Panasonic FP7 Series User manual

Safety Precautions
Observe the following notices to ensure personal safety or to prevent accidents.
To ensure that you use this product correctly, read this User’s Manual thoroughly before use.
Make sure that you fully understand the product and information on safety.
This manual uses two safety flags to indicate different levels of danger.
If critical situations that could lead to user’s death or serious injury is assumed by
mishandling of the product.
WARNING
-Always take precautions to ensure the overall safety of your system, so that the whole
system remains safe in the event of failure of this product or other external factor.
-Do not use this product in areas with inflammable gas. It could lead to an explosion.
-Exposing this product to excessive heat or open flames could cause damage to the lithium
battery or other electronic parts.
-Battery may explode if mistreated. Do not recharge, disassemble or dispose of fire.
If critical situations that could lead to user’s injury or only property damage is
assumed by mishandling of the product.
CAUTION
-To prevent excessive exothermic heat or smoke generation, use this product at the values
less than the maximum of the characteristics and performance that are assured in these
specifications.
-Do not dismantle or remodel the product. It could cause excessive exothermic heat or smoke
generation.
-Do not touch the terminal while turning on electricity. It could lead to an electric shock.
-Use the external devices to function the emergency stop and interlock circuit.
-Connect the wires or connectors securely.
The loose connection could cause excessive exothermic heat or smoke generation.
-Ground the protective earth (PE) terminal (Class D grounding). Failure to do so could lead to
an electric shock.
-Do not allow foreign matters such as liquid, flammable materials, metals to go into the inside
of the product. It could cause excessive exothermic heat or smoke generation.
-Do not undertake construction (such as connection and disconnection) while the power
supply is on. It could lead to an electric shock.
Copyright / Trademarks
-This manual and its contents are copyrighted.
-You may not copy this manual, in whole or part, without written consent of Panasonic
Industrial Devices SUNX Co., Ltd.
-Windows is a registered trademark of Microsoft Corporation in the United States and other
countries.
-Ethernet is a registered trademark of Fuji Xerox Co., Ltd. and Xerox Corp.
-All other company names and product names are trademarks or registered trademarks of
their respective owners.
PLC_BATPE_ET

Introduction
Thank you for buying a Panasonic product. Before you use the product, please carefully read
the installation instructions and the users manual, and understand their contents in detail to
use the product properly.
Types of Manual
•There are different types of users manual for the FP7 series, as listed below. Please refer to
a relevant manual for the unit and purpose of your use.
•The manuals can be downloaded on our website:
http://industrial.panasonic.com/ac/e/dl_center/manual/ .
Unit name or purpose of
use
Manual name Manual code
FP7 Power Supply Unit FP7 CPU Unit Users Manual
(Hardware) WUME-FP7CPUH
FP7 CPU Unit
FP7 CPU Unit Programming Manual WUME-FP7CPUPGR
Instructions for Built-in
COM Port
FP7 Extension
(Communication)
Cassette
FP7 CPU Unit Users Manual
(COM Port Communication) WUME- FP7COM
Instructions for Built-in
LAN Port
FP7 CPU Unit Users Manual
(LAN Port Communication) WUME-FP7LAN
FP7 Digital Input/Output Unit FP7 Digital Input/Output Unit Users Manual WUME-FP7DIO
FP7 Analog Input Unit FP7 Analog Input Unit Users Manual WUME-FP7AIH
FP7 Analog Output Unit FP7 Analog Output Unit Users Manual WUME-FP7AOH
FP7 High-speed Counter unit FP7 High-speed Counter Unit Users Manual WUMJ-FP7HSC
FP7 Positioning Unit FP7 Positioning Unit Users Manual WUME-FP7POSP
PHLS System PHLS System Users Manual WUME-PHLS
Programming Software
FPWIN GR7 FPWIN GR7 Introduction Guidance WUME-FPWINGR7

ii
Table of Contents
1. Overview............................................................................. 1-1
1.1 System Configuration ............................................................................1-2
1.1.1 Units ........................................................................................................1-2
1.1.2 Combination of Units ...............................................................................1-4
1.2 Selection of Power Supply and Restrictions on Combination.................1-5
1.2.1 Power Supply for Internal Circuit.............................................................1-5
1.2.2 Power Supply for External Circuit ...........................................................1-7
1.3 Programming Tools ...............................................................................1-8
2. Names and Functions of Parts ......................................... 2-1
2.1 CPU Unit ...............................................................................................2-2
2.2 Power Supply Unit .................................................................................2-4
3. I/O Number Allocation ....................................................... 3-1
3.1 Basics of I/O Allocation..........................................................................3-2
3.1.1 How to Count the I/O Numbers ...............................................................3-2
3.1.2 Concept of I/O Number Allocation...........................................................3-2
3.1.3 Occupied I/O Points for Each Unit ..........................................................3-3
3.2 Optional Allocation Using FPWIN GR7 ..................................................3-4
3.2.1 Registration of a Unit to be Used and the Initial Word Number ..............3-4
3.2.2 Optional Settings in the “Select Unit” Dialog Box....................................3-5
3.3 Mount Allocation Using FPWIN GR7 .....................................................3-6
3.3.1 Mount Registration of a Unit to be Used and the Initial Word Number ...3-6

iii
3.3.2 Changing the Initial Word Number ..........................................................3-6
3.4 Automatic Allocation.............................................................................. 3-8
3.4.1 Allocation without Using FPWIN GR7 .....................................................3-8
3.5 I/O Map Registration ............................................................................. 3-9
3.5.1 I/O Map Registration ...............................................................................3-9
3.5.2 I/O Map Clearance ..................................................................................3-9
4. Installation and Wiring....................................................... 4-1
4.1 Installation............................................................................................. 4-2
4.1.1 Installation Environment and Space........................................................4-2
4.1.2 Attaching Units ........................................................................................4-4
4.1.3 DIN Rail Attachment................................................................................4-6
4.2 Wiring the Power Supply....................................................................... 4-8
4.2.1 Common Precautions..............................................................................4-8
4.2.2 Wiring for Power Supply Units ................................................................4-9
4.2.3 Wiring for the Power Supply Part of the CPU Unit................................4-10
4.2.4 Grounding..............................................................................................4-11
4.3 Safety Measures ................................................................................. 4-12
4.3.1 Safety Circuit .........................................................................................4-12
4.3.2 Momentary Power Drop ........................................................................4-12
4.3.3 Alarm Output .........................................................................................4-13
5. Operation ............................................................................ 5-1
5.1 Before Powering On.............................................................................. 5-2
5.1.1 Check Points ...........................................................................................5-2
5.1.2 Procedures before Starting Operation ....................................................5-3
5.2 RAM/ROM Operation............................................................................ 5-4
5.2.1 Transmission of the Project.....................................................................5-4
5.2.2 Operations following Powering On..........................................................5-5
5.2.3 Data Hold During Power Failure .............................................................5-6

iv
5.2.4 Online Editing ..........................................................................................5-6
5.3 Backing Up the Project ..........................................................................5-7
5.3.1 Transmission from the Execution Memory RAM to the Backup Memory
ROM2 ......................................................................................................5-7
5.3.2 Transmission from the Backup Memory ROM2 to the Execution Memory
RAM/ROM1 .............................................................................................5-8
5.3.3 Operations following Powering On/Off ....................................................5-8
5.4 SD Memory Card Operation ..................................................................5-9
5.4.1 Preparing SD Memory Cards ..................................................................5-9
5.4.2 How to Insert an SD Memory Card .......................................................5-10
5.4.3 Saving an Execution File for SD Memory Card Operation....................5-11
5.4.4 Provisional Operation by an SD Memory Card .....................................5-12
5.4.5 Transmission from an SD Memory Card to the Execution Memory......5-14
5.4.6 Precautions Concerning SD Memory Card Operation ..........................5-15
6. Troubleshooting ................................................................ 6-1
6.1 Self-Diagnosis Function.........................................................................6-2
6.1.1 CPU Unit's Operation Monitor LED .........................................................6-2
6.1.2 Operation at the Time of Error ................................................................6-2
6.2 What to Do If an Error Occurs................................................................6-3
6.2.1 ERROR LED Turns ON on the CPU Unit................................................6-3
6.2.2 PROG Mode Does Not Change to RUN .................................................6-4
6.2.3 ALARM LED Turns ON on the CPU Unit ................................................6-4
6.2.4 POWER LED Does Not Turn ON on the Power Supply Unit ..................6-5
6.2.5 A Protect Error Message Appears ..........................................................6-5
6.2.6 If Expected Output Is Not Available ........................................................6-6
7. Maintenance and Inspection ............................................. 7-1
7.1 Handling of Backup Battery ...................................................................7-2
7.1.1 Functions of Backup Battery ...................................................................7-2
7.1.2 Replacement of Backup Battery..............................................................7-3

v
7.1.3 Lifetime and Replacement Interval of Backup Battery ............................7-4
7.2 Inspection ............................................................................................. 7-5
8. Specifications..................................................................... 8-1
8.1 CPU Unit Specifications ........................................................................ 8-3
8.1.1 General Specifications ............................................................................8-3
8.1.2 Performance Specifications ....................................................................8-4
8.1.3 CPU Unit Communication Specifications ................................................8-6
8.1.4 Operation Memory Area ..........................................................................8-8
8.1.5 List of System Relays............................................................................8-10
8.1.6 List of System Data Registers...............................................................8-17
8.1.7 Error Codes Table .................................................................................8-20
8.2 Power Supply Unit Specifications........................................................ 8-24
8.2.1 General Specifications ..........................................................................8-24
8.2.2 Performance Specifications ..................................................................8-25
8.2.3 Alarm Output Specifications..................................................................8-25
8.3 Dimensions ......................................................................................... 8-26
8.3.1 Power Supply Unit.................................................................................8-26
8.3.2 CPU Unit ...............................................................................................8-27
8.3.3 Terminal Block Type Unit ......................................................................8-27
8.3.4 Connector Type Unit .............................................................................8-28
8.3.5 PHLS Master Unit..................................................................................8-29
8.3.6 End Unit.................................................................................................8-29
8.3.7 Figures of Unit Combination..................................................................8-30

vi

1
Overview

1-2
Overview
1.1 System Configuration
1.1.1 Units
(1) Power Supply Unit
(2) CPU Unit
(3) Input/Output Units
●Digital I/O Unit

1.1 System Configuration
1-3
●Analog I/O unit
●High-speed Counter Unit
●Positioning Unit
(4) End Unit
(5) Add-on Cassette (Optional)
(6) CPU Unit Attachment Options
●Backup battery

1-4
Overview
●SD memory card
1.1.2 Combination of Units
•You can use FP7 series combining the CPU unit with optional input/output units and
intelligent units.
•Up to 16 input/output units and intelligent units can be connected.
•Make sure to connect an end unit to the end of the system.
•You can either connect a power supply unit for system driving power, or directly supply
power from an external 24 V DC power supply to the CPU unit. See Section 1.2 for
restrictions on combination.

1.2 Selection of Power Supply and Restrictions on Combination
1-5
1.2 Selection of Power Supply and Restrictions on
Combination
1.2.1 Power Supply for Internal Circuit
Restrictions on combination of power supply for internal circuit and units
•Power for internal circuit is supplied from a power supply terminal of the power supply unit or
the CPU unit.
•Select units within the respective restrictions indicated below.
When a power supply unit is used When no power supply unit is used
Select units so that the sum of internal current
consumptions of connected input/output units and
intelligent units does not exceed the capacity of the
power supply unit.
Select units so that the sum of internal current
consumptions of connected input/output units and
intelligent units does not exceed Max. 2 A.
Selection of a 24V DC power supply
•Select a power supply larger than the capacity of the units. In the minimum configuration,
select a power supply of 24 W or larger.
•In order to protect the unit against abnormal voltage from the power supply line, the power
supply should be an insulated type, and should be enclosed within a protective circuit.
•If using a power supply device without an internal protective circuit, always make sure power
is supplied to the unit through a protective element such as a fuse.
When a power supply unit is used, do not connect a DC power supply to the CPU unit.

1-6
Overview
Output current of power supply units (24V)
Product name Model number Rated output
current (mA)
Power Supply Unit 100 to 240V AC, 24W AFP7PSA1 1,000
100 to 240V AC, 43W AFP7PSA2 1,800
Unit’s current consumption table (24V)
Product name Model number Current
consumption (mA)
CPU Unit
196k steps, Built-in Ethernet function AFP7CPS4E 200 mA or less
120k steps, Built-in Ethernet function AFP7CPS3E 200 mA or less
120k steps, No Ethernet function AFP7CPS3 200 mA or less
Add-on Cassette
(Communication
Cassette)
(Note 1)
RS-232C x 1ch AFP7CCS1 35 mA or less
RS-232C x 2ch AFP7CCS2 60 mA or less
RS-422 / 485 x 1ch AFP7CCM1 60 mA or less
RS-422 / 485 x 2h AFP7CCM2 90 mA or less
RS-232C x 1ch
RS-422 / 485 x 1ch AFP7CCS1M1 35 mA or less
Input
Unit DC Input
16-point terminal block, 5 to 24 V DC AFP7X16DW 25 mA or less
32-point MIL connector, 24V DC AFP7X32D2 30 mA or less
64-point MIL connector, 24V DC AFP7X64D2 35 mA or less
Output
Unit
Relay
output 16-point terminal block AFP7Y16R 180 mA or less
Transistor
output
16-point terminal block, sink type AFP7Y16T 35 mA or less
32-point MIL connector, sink type AFP7Y32T 50 mA or less
64-point MIL connector, sink type AFP7Y64T 75 mA or less
16-point terminal block, source type AFP7Y16P 35 mA or less
32-point MIL connector, source type AFP7Y32P 50 mA or less
64-point MIL connector, source type AFP7Y64P 75 mA or less
I/O mixed unit
Input 32-point / output 32-point MIL
connector, sink type AFP7XY64D2T 55 mA or less
Input 32-point / output 32-point MIL
connector, source type AFP7XY64D2P 55 mA or less
Analog Input Unit 4ch AFP7AD4H 100 mA or less
Analog Output Unit 4ch AFP7DA4H 250 mA or less
High-speed Counter
Unit
2-ch type AFP7HSC2T 65 mA or less
4-ch type AFP7HSC4T 65 mA or less
Positioning Unit
2-axis, open collector output AFP7PP02T 120 mA or less
4-axis, open collector output AFP7PP04T 120 mA or less
2-axis, line driver output AFP7PP02L 120 mA or less
4-axis, line driver output AFP7PP04L 120 mA or less
PHLS master unit AFP7RMTM 85 mA or less
Programmable display GT series (5V DC type) (Note 2) - 100 mA or less
(Note 1) Power consumption indicated under "Add-on Cassette" refers to the current consumption increment of the
CPU unit following addition of the relevant cassette.
(Note 2) Power consumption indicated under "Display" refers to the current consumption increment of the CPU unit
following connection of a GT series display (5V power supply type) to the GT power supply terminal of the CPU
unit. For GT series displays (24V power supply type), please see their respective hardware specifications.

1.2 Selection of Power Supply and Restrictions on Combination
1-7
1.2.2 Power Supply for External Circuit
The 24 VDC power supply used as the input power supply of the input units and the output
circuit driving power of the output units are supplied from the external terminal of each unit.
Unit’s current consumption table (24V)
Product name Model name Current
consumption (mA)
Input
Unit
(Note 1)
DC Input
16-point terminal block, 5 to 24 V DC AFP7X16DW 6 mA per point
32-point MIL connector, 24V DC AFP7X32D2 2.7 mA per point
64-point MIL connector, 24V DC AFP7X64D2 2.7 mA per point
Output
Unit
Relay output 16-point terminal block AFP7Y16R -
Transistor
output
16-point terminal block, sink type AFP7Y16T 70 mA or less
32-point MIL connector, sink type AFP7Y32T 110 mA or less
64-point MIL connector, sink type AFP7Y64T 140 mA or less
16-point terminal block, source type AFP7Y16P 70 mA or less
32-point MIL connector, source type AFP7Y32P 130 mA or less
64-point MIL connector, source type AFP7Y64P 180 mA or less
I/O mixed
unit
Input 32-point / output 32-point MIL connector, sink
type AFP7XY64D2T Input 2.7 mA per point Output 70 mA
Inupt 32-point / output 32-point MIL connector, source
type AFP7XY64D2P Input 3.4 mA per point Output 90 mA
(Note 1) Figures for input unit indicate current that flows into the internal circuit. Figures for other units indicate current
values required for driving the internal circuit. This value does not include the load current of the output unit.
(Note 2) For current consumption of a 24 V power supply used for the high-speed counter unit and positioning unit,
please see the Users Manual of each unit.

1-8
Overview
1.3 Programming Tools
Required tools
1. Tool software FPWIN GR7 Japanese Menu
•Dedicated to the FP7 series
•Used for program editing, debugging and documentation.
2. PC connection cable
•Use a commercial cable.
Cable type Length
USB 2.0 cable (A:miniB) Max. 5m

2
Names and Functions of
Parts

2-2
Names and Functions of Parts
2.1 CPU Unit
Names and functions of parts
(1) Operation monitor LEDs
Body display LED
color
Contents
- Blue Turns on when the CPU unit power is ON.
RUN Green Turns on in the RUN mode. Blinks during forced input/output.
PROG. Green Turns on in the PROG. mode.
COM.0 SD Green Turns on while sending data from the COM.0 port.
RD Green Turns on while receiving data from the COM.0 port.
SD Green Turns on while accessing the SD memory card.
CARD Green Turns on while operation by the SD memory card is selected.
COPY Green Turns on during the COPY operation.
ERROR Red Turns on when an error has been detected through self-diagnosis.
ALARM Red Turns on if a hardware error occurs, or operation slows because of the program,
and the watchdog timer is activated.
(2) Add-on cassette (Optional)
Attach an optional Add-on Cassette (Communication Cassette).
(3) COM0 port terminal
3-wire RS-232C port
(4) GT power supply terminal
For our programmable display "GT series", either 5V DC or 24V DC can be used.

2.1 CPU Unit
2-3
(5) Power supply connector
Connected with an external power supply (24V DC); When a power supply unit is used, do not
connect this.
(6) DIN hook
Used for fixation on the DIN rail.
(7) LAN port (CPS4E, CPS3E)
Port for connection to Ethernet LAN
(8) USB port
Connected to a PC using the tool software
(9) Unit connectors
Connected to the internal circuit of I/O units and intelligent units
(10) CF card cover
Number Name Functions
10-1 Battery holder Attach a battery.
10-2 SD memory card slot Insert an SD memory card.
10-3 Card operation switch
Select between ROM operation or SD operation. By selecting SD
operation, provisional operation from the SD memory card
becomes possible.
10-4 Power supply connector Connected to a power supply connector
(11) Mode switch
Switch position Operation Mode
RUN (left) Set to the RUN mode. The program is executed and operation begins.
PROG. (middle) Set to the PROGRAM mode.
COPY (right, momentary) When the switch is set to COPY, a project stored in the internal RAM /
ROM1 is transmitted to ROM2 as a backup project.
(Note) Whether the switch is set to RUN or PROG., the mode can be switched through remote operation from the
programming tool. When power is turned on again, it operates in the mode set on the switch.
(12) Fixing hook
Used for fixing a power supply unit to the CPU unit.

2-4
Names and Functions of Parts
2.2 Power Supply Unit
Names and functions of parts
(1) POWER LED (blue)
Turns on when power supply is turned on.
(2) Power supply terminals
Terminal block for power supply wiring. A solderless terminal for M3 can be used.
(3) Earth terminals
The unit should be grounded at a grounding resistance of 100 Ω or less to prevent noise and
electric shock.
(4) Alarm contact output terminal
Closed when power supply is ON. If the watchdog timer is operated due to a hardware error
or a program error, turning the relay contact into an open status.
(5) DIN rail attachment lever
Used for fixation on the DIN rail.