3
2.3 System Equipment 2 - 8 4
2.3.1 Modules which can be connected to the A2CCPU 2 - 8
2.3.2 Peripheral devices 2 - 15
3GENERAL SPECIFICATIONS 3-1
4A2CCPU ••••••...••••....••••••••••••..••....••••••.•...••••...••••. 4-1 - 4-94
4.1 Performance ............................................................•.. .. 4 - 1
4.1.1 Repeated operation processing 4 - 4
4.1.2
In~ial processing 4 - 4
4.1.3 END processing 4 - 5
4.1.4 Timerprocessing and accuracy 4 - 6
4.1.5 Counterprocessing and maximum counting speed 4 - 8
4.1.6 Operation processing at momentary powerfailure 4 - 9
4.1.7 Scantime 4
-10
4.1.8 Watch dog timer (WDl) 4 - 11
4.1.9 RUN. STOP. PAUSE operation processing
4-13
4.2 Functions 4 - 18
4.2.1 Constant scan 4 - 19
4.2.2 Power failure compensation for device data in the A2C
(LATCHfunction) 4 - 22
4.2.3 Running and stoppingthe A2C from external devices
(Remote RUN/STOPfunction) 4 - 24
4.2.4 Stoppingthe sequence program operation retaining outputs (PAUSEfunction)
.. 4 - 26
4.2.5 Status latch
.......................................................•.. 4 - 28
4.2.6 Samplingtrace 4 - 30
4.2.7 Offline
sw~ch function 4 - 33
4.2.8 Setting priority for ERRORLED indication 4 - 35
4.2.9 Control functions of remote I/O modules and remote terminal modules 4 - 37
4.2.10 Outputfrom the ERRterminals 4 - 41
-i-

I4.3 Fault Detection 4 - 42
4.3.1 SeR-diagnosis 4 - 42
4.3.2 Faultdetection with annunciator
(F) 4 - 47
4.4 ParameterSetting Range 4 - 49
4.4.1 Memory capacity setting 4 - 53
4.4.2 Operation mode at an occurrence of error 4 - 55
4.4.3 STOP
-+ RUN output mode 4- 56
4.4.4 Entry code registration 4 - 57
4.4.5 Printtitle registration .
.. .. . .. . .. .. .. . .. .. ... .. . .. . .. . . .. .. . . .. . .. . .. . 4- 57
4.5 Devices 4 - 58
4.5.1 Device list 4 - 58
4.6
INSTRUCTIONS 4 - 60
4.6.1 Sequence instructions 4 - 60
4.6.2 Basic instructions 4 - 62
4.6.3 Application instructions 4 - 68
4.7 I/O Numbers and Station Number Setting 4 - 74
4.8 Precautions on Handling 4 - 76
4.9 PartIdentification 4 - n
4.10 PartIdentification 4 - 84
4.10.1 Externalview of A2CCPUP21/R21 4 - 84
4.10.2 Setting for MELSECNET Data Link 4 - 92
4.10.3 Selecting test mode 4 - 93
4.10.4 SeR-loopbacktest
4-94
5 MEMORY ICa, BATTERY, CABLES AND DIN ADAPTER 5 -1 - 5 -10
5.1 MemoryICs 5- 1
5.1.1 Specifications 5- 1
5.1.2 Handling instructions 5- 1
• 5.1.3 Installation............................................................ 5- 2
5.2 Battery......................................................................5-3
5.2.1 Specifications.. ..................................................... .. 5- 3
5.2.2 Handling instructions 5- 3
5.2.3
Installation............................................................ 5- 4
5.3 Cables 5 - 5
5.4 DINAdapter 5- 7
5.4.1 Specifications.. . .. . . . .. . .. . .. .. .. . .. . .. . . .. . . .. . .. .. . . .. . . .. . .. .... 5- 7
5.4.2 Handling instructions 5- 7
5.4.3 Fixinga DIN adapter to a module 5- 9
5.4.4 Mounting to the DINrail 5- 10
-ii-

6 LOADING AND INSTALLATION 6 -1 -6 -11
6.1 Fail-safe Circuit. ............................................................ .. 6 - 1t
6.2 Installation Environment 6 - 1 ,
6.3 Calculation of Heat Generated by the A2C System 6 - 2
6.4 Wiring. ................................................................... .. 6 - 4
6.4.1 Wiring instructions 6 - 4
6.4.2 Connection between
modules. ......................................... .. 6 - 8
6.5 InstallingThe A2CCPU 6 - 11
7TEST RUN
••••••••••••••••••••••.•••••••.....••••••••••••...•••••••••• 7- 1 - 7 - 4
7.1 Check Points before Test Run 7 - 1
7.2 Test Run Procedures. ....................................................... .. 7 - 3
8MAINTENANCE AND INSPECTION 8 - 1 - 8 - 4
8.1 Daily Inspection ...........................................................•.. 8 - 1
8.2 Periodic Inspection
..........................................................• 8 - 2
8.3 Replacement ofBattery......................................................
.. 8 - 3
8.3.1 Battery
IKe 8 - 3
8.3.2 Replacing procedures 8 - 4
9TROUBLESHOOTING .•••••....••••••••••••••••.•••......•.......••••.. 9 - 1 - 9 - 15
9.1 Basic Troubleshooting. ...................................................... .. 9 - 1
9.2 Troubleshooting 9 - 2
9.2.1 Troubleshootingflow
charts. ........................................... .. 9 - 2
9.2.2 Flow chart used when "POWER" LEDof the A2CCPU has turned off 9 - 3
9.2.3 Flow chart used when "RUN" LEDof the A2CCPU has turned off
.. ........... .. 9 - 4
9.2.4 Flow chart usedwhen "RUN" LEDof the A2CCPU flickers
..................•.. 9 - 5
9.2.5 Flow chart used when "ERROR" LEDhas turned on 9 - 6
9.2.6 Flow chart used when "ERROR" LEDof the A2CCPUflickers
...............•.. 9 - 8
9.2.7 Flow chart used when "RD/SD" LEOs of
the A2CCPU do not flicker 9 - 9
9.2.8 Flow chart used when output load of output module does not turn on 9 - 10
9.2.9 MaKunetion in program download to PC
............................•..... 9 - 11
9.3 Error Code Ust 9 - 12
9.3.1 Error code list 9
-12
APPENDICES •••••••••.••••••••••..•••....••••....•••.•.•••••..••••• APP - 1 - APP - 28
APPENDIX1 Outside Dimensions APP- 1
APPENDIX2 Ust of Special Relays APP- 6
APPENDIX3 List of Special Registers APP- 10
APPENDIX4 Instructionsfor Use with Peripheral Devices APP- 20
APPENDIX5 Cautions on Editing Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.. APP- 28
-iii-
•

1. INTRODUCTION
--------------------
MELSEC·A
Remote I/O
module:
•
1. INTRODUCTION
This manual gives the system, specifications and handling of the A2CCPU,
A2CCPUP21 and A2CCPUR21 General-purpose Programmable Controller
(referred to as A2C in this manual).
The A2C is a building block type CPU module which can construct asystem
including remote I/O modules (I/O modules) and remote terminal modules
(special-function modules)
(*')
without using abase unit.
The A2C uses the MELSECNET/MINI-S3 data link system (*2) (referred to as
MINI-53 in this manual) in place of a base unit for data communication with
the
remote I/O module and the remote terminal module
through
s-core flat
cables or twtsted-pair cables.
Using s-core flat cables,
the
system modules can be arranged close to each
other just as the building block type CPU is used.
Using twisted-pair cables, the system modules can be separated up to 100
meters (328.1
It)
away from each other
(*1.
This feature makes it possible
to install
the
remote I/O module and the remote terminal module to conform
with the arrangement of equipment to be controlled.
IREMARKsl
(1)
.1...
"Remote I/O module" and "remote terminal module" are general terms for the
mcdulee
mentioned below.
Input/output modules connectable to the A2C. Mitsubishl
general-purpose
inverter
FR~Z200
series,
MELSEC-F
series programmable controllers
Remote terminal
module:
Special function modules connectable to the A2C, RS-
232C
interface
modules
See Section
2.3
for names and types of the remote I/O modules and the remote
terminal modules.
(2)
*2
.,.
The MELSECNET/MINI-S3 data link system has been designed to reduce the amount
of wiring between the PC and equipment to be controlled. Since the PC, the remote
I/O module and the remote terminal module are connected with twisted-pair cables
or optical fiber cables, it is possible to install the remote I/O module and the remote
terminal module to suit with the arrangement of equipment to be controlled.
(3)
*3...
Distance allowed when twisted-pair cables of
0.5
mm2(20 AWG) or thicker are used.
The maximum allowable distance is 50 meters (164.1
tt)
when twisted-pair cables of
0.3
mm
2
(22 AWG) or thinner are used.
1
-1

1. INTRODUCTION
-------------------- MELSEC·A
1.1 General Description of Operation
Thissection describesthe datacommunication between the A2C, the remote
I/O module and
the remote terminal module.
See Section 4.2
for the A2C functions.
1.1.1 ON/OFFdata communication between the A2C and the remote I/O module
ON/OFF data communication is performed using inputs (X) and outputs
(Y).
(1) Input/output number assignment of the remote I/O module
The
input/output numbers of the A2C system are assigned from x/yOOO
to X/y1FFin the order ofthe station number (1 to 64) set for each remote
I/O module.
Data communication with a remote I/O module is performed using ..
inputs (X) and outputs
(Y) assigned for each module. 'Ill
See Section 4.7 for the relationship between station numbers and i/O
numbers.
(2) ON/OFF data communication with
the remote I/O module
The ON/OFF data communication with the remote I/O module is per-
formed in the refresh mode.
Fig. 1.1 shows the data communication between the A2C and the
~
remote I/O modules. ,
(b) ON/OFF data of output (Y) is output.
I
A2C
Station: 1
(a) Sequence program execution I-:
CPU
I/O
H
X?
/' (c) ON/OFF data from the
o ,
Y20
input (x) module Is taken in.
,
Station: 9
I/O
,
MINI-S3Iink
,
~_r,l
,
n '-'
Y21
~
I/O
0------
I/O
The sequence program uses input (X) and
output M numbers to control remote I/O
Station: n Station: 5
modules.
When the A2C is running, operations (a), (b) and (0) mentioned below are executed repeatedly.
(a) The sequence program is executed from step 0 to END (FEND).
(b)
ON/OFF data of an output (Y) in the sequenca program is output by the MINI-S3 link.
(c)
ON/OFF data from an input module is taken In by the MINI-S3 link.
Fig. 1.1 ON/OFF Data Communication between the A2C and the Remote I/O Modules
1-2
41

•
,
1. INTRODUCTION
--------------------
MELSEC·A
(3)
Input/output
response time
The
data
communication response time between the A2C
and
the
remote I/O modules is as described below.
(a) To take in an ON/OFF change from
the
input
module, 1scan at
maximum is required.
(b) When an output ON/OFF is changed by the sequence program, 1
scan at maximum is required to
output
the change to
the
output
module.
(c) When ON/OFF control of the
output
moduleis done by ON/OFF data
of
the
input
module, 2scans at maximum are required till the
ON/OFF status of the outputmodule changes afteran ON/OFF
input
changed.
1-3

1. INTRODUCTION
--------------------
MELSEC·A
1.1.2
Data communication betweenthe A2CCPU and the remote terminal module
(1) Maximum
number
of remote terminal modules to be connected
Amaximum of 14 remote terminal modules (a maximum of 7 AJ35PTF-
R2 RS-232C modules) can be connected to
the
A2C. (See Section 2.2.)
(2) Data communication with remote terminal modules
(a) Perform the following initial setting.
1)
The first station
number
of
the
remote terminal module
2) Protocol
See Section 4.2.9
for
details of initial setting.
(b) Execute data communication with the FROM/TO instruction.
See the ACPU Programming Manual (Common Instructions)
for
4
details of the FROM/TO instruction.
(b)Transmission of
designated
data
by
Iexecuting TO instruction
A2C
Station:
1
(a) Sequence
program
execution I-: CPU I/O
HXf
0I
TopIH91KOIooIK11-
Remote
PRCIM1IYOI-
MINI-S3Iink
Station:
9
terminal
,
module
,
cOmPI~ignal
!=:i?
,
n
..!.-
Y21
@[]
I/O
1------
I/O
(c)
Tra~mission
Station:
n
Station:
5of
complete
signal
Data
communication
with the remote terminal
module
is executed as
described
below.
(a)The FROMITO and PRC
instructions
are executed by the sequence program.
(b)The request to
send
designated
data
or the data is transmitted by
executing
the FROMITO instruction.
1)
At FROM
instruction
execution
:Data
send
request
2) TO
instruction
:Data
sending
(c) The remote terminal
module
sends the
completion
signal
of
data
send or receive to
the
A2C.
Cd)
The A2C turns ON
the
complete
signal
when it received the send/receive
complete
signal
from
the
remote
terminal
module.
•
Fig.
1.2
Data
Communication
between
the
A2C
and
the
Remote
TermInal
Module
(3) Response time
Communication of
8
data with one FROM/TO instruction requires ap-
...
proximately 400 msec (when scan time is 100 msec). •
1-4

1. INTRODUCTION
-------------------- MELSEC-A
I
1.2 Features
The A2C has the following features.
(1)
Compact size
(a)
The A2C has compact outside dimensions: 170 mm (6.69
in)(height) x 100 mm (3.94 in)(width) x 80 mm (3.15 in) (length)
(b) The A2CCPUP21/R21
data link module has compact outside dimen-
sions : 170 mm (6.69 in)(height) x 170 mm (6.69 in)(width) x 80 mm
(3.15 in)(length).
(c) The A2CI/O
module has a short width of 64 mm (2.5 in).
A2CCPU
80 mm
(3.15 in)
170 mm
(6.69 in)
A2CCPUP21/R21
80 mm
(3.15 in)
170 mm
(6.69 in)
80 mm
(3.15 in)
170 mrn
(6.69 in)
A2CI/O module
•
Fig. 1.3 A2C Outside Dimensions
(2) 512 points of input/output control
The A2C is capable of controlling
input/output operation at 512 points
specified between
X/YO and X/Y1FF. 170 mm (6.69 in)
(3) A maximum of 8K steps can be contained in one program.
With sequence instructions, basic
instructions and application instruc-
tions, amaximum of 8K
steps can be contained in one sequence
program. Also, microcomputer programs and utility programs made by
the user can be run in combination with a sequence program.
(4) Data link modules usable as master stations or local stations
The A2CCPUP21/R21 can be used as either amaster station or a local
station in
the MELSECNET link system.
The A2CCPUP21/R21 cannot be used as
the masterstation for the third
tier.
1-5

1. INTRODUCTION
-------------------- MELSEC·A
(5) Cable connection between modules
Cables designed exclusively for
the A2C or twisted-pair shield cables I
are used for connection between the A2C and the A2CI/O module and
between the A2CI/O modules.
When the I/O modules are arranged side by side
A2CI/O module
A2C
0
-0
--
lI\Cable
When the I/O modules are arranged apart I
A2C A2CI/O module A2CI/O module
0-
-0
A2CI/O module
/
Twisted-pair cable
Fig. 1.4 Connection of the A2C System
1-6
•

I
•
1. INTRODUCTION
-------------------- MELSEC.A
(6) Connection with the MINI-53 link remote I/O modules and remote ter-
minal modules is possible.
The A2C can be connected with the MINI-53 link remote I/O modules,
remote terminal modules. (See Section 2.3.1.)
The
A2CI/0 modules, MINI-53 link remote I/O modules, remoteterminal
modules can be used together.
"A2CCPU
]1
~ Twisted-pair cable
1
Remote terminal I
module
II
A2CI/O module
JI
II
A2CI/O module
11
Remote I/O module
Fig. 1.5 Use with the MINI·53 Link Modules
(7) Vertical and horizontal positions and mounting on a flat base are
possible.
The A2C and
A2CI/0 modules can be installed in three different posi-
tions.
0Front
-
r-'-
1
-
~
==0
0
~
~
111111
Vertical Horizontal
;:;
FI~t b'-sO / // ~
Fig. 1.6 Installing Positions of the A2C and A2CI/O Modules
1-7

1. INTRODUCTION
-------------------- MELSEC·A
(8) Can be mounted to the DIN rail.
The A2C and A2CI/O modules are usually mounted directly
to acontrol I
panel or equipment to be controlled using screws. Using the DIN rail
adapter, however, the A2C modules can be mounted to
the DIN rail.
(A clearance of 4 mm (0.16 in) between modules is obtained when
the
DIN adapters are mounted side by side without leaving clearance
between them. (See App. 1.)
HOOKfor removing the DIN rail adapter
module from the DIN A2C A2CI/O module
/Nrall
V-;;;N rail
-.
0
=-V
-
r---
1[1
-
\t=
r----f
\
tr
0
~
~
Fig. 1.7 A2C and A2CI/O Modules Mounted to the DIN Rail
1-8

1. INTRODUCTION
-------------------- MELSEC-A
I
•
•
1.3
General Terms and Abbreviations
General terms and abbreviations used in this manual are explained below.
(1) A2C
An abbreviation of
the A2CCPU general-purpose programmable con-
troller.
In case
the A2CCPU should be discriminatedfrom the A2CCPUP21/R21,
A2C is described as A2CCPU or A2CCPUP21/R21.
(2)
A2CI/0 module
Ageneral term for
the following I/O modules which are of the same type
as the A2CCPU.
(a) 32-point
input modules
(b) 32-point
output modules
(c) 32-point I/O modules
See Section 2.3
for type classification of the A2CI/0 modules.
(3) A2C special function module
Ageneral term for
the following special function modules which are of
the same type as the A2CCPU.
(a) High speed
counter module
(b) Analog-digital conversion module
(c) Digital-analog conversion module
See Section 2.3 for type classification of the A2C special function
modules.
(4) MINI-S3 link
An abbreviation of
the MELSECNET/MINI-S3 data link system.
(5) Peripheral devices
Ageneral term
for A6GPP, A6PHP, A6HGP and A7PU.
1-9

1. INTRODUCTION
-------------------- MELSEC·A
(6) Remote I/O module
Ageneral term
for the following modules.
(a)
A2CI/0 modules
(b) MINI-53 link remote I/O modules
1) Out-of-panel
type remote I/O modules
2) Compact
type remote I/O modules
3) AJ72PT35 type link module
4) MELSEC-F series programmable controllers
5) Mitsubishi general-purpose inverters
See Section 2.3
for type classification of A2CI/0 modules and
applicable MINI-53 link remote I/O modules.
(7) Remote module
Ageneral term
for remote I/O modules and remote terminal modules.
(8) Remote terminal module
Ageneral term
for the A2C special function modules and the MINI-53
link remote terminal modules.
See Section 2.3 for
type classification of A2C special function modules
and applicable MINI-53 link remote terminal modules.
1 -10
I
•
41

1. INTRODUCTION
-------------------- MELSEC·A
I
•
•
1.4 Reference Manuals
Refer to the manuals listed below to use the A2C.
(1) ACPU Programming Manual (Fundamentals) :IB(NA)-66249
For details of
the programming method, devices, parameters and kind
of program necessary for
the programming for the A2C.
(2) ACPU Programming Manual (Common instructions) :IB(NA)-66250
For details of operation by
the sequence instructions, common instruc-
tions and application instructions feasible with the A2C.
(3)
A2CI/0 Module User's Manual: IB(NA)-66236
For specifications and outside dimensions of
the A2CI/0 modules.
(4) MELSECNET/MINI-S3 Batch Refresh
Type Remote I/O Module User's
Manual: IB(NA)-66215
For specifications and
handling of the batch refresh type remote I/O
modules.
(5) MELSECNET(II) Data Link Reference
Manual: IB(NA)-66263
For specifications functions, and programming of
the MELSECNET(II)
data link system.
(6) AJ35PTF-R2
Type RS-232C Interface Module User's Manual: IB(NA)-
66219
For specifications and
handling for communication with calculators
using
the RS-232C interface module.
(7) Special Function Modules Manual
For
specifications, handling and programming for special function
modules used.
(8) MELSEC-F Series Programmable Controllers Manual
For specifications, handling and programming for
the MELSEC-F series
PCs.
(9) FR-Z200 Series General-Purpose Inverters Manual
For specifications and handling of
the FR-Z200 series general-purpose
inverters.
1- 11

2. SYSTEM CONFIGURATION
-------------------- MELSEC·A
2. SYSTEM CONFIGURATION
2.1 Overall Configuration
I
~
+
~
.....
Memory CPU module
Type [ jKROM Type
A2CCPU
....
~
(P21/R21)
...
....
+~
.....
~
...
•A2CI/O
module
•
s.ccre flat cable
I-
(A2C-005)
DIN
adapter
Twlsted-pafr
•
lIJ
•
Type A6DIN2C
shield cable
~
...
.....
~
...
A2C special
function module
~
•
.. •
...
MINI-53 link
~
5-core flat cable
t
DIN rail remote I/O (A2C-005)
..
module
....
•e
DIN adapter
AJ35PTF-R2 Twisted-pair
A6
...
RS-232C
~ .
shield cable
Type
DIN[ jC
...
interface
....
module
~-nl
•
~.! ~ ,
"I
~
Power supply
For 24 VDC Imodule
....
power supply
I
Type A66PC
I I
lL5
eral
[]
pose power
supply
i
Fig. 2.1
Overall Configuration
2-1