Mitsubishi MELSEC-A A2USHCPU-S1 User manual

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SAFETY PRECAUTIONS
(Be sure to read these instructions before use.)
Before using the product, read this and relevant manuals carefully and handle the product correctly with full
attention to safety.
In this manual, SAFETY PRECAUTIONS are classified into 2 levels: "DANGER" and "CAUTION".
Under some circumstances, failure to observe the CAUTION level instructions may also lead to serious
results.
Be sure to observe the instructions of both levels to ensure the safety.
Please keep this manual in a safe place for future reference and also pass this manual on to the end user.
[DESIGN PRECAUTIONS]
DANGER
Create a safety circuit outside the programmable controller to ensure the whole system will operate
safely even if an external power failure or a programmable controller failure occurs.
Otherwise, incorrect output or malfunction may cause an accident.
(1) For an emergency stop circuit, protection circuit and interlock circuit that is designed for
incompatible actions such as forward/reverse rotation or for damage prevention such as the
upper/lower limit setting in positioning, any of them must be created outside the programmable
controller.
(2) When the programmable controller detects the following error conditions, it stops the operation
and turn off all the outputs.
• The overcurrent protection device or overvoltage protection device of the power supply
module is activated.
• The programmable controller CPU detects an error such as a watchdog timer error by the
self-diagnostics function.
In the case of an error of a part such as an I/O control part that cannot be detected by the
programmable controller CPU, all the outputs may turn on. In order to make all machines
operate safely in such a case, set up a fail-safe circuit or a specific mechanism outside the
programmable controller. Refer to "LOADING AND INSTALLATION" in this manual for example
fail safe circuits.
(3) Depending on the failure of the output module's relay or transistor, the output status may remain
ON or OFF incorrectly.
For output signals that may lead to a serious accident, create an external monitoring circuit.
DANGER Indicates that incorrect handling may cause hazardous conditions, resulting in
death or severe injury.
CAUTION Indicates that incorrect handling may cause hazardous conditions, resulting in
minor or moderate injury and/or property damage.

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[DESIGN PRECAUTIONS]
DANGER
If load current more than the rating or overcurrent due to a short circuit in the load has flowed in the
output module for a long time, it may cause a fire and smoke. Provide an external safety device such
as a fuse.
Design a circuit so that the external power will be supplied after power-up of the programmable
controller.
Activating the external power supply prior to the programmable controller may result in an accident
due to incorrect output or malfunction.
For the operation status of each station at a communication error in data link, refer to the respective
data link manual.
The communication error may result in an accident due to incorrect output or malfunction.
When controlling a running programmable controller (data modification) by connecting a peripheral
device to the CPU module or a PC to a special function module, create an interlock circuit on
sequence programs so that the whole system functions safely all the time.
Also, before performing any other controls (e.g. program modification, operating status change
(status control)), read the manual carefully and ensure the safety.
In these controls, especially the one from an external device to a programmable controller in a
remote location, some programmable controller side problem may not be resolved immediately due
to failure of data communications.
To prevent this, create an interlock circuit on sequence programs and establish corrective
procedures for communication failure between the external device and the programmable controller
CPU.
When setting up the system, do not allow any empty slot on the base unit.
If any slot is left empty, be sure to use a blank cover (A1SG60) or a dummy module (A1SG62) for it.
When using the extension base unit, A1S52B(S1), A1S55B(S1) or A1S58B(S1), attach the included
dustproof cover to the module in slot 0.
Otherwise, internal parts of the module may be flied in the short circuit test or when an overcurrent or
overvoltage is accidentally applied to external I/O section.

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[DESIGN PRECAUTIONS]
[INSTALLATION PRECAUTIONS]
CAUTION
Do not install the control lines or communication cables together with the main circuit or power lines,
or bring them close to each other.
Keep a distance of 100mm (3.94inch) or more between them.
Failure to do so may cause malfunctions due to noise.
When an output module is used to control the lamp load, heater, solenoid valve, etc., a large current
(ten times larger than the normal one) may flow at the time that the output status changes from OFF
to ON. Take some preventive measures such as replacing the output module with the one of a
suitable current rating.
CAUTION
Use the PLC under the environment specified in the user's manual.
Otherwise, it may cause electric shocks, fires, malfunctions, product deterioration or damage.
Insert the module fixing projection into the fixing hole in the base unit and then tighten the module
mounting screw within the specified torque.
When no screw is tightened, even if the module is installed correctly, it may cause malfunctions, a
failure or a drop of the module.
If too tight, it may damage the screw and/or the module, resulting in a drop of the module, a short
circuit or malfunctions.
Connect the extension cable to the connector of the base unit or module.
Check the cable for incomplete connection after connecting it.
Poor electrical contact may cause incorrect inputs and/or outputs.
Insert the memory cassette and fully press it to the memory cassette connector.
Check for incomplete connection after installing it.
Poor electrical contact may cause malfunctions.
Be sure to shut off all phases of the external power supply used by the system before mounting or
removing the module.
Failure to do so may damage the module.
Do not directly touch the conductive part or electronic components of the module.
Doing so may cause malfunctions or a failure of the module.

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[WIRING PRECAUTIONS]
DANGER
Be sure to shut off all phases of the external power supply used by the system before wiring.
Failure to do so may result in an electric shock or damage of the product.
Before energizing and operating the system after wiring, be sure to attach the terminal cover
supplied with the product.
Failure to do so may cause an electric shock.
CAUTION
Always ground the FG and LG terminals to the protective ground connector.
Failure to do so may cause an electric shock or malfunctions.
Wire the module correctly after confirming the rated voltage and terminal layout.
Connecting a power supply of a different voltage rating or incorrect wiring may cause a fire or failure.
Do not connect multiple power supply modules to one module in parallel.
The power supply modules may be heated, resulting in a fire or failure.
Press, crimp or properly solder the connector for external connection with the specified tool.
Incomplete connection may cause a short circuit, fire or malfunctions.
Tighten terminal screws within the specified torque range.
If the screw is too loose, it may cause a short circuit, fire or malfunctions.
If too tight, it may damage the screw and/or the module, resulting in a drop of the module, a short
circuit or malfunctions.
Carefully prevent foreign matter such as dust or wire chips from entering the module.
Failure to do so may cause a fire, failure or malfunctions.
Install our programmable controller in a control panel for use.
Wire the main power supply to the power supply module installed in a control panel through a
distribution terminal block.
Furthermore, the wiring and replacement of a power supply module have to be performed by a
maintenance worker who acquainted with shock protection.
(For the wiring methods, refer to Section 8.7.)

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[STARTUP AND MAINTENANCE PRECAUTIONS]
DANGER
Do not touch any terminal during power distribution.
Doing so may cause an electric shock.
Properly connect batteries.
Do not charge, disassemble, heat or throw them into the fire and do not make them short-circuited
and soldered.
Incorrect battery handling may cause personal injuries or a fire due to exothermic heat, burst and/or
ignition.
Be sure to shut off all phases of the external power supply used by the system before cleaning or
retightening the terminal screws or module mounting screws.
Failure to do so may result in an electric shock.
If they are too loose, it may cause a short circuit or malfunctions.
If too tight, it may cause damage the screw and/or module, resulting in a drop of the module, a short
circuit or malfunctions.

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CAUTION
When performing online operations (especially, program modification, forced output or operating
status change) by connecting a peripheral device to the running CPU module, read the manual
carefully and ensure the safety.
Incorrect operation will cause mechanical damage or accidents.
Do not disassemble or modify each of modules.
Doing so may cause failure, malfunctions, personal injuries and/or a fire.
When using a wireless communication device such as a mobile phone, keep a distance of 25cm
(9.84inch) or more from the programmable controller in all directions.
Failure to do so may cause malfunctions.
Be sure to shut off all phases of the external power supply used by the system before mounting or
removing the module.
Failure to do so may result in failure or malfunctions of the module.
Do not drop or apply any impact to the battery.
Doing so may damage the battery, resulting in electrolyte spillage inside the battery.
If any impact has been applied, discard the battery and never use it.
Do not mount/remove the module onto/from base unit more than 50 times (IEC61131-2-compliant),
after the first use of the product.
Before handling modules, touch a grounded metal object to discharge the static electricity from the
human body.
Failure to do so may cause failure or malfunctions of the module.

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[DISPOSAL PRECAUTIONS]
[TRANSPORTATION PRECAUTIONS]
CAUTION
When disposing of the product, treat it as an industrial waste.
When disposing of batteries, separate them from other wastes according to the local regulations.
(For details of the battery directive in EU member states, refer to Appendix 7.)
CAUTION
When transporting lithium batteries, make sure to treat them based on the transportation regulations.
(Refer to Appendix 6 for details of the relevant models.)

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Revision
*The manual number is given on the bottom left of the back cover.
Print Date *Manual Number Revision
Jun., 1997 IB(NA)-66789-A First edition
Jun., 2002 IB(NA)-66789-B Equivalent to the Japanese version C
SAFETY PRECAUTIONS, Chapter 1, Section 1.2, Section 2.1, 2.2.1, 2.2.2,
2.2.3, 2.3, Chapter 3, Section 4.1.4, 4.2.2, 4.2.5, Section 5.1, 5.2, Section 6.1.2,
6.1.3, Section 7.1.1, 7.1.5, Section 8.1, Chapter 9, Section 10.3.2, Appendix 2.1,
2.2, Appendix 4.2
Dec., 2003 IB(NA)-66789-C
A1SY42P
SAFETY PRECAUTIONS, Section 1.1, Section 2.2.1, 2.3, Section 7.2.1, Section
8.4.1, 8.8, Section 9.1.3, 9.1.4, Section 11.3.2
Appendix 7, 7.1, 7.2
Oct., 2006 IB(NA)-66789-D
SAFETY PRECAUTIONS, Section 1.2, Section 2.2.1, 2.3, Chapter 3,
Section 4.1, 4.1.3, 4.1.5, 4.2.2, 4.3, 4.4, 4.5.1, Section 5.1, 5.2, Section 6.1.1,
6.1.3, 6.2, Section 7.2, Section 8.1, 8.4.1, 8.5, 8.6, 8.7.1, 8.7.2, 8.8, Chapter 9,
9.1.3, 9.2.4, 9.2.6, Chapter 10, Section 10.3, 10.3.1, 10.3.2, Section 11.2.1,
11.2.8, 11.3.2, 11.4.1, 11.4.2, Appendix 2.1, 2.2, Appendix 3, Appendix 4.3
SAFETY PRECAUTIONS, Section 6.3, Section 11.2.9
Section 7.1.4
May, 2007 IB(NA)-66789-E
Section 4.2.2, 4.5.1, 8.7.1, 8.7.2, 9.1.3, 9.2.7,10.3.1, 11.4.2
Section 9.1.7
Jul., 2007 IB(NA)-66789-F
Section 6.2, Appendix 5.4.1, Appendix 5.4.3, Appendix 5.4.4, Appendix 5.4.5,
Appendix 5.4.8, Appendix 5.4.9, Appendix 5.4.10
Oct, 2008 IB(NA)-66789-G
SAFETY PRECAUTIONS, Chapter 3, Section 7.2.1
Appendix 7, 7.1, 7.2
Correction
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