W51 Series Installation Manual
Contents
1. y J x FAILURE lamp red Lights up when an error is established by the selfcheck and the programmable controller stops its operation But in the cause of a battery failure the programmable controller continues to operate Support tool interfacing connector Support tool like the programmer is connected through this connector Terminal board 12 terminals Power and halt output cables and communication wires are connected on this terminal board Halt output fuse 1A A 250V 1A glass tube mini fuse is used for the halt output circuit Power fuse 2A A 250V 2A glass tube mini fuse is used on the primary side of power supply Source voltage select switch Power source of either ACLOOV or AC200V can be chosen by means of this switch Before it left the factory it has been set to the ACLOOV side Lock plate securing screw and 44 switch locking plate Holds secure the source voltage select switch knob to prevent incidental changing of the switch CPU rack holding screw This screw secures the control module on the CPU rack CPU card By this card is carried out the operation in accordance with the programmed sequence Battery connector The Lithium battery is connected through this connector to supply power for retaining memory contents during AC power shutdown Lithium battery parts code DUNT 5211NCZZ The memory backup battery that required to retain the data memory contents even with2. Maximum rated output current Qutput element perform ance 8A 10ms max 125VAC 5A normal class Output element perform ance 8A 10ms max 125VAC 5A normal class mini fuse one fuse per mini fuse one fuse per 8 points 16 points On voltage 2V max 2A 0 3V max 0 1A 1 0V max 0 54 OFF gt ON ba ponse time ON gt OFF NOTE A delay of more than one second may encountered in the ON to OFF response time when an inductive load is used depending on the value of the load sd G Surge on current Fuse E y Ga ZW 1652 12 24VDC _ output module output module Internal power sonsunprion DUDO 200mA max 320mA max External power 12 24VDC 12 24VDC supply capacity 5mA point maximum 5mA point maximum Operational status LED active when ON LED active when ON Terminal board resin in Connections red color Operating temperature O v 55 C Operating humidity 35 90 RH Insulation resistance 500VDC more than 10Mohms across output terminal and secondary circuit Dielectric strength 1500VAC one minute across output terminal and secondary circuit ZW 32S data 40 pin connector Common 32 points common 18 jack terminal board 16 output and 2 commons Common one common per 8 points P 9 M3 5x Self locking screw in use A Circuit configuration ZW 1653 200VAC output module
3. Stop output fuse 1A The 250V 1A glass tube mini fuse for the stop output circuit Supply voltage select switch There is a choice of l100VAC and 200VAC for the supply voltage input The switch has been factory set to the LOOVAC side 64 Lock plate securing screw 68 switch lock plate Used to secure the supply voltage select switch knob to avoid inci dental switch relocation 69 Rack securing screw f Used to secure the expansion power supply module to the ZW 108ZB I O rack 21 Dimensional view I 1 l t t t I I I I l t l I Includes the I O rack ee oe 3 Specification 10 10 Supply voltage 100VAC_152 or 200VAC 5 Output voltage 5 1V10 05V 7A 5OW max at the largest configuration Class 3 ground L 5kg Power consumption 4 Supply voltage selection It is possible to make choice of LOOVAC and 200VAC power supply from the expansion power supply module The select switch has been set to the 100VAC when the machine left the factory Refer to 3 1 4 Source power setup AE Sy 4 1 Installations Installation cautions The following conditions must be taken into consideration during instal lation in order to enhance system reliability as weil as attaining full performance of all functions even though it has been built with high degree of performance reliability as a programmable controller stout against enviro
4. 5 6 7 8 9 10 11 Prepare an independent ground line of Class 3 or above and do not try to share ground with a high tension ground line Be sure to provide the emergency circuit in an external relay circuitry and connect it with the halt line from the W 51 Do not install the W 51 under environments described next Where exposed to a direct sunlight or where ambient temperature exceeds limits of O to 55 C Where relative humidity exceeds limits of 35 to 90ZRH and where moisture condensation is met by an abrupt temperature change Where corrosive or flammable gas is prevaling e Where direct vibration or impact is encountered Avoid to store the PC under a hot and damp place as the PC has a battery in it Because static electricity is likely to arise under a dry weather be sure to touch your hand with the grounded metallic part to release static before touching the W 51 directly Every locking screws of all modules must be fastened securely Firmly engage connectors that interface the standard base unit with I O rack Never use cleaning solution like thinner to clean the modules as it is likely to melt and discolor surface Do not handle switches and connector fastening metals with too much force Ensure polarity of DC 5V line between the CPU rack and the I O rack Wrong connection may destroy input output modules concerned Battery is mandatory to retain data memory conten
5. Load OS Output lam NO E Loa ommon SUN Output lamp WY AY 1 Ze a wr acaov Common SS Number of ocutput Rated output voltage Output voltage range Maximum rated output current 200VAC 50 60Hz with less than 5 of waveform distortion 15VAC x 242V AC 2A 5A maximum per 8 points of 1 group Output element performance 804 single cycle Leak current 250VAC 5A normal class mini fuse one fuse per 8 points 3mA max sine wave NOTE When such as the neon lamp or light load relay is used it may not turn off because of the leak current 2V max 2A Res OFF gt ON lms max ponse time ON gt OFF LOms max Internal power consumption 5VDC External power supply capacity 12 24VDC 400mA max lt m s lt s 8 h LED active when ON Connections Operating temperature Operating humidity Insulation resistance Dielectric strength 18 jack terminal board 16 outputs and 2 commons Common one common per 8 points P 9 M3 5x8 Self locking screw in use Terminal board resin in red color 35 90 RH 500VDC more than 10Mohms across output terminal and secondary circuit 1500VAC one minute across output terminal and secondary circuit T foe Circuit configuration Number of output points Maximum make break voltage current Minimum load Operational life Res OFF gt ON ponse time ON gt OFF Internal p
6. Noise immunity LOOOVp p lus as measured between power line and chassis on the noise simulator Ambient humidity 35 90 RH mon condensed Anti vibration Conforms to JISC O911II B Class 3 two hours each on X Y and Z 50W max at the largest configuration Weight Approx 7Kg CPU rack control module and 128 points I 0 Environmental air Free of corrosive gas and flammable gas Ground Class 3 under 1002 NOTE As concerns the support tool refer to the respective specification for allowable ambient temperature and storage temperature 5 Configuration of each module and functions 5 1 ZW 501CU control module l Parts identification and functions 5 RUN lamp green 4 POWER lamp green a 6 Support tool IN lt USE IDEL switch 7 FAILURE lamp red Battery expiration label noi Gs gt rg pu D a O E af 00 tn O H M z Oc tool interfacing connector 1 Control unit panel CPU rack securing screws 4 pcs Switch locking plate Lock plate securing Screw Power source select switch Power fuse 2A 16 CPU card E Py m ETSE a 17 Battery connector Hait output fuse 1A ao Terminal board RON o 18 Lithium battery 19 Battery holder View without control module panel 2 yy e Control module panel The panel has to be removed in one of the following conditions The
7. 2A 3 5KW program memory 16 input points 115VAC 16 input points 12 24VDC 16 input points 200VAC No F Fe Accessory Module name Model name Description Model mame Description Item DRA Output ZW 3282 Glass tube 125VAC 5A module mini fuse Interfacing connector 32 transistor output points 5 12 24VDC 0 5A I O module ZW 31102 16 input points Glass tube 125VAC 2A 16 transistor mini fuse output points Glass tube 125VAC 5 12 24VDC 300mA mini fuse Interfacing connector Installation Manual Special ZW 1HC5 50K PPS 90 phase Glass tube 125VAC modules differential 0 54 mini fuse signal BCD Glass tube 125VAC 2A 6 digit up down mini fuse compare functions Installation Manual ZW 4AD2 Input 0 to 20mADC or DC O to 10VDC i Installation Manual Output BCD 3 digit 4 channels module Input BCD 3 Installation Manual digit Output O to 10VDC or O to 20mADC 2 channels module Programmer ZW 101PG1 LCD dot matrix Control module display programmer interfacing cable 3m I Cassette tape recorder interfacing cable 1 5m I Connector lock spring 2 Instllation manual 1 Liquid ZW 100PG2 Message section Control module crystal 20 colums interfacing cable 3m display 2 rows Case programmer LCD dot matrix Shoulder strap Display section Installation Ma
8. 8 9 10 li Wiring cautions Keep away the power supply and signal cables from a high tension line and power supply line and do not install cables parallel to such a line Use the I O signal expansion and DC5V supply cables that contained among accessories Avoid to install the I O expansion cable and DC5V supply cables inside a conduit Choose such a wiring layout that may facilitate easier installation and removal of I O module Install wirings to 1 0 module in such a manner that the operating status of 1 0 module may be easily recognized Use more than KIV1 25 square twisted wire for CAER of the control module to the AC source input terminal Use more than KIVO 5 square wire for connection of the input module from the junction terminal board For wiring from the junction terminal board to the output module use more than KIVO 75 square wire for connection of a relatively large capacity item like a solenoid valve and KIVO 5 square wire for others For wiring from the junction terminal board to I O device use the wire of more than KIV1 25 square In case an entire factory is high tension grounded and not suitable for grounding of the module simply connect the ground terminal to the metallic enclosure cabinet Be sure to use the crimped terminal lug for the wire connected to the terminal board of the module Choose the crimp terminal lug according to the size of the 1 0 module terminal board control module termina
9. End Check if the fuse is Yes Replace the fuse with SSE Goen the new one 250VAC pees 2A mini fuse No a Recovered Yes End Replace the power supply module of the control module with the new one Recovered To the main check procedure Shut power off prior to changing of the source power select Power source select switch switch Power fuse 2A CPU board Halt output fuse LA E u DD T u u u 11 Halt output check procedure Check if the RUN lamp No of the CPU board is ON Yes To the main check procedure Short the halt output terminal of the control module No a Yes Check the external wiring of the control module Check if the 250VAC Yas 1A fuse of the control module is not open N Replace the fuse with the new one 250VAC LA No Recovered Yes End To the CPU error check procedure 78 Input module Output module PB FL I O check procedure L 0020 0000 Procedure is shown in reference to an example in the Commo Common right s To next page Push the PB to check if the PL lights up Check if the LED 0020 is ON on the output module Ladder chart 0000 0020 Yes Check if the fuse of the output module is not open No Open Replace the fuse with the new one equivalent to the spare fuse Monitor OUTOO20 by the programmer to check if the ON lamp com
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11. 0 module and expansion power supply module to the rack 24V terminal board External 24VDC or 12VDC is supplied when the ZW 1652 DC output module is used for the I O module 5V terminal board 1 0 rack only 5VDC is supplied from the control module Use the 1 0 rack or the 5VDC cable that comes with the control module for the inter facing cable DA te 63 Expansion power supply module installation guide hole Used to hold the expansion power supply module on its position 62 Power indicator Used to indicate supply of 5VDC to the ZW 108ZB I O rack 69 1 0 expansion connector IN Signals are connected from the ZW 108ZB I O rack or CPU rack from the preceding stage 69 I O expansion connector OUT Signals are connected to the I O rack in succeeding stage NOTE 1 In addition to the above four kinds of racks there are two kinds of racks available the ZW 104ZB which can contain an expansion power supply module and a maximum of four 1 0 modules and the ZW 102ZB which can contain an expansion power supply module and a maximum of two I O modules Sa 2 Detailed view Dimensional view of the support hole ol o O Oas GO ZW 108ZB 1 0 rack ela p ZW 508ZB I O rack 2 33 Precautions about the CPU and I 0 racks 1 In case the I O module installation space 8 modules of the ZW 508KB CPU rack is not sufficient it is possible to expand with 16 I O modules with the ZW
12. 120mA max 120mA max LED active when ON LED active when ON 18 jack terminal board 16 inputs and 2 commons Common one common per 8 points P 9 M3 5x8 Self locking screw in use Terminal board resin in blue color 0 586 35 Y 90 RH 500VDC more than 10Mohms across input terminal and secondary circuit 1500VAC one minute across input terminal and secondary circuit e Ye ZW 16N2 12 24VDC ZW 32N2 data input module input module Terminal number sS SSS DSS A SS input lamp Es SIN 12 26 PAZ Input 82 lamp P Circuit configuration s Pa Q 2 F av NG N Within module Nunber On Topic 16 points 32 points DOANES 12 24VDC 12 24VDC NOTE 1 NOTE 1 Power supply of less Ripple must be less than than 10 ripple must be 5 in the case of 12VDC R a used when used under and 15 in the case of 12VDC 24VDC NOTE 2 Pay attention for the OFF level when such as the proximity switch and photoelectric switch is used as it may not turn OFF properl sometimes Input voltage range OVDC uv 30V OVDC v 26 4V Input ON level 10V max voltage level OFF level 6V min ON level mA max 1 5m4 min f OEE EENES full wave pulse 1 0mA eo ins Abt 2Kohms _ Abt 2 5Kohms OFF gt ON I5ms max 12 24VDC 15ms max 12 24VDC ON gt OFF 20ms min 12 24VDC 20ms min 12 24VDC Internal power 85mA 2 consumption 5VDC 120mA max max Operational status LED active when ON
13. Check the voltage between 0000 terminal Yes of the input module and the common terminal T it s 0V No Check the external wiring of the input module short defective PB Replace the input module with the new one 80 Battery failure check procedure Replace the battery with Refer to Section 6 2 the fresh one Battery replacement procedure Yes Recovered y No End Replace the CPU board with the new one I O failure check procedure Take out the I O module Be sure to turn power off before mounted on the rack by one dismounting and mounting the module by from the module closely located to the control module and turn on power after removal of each module Check if the FAILURE lamp Yes off Replace the respective module with the new one No To the CPU error check procedure CPU error check procedure Replace the CPU board with the new one Recovered Yes No End Replace the standard rack with the new one 81 Parity error check procedure Check if the ROM module is in use Yes Correct the parity error using the programmer Recovered No Replace the CPU board with the new one Replace the ROM module with the new one 1 Refer to Section 3 1 5 Programmer failure check procedure Check if the programmer IN USE IDLE switch is correctly positioned Yes N Yes O lt _Recovered
14. LED active when ON 18 jack terminal board 40 pin connector 16 inpus and 2 commons Common 32 points w Common one common per one common Connections i 8 points common P 9 M3 5x8 3 Self locking screw in use Terminal board resin in blue color A BS s ZW 16N2 12 24VDC input module ZW 32N2 data input module Operating temperature 0 55 35 w 90 RE Insulation resistance 500VDC more than 10Mohms across input terminal and secondary circuit Dielectric strength J1500VAC one minute across input terminal and secondary circuit zt T A a 4 Output module specification ZW 851 100VAC ZW 16S1 100VAC output module output module Circuit configuration Output lamp E te N f tput i points LOOVAC 50 60Hz less 100VAC 50 60Hz less Rated output voltage than 5 of waveform than 5 of waveform distortion distortion Output voltage range 15VAC x 121V 15VAC x 121V Maximum rated AC 2A 5A maximum per 4 AC 2A 5A maximum per 8 output current points of 1 group points of 1 group Surge on current Output element perform Output element perform ance 80A single cycle ance 80A single cycle Pu 125VAC 5A normal class 125VAC 5A normal class N mini fuse one fuse per mini fuse one fuse per four points eight points 2mA max sine wave 2mA max sine wave L s NOTE When such as the neon lamp or light load relay is used it may not be controlled OF
15. RUN lamp is out and the FAILURE lamp is on instead The facility does not start Input output function is not normal sequence operation is not normal The RUN lamp is on with the FAILURE lamp in activation The control unit can not be controlled from a peripheral such as the programmer procedure Module check Check if the special relay 7370 is ON No Check if the special relay 7371 is ON No Check if the special relay 73 2 is ON No Check if the special relay 73 3 is ON No Check if the special relay 7374 is ON TG amp Yes poi A Yes Yes Yes Proceed to the power supply check procedure Proceed to the module check procedure Proceed to the halt output check procedure Proceed to 1 0 check procedure Proceed to the battery failure check procedure Proceed to the programmer failure check procedure Proceed to the parity error check procedure Proceed to the CPU error check procedure Proceed to the battery failure check procedure Proceed to the I O error check procedure Proceed to the link error check procedure Power supply check procedure Check if the power source select switch is at the correct position No Set it to the correct side No Yes Yes Check the voltage at End the power input A N terminal if it is e R be within 15 to 10 zs piven rating of the rated power Recovered tes
16. ZW 3252 Load O ES Load O Common Load ol J Load ES b a Na FA o kna ENE i DC output module 4 24V terminal O board of the 0 rack gt NOTE The negative w side may not be ZW 16S2 connected necessarily ZW 3252 DCSVA2V 24V Load O b Relay drive circuit a Om Commo AC or DC load Relay contact power supply output module DO24VY 24V terminal A board of the ZW 16S4 3 4 1 62 Lock plate securing screw 4 Expansion power supply module ZW 100PUl Parts identification and functions Cover securing screw hole 69 Rack securing screws 4 pieces 63 Switch lock plate 63 Supply voltage select switch Cover securing screw fuse 1A 6 Power fuse 2A 62 Stop output 69 Terminal board Power supply module cover Power supply module cover The cover needs to be removed in one of the following conditions It has to be installed during the operation When the power supply and stop output cable is connected to the terminal board When the fuse is replaced When the supply voltage is changed Cover securing screw 63 cover securing screw hole hinge They are used to secure the power supply module cover on its place Terminal board 12 jacks The power supply and stop output cable is connected on this terminal board Power fuse 2A The 250V 2A glass tube mini fuse for the primary side BY
17. the ROM module in use It has to be replaced with Z AD ri the fresh one before the battery expiration date mentioned in Item 3 above 19 Battery holder Used to secure the lithium battery on the CPU card 2 Dimensional view 100 Includes the standard rack 3 Performance specification Programming method Stored program Cyclic operation About 1 63us word for basic instruction excluding timer counter MD and application instructions Control method Processing speed Reference Processing speed for basic instruction only 2 5KW abt 5ms 3 5KW abt 6 7ms 5 5KW abt 10ms Note For details of instruction processing speeds refer to Programming Manual Section 3 6 a ee Item Specification Instruction set Basic instructions 12 Application instructions instruction used in conjunction with the key 42 Program RAM 3 5KW basic capacity Up to a maximum of 5KW by the use of optional RAM module ROM 3 5KW by the use of optional ROM module User program CMOS RAM with battery backup or PROM option memory element Battery Lithium battery parts code DUNT 5211NCZZ Control 1 0 points 512 points max 1 0 relays 512 points 000010777 relays relays Special Non carry flag 7354 relays Error flag 7355 Carry flag 7356 Zero flag 7357 0 1 second clock 7360 E 1 0 second clock 7364 E Preset value change switch 7365 B Zero cross switch
18. the memory module securing metal of the CPU board 7 Replace the CPU board back into its place ze E 8 Replace the control module panel back into its place 9 Turn on AC power to the control module 10 Clear the memory area by means of such as the programmer However it does not need to apply for the ROM module DG 3 2 CPU rack and 1 0 rack i Parts identification and functions 28 Control module installation guide hole Card edge connector I O module installation guide hole Module holding screw hole I O expansion connect onnector 81 24V terminal board 25 Support hole nea Control I O module module 8 modules CPU rack ZW 508KB Control module installation guide hole 9 I O module installation guide hole 2 Card edge connector 6 Module holding screw hole 69 1 0 expansion connector 6 24V terminal board E Support hole Control I O module module 4 modules CPU rack ZW 504KB ls 63 Expansion power supply module installation guide hole T O module installation guide hole 2 Card edge connector Module holding screw hole G4 Power indicator r Tatan 8 a of oF ot m 63 I O expansion tae Ns mo om a Q m n E alo i n connector IN EI x x I O expansion M YU connector OUT 6D 24V terminal board a 1 14 iu u 62 5V terminal board o Ip 9p 9o Vo Da Cy Oa Do De A _ OES JUPON lo Expansion I O module o power 8 modules supply mo
19. the panel never try to remove it from the panel Lift the peripheral interfacing connector locking spring upright to remove it from the panel O Insert four guide studs of the control module into guide holes of the CPU rack then push in the control module to the CPU rack install Tighten four CPU rack securing screws E of the control module to the module securing screw holes 69 of the CPU rack 58 83 securin I O 9 G3 65 Securing module 170 screw A L cover I module 4 4 Installation of input modules and output modules Guide hole BA Guide stud Guide hole i 8 N 9 Guide hole 62 Guide stud 69 I O terminal board 65 Securing screw 62 Secur 4 29 Guide hole G Guide stud I O connector ing screw 1 Remove the 1 0 module cover 63 Hold the opening on top part of the cover by finger tip then lift it to remove 2 Insert the guide studs 64 on the reverse side of the 1 0 module into the guide holes of the CPU rack or I O rack then put in the 1 0 module to install 3 Tighten two securing screws 6 to the CPU rack or I O rack 4 Fasten the cable from the E O device to the I O terminal board 69 5 House the cable from the I O device through the cable slit below the I O module cover then fit the cover on ao hd e AN ELADAN A ISS A AK SOS i She Push the ES arrow E n 4 indication x portio
20. within date is not expired the effective period Installed Check if the control Free of conditions module is firmly looseness secured Check for any loosened Free of screw looseness Check if connector The Locking locking metal of the screw must be I O signal expansion in firm cable is firmly engaged engagement 3 I O module 100VAC input module 85VAC to 11OVAC aa DC input module 10VDC to 30VDC eae Data input module 10VDC to 26 4VDC fice 200VAC input module 17OVAC to 220VAC a Input power source or Check if the supply voltage to every 1 0 output module is within the 100VAC output module ZW 8S1 power given voltage L5VAC to 121VAC ZW 16S1 source DC output module _ LOVDC to 30VDC cab Data output module 4 75VDC to 30YDC s 200VAC output module L5VAC to 242VAC ART a Relay contact output ZW 16S4 module AC 240VAC max DC 30VDC max Check if every module Free of looseness is firmly secured Check if the terminal board securing screw is fastened firmly Installed condition Free of looseness 4 Expansion power supply module Check if the input voltage measured on the Must be 15 to 10 terminal board is of the rating Input power within the given rating Installed is firmly secured condition Check if the terminal board securing screw Free of looseness is fastened fir
21. 0VAC while the select switch is at the 100V side will result in damage of the control module ae ae 5 3 I O rack wirings When the I O rack is used make the control module connected with the CPU rack or I O rack using the 1 0 expansion signal cable and the expansion 5V cable that come with the 1 0 rack See the figure below Pay attention for IN and OUT connections of the I O expansion connector Z W 508 Z B I O expansion signal cable 45cm a x niiill o i I ZW 108Z B al I O expansion 5V cable 60cm E ZW 508K B When the I O racks are to be installed side by side use the 1 0 expansion signal cable and the expansion 5V cable that come with the control module I O expansion signal cable 1m IIIII I III Ine a pL El Y I O expansion NZD i 5V cable Im a NOTE Tighten the terminal board screw with a torque of less than 12kg cm Guide Lock lever The I O expansion signal cable connector has the guide The connector must be fastened firmly by the lock lever after the py insertion 66 D 4 Input output module wiring 1 Terminal board type Use the crimped terminal lug to connect the 1 0 module with an external device such as limit switch and solenoid valve M3 5x 8 self locking fe ARA cans OE co 7 mm max Less than 12Kg cm tightening torque ae lt gt After fastening of the lug the cable has to be threaded b
22. 2 Installation 4 3 Installation 4 4 Installation 4 5 Installation 4 6 Installation ete Daan cautions 4 of the 1 0 rack on the panel d of control module of input modules and output modules of input output module side panel of expansion power supply module 85 Wirings 5 1 Wiring cautions sn 5 2 Control module wiring rr er mem mmm mme 5 3 I O rack wirings 5 4 Input output module wiring p Y 5 5 24VDC terminal board wiring a mm 5 6 Expansion power supply module wiring E n 5 7 Example of internal panel wiring 6 Maintenance and inspections PT 6 1 Routine maintenance A ee 6 2 Battery replacement procedure T 6 3 Error checks cn da dnd a ee le w El a i ie 62 62 63 65 67 69 Tal 72 73 13 75 76 What must be cared for Observe the following cautions before operation or storage of the W 51 1 2 3 4
23. 508ZB or ZW 108ZB I O racks in use 2 For a smaller system the ZW 504KB CPU rack is available that permits expansion for 4 I O modules with which permits expansion with 12 I O modules with the ZW 508ZB or ZW 108ZB 1 0 racks in use ZW 508KB ZW 504KB CPU rack CPU rack aah ZW 508ZB or pets ZW 508ZB or rac ZW 108ZB s ZW 108ZB I O rack 1 0 rack Maximum number of See a r Maximum number of 1 0 points when 16x8 128 16x16 256 16x4 64 16x12 192 l6 point module is used for all Maximum number of 32x8 256 32x16 512 32x4 128 32x12 384 I O points when 32 point module 16xn 32xm Ea is used for all When n number of 16 point modules are used in con junction with m number of 32 point modules O 3 To expanded to 512 points with 16 point modules use two or three units of the ZW 108ZB 1 0 racks ZW 504KB CPU rack ZW 508KB CPU rack ZW 508KB ZW 504KB CPU rack ZW 508ZB CPU rack ZW 108ZB CPU rack x2 1 0 rack x2 ZW 108ZB ZW 108ZB CPU rack x2 ZW 508ZW or 1 0 rack x2 ZW 508ZB or ZW 108ZB ZW 108ZB L O rack 1 0 rack Maximum number of Homme gt lt gt a e _ Maximum number of s ae 16x24 384 16x32 512 16x20 320 16x28 448 is used for all When n number of 16 point modules are used in con 16 xn 32xm lt 512 Junction with m number of 32 point modules 4 When two or three units of the I O rack
24. 5ms the following result is obtained Ton gt At ton 5 15 20 ms Torr gt At tog 5 20 25 m8 Bleeder resistor Only a certain amount of current which is dependent on the input impedance and input supply voltage can flow through the contact point of the input device About 3 5mA when 12VDC is added to the ZW 32N2 As this current value may evoke a contact failure depending on the type of the contact point an external bleeder resistor should be inserted in such event P Ot b 15 Wattage E shall be P gt R x 2 resistor DC input module power input polarity Since the bridge rectifier circuit is used in the ZW 16N2 either plus common or minus common may be used Plus common must be used for the ZW 32N2 E s 4 To connect a transistor output device to the DC input module Choose the open collector output type to use the input device such as contactless relay photoelectric switch proximity switch NPN transistor output example PNP transistor output example common common Input device or DC12V or DC12V ZW 46N2 ZW 16N2 7W 32N2 NOTE 1 Make sure that the rating of the transistor meets the given input supply voltage and input current 5 Pay attention for the OFF time current of the input device a Limit switch with LED The input module may not turn OFF because of the LED driving current even if the limit Input switch is OFF module b Proximity sw
25. 7367 a Parity error 7370 A CPU error 7371 Battery failure 7372 I O error 7373 Option error 7374 ROM error 7376 Power failure detect 7377 Total 128 points 000 177 Timer preset range 0 1 to 199 9 seconds Counter preset range 1 to 1999 MD preset range 0 to 999 Counter and MD current values are retained at a time of power failure Choice of reset or retention of the contents at time of power failure for the timer 14 specification 256 bytes 8 bit structure retained at a time of power failure Registers Special One byte 1 734 store of error code register File For register expansion of 4KB maximum 30000437777 register Program File register memory Basic configuration 3 5KW 30000 33777 Used in confunction with the optional RAM module 30000437777 30000437777 Used in conjunction with 3 5KW the ROM module ZKD 30000433777 Data memory System memory For specifying control module operation memory retention at power failure Address Function 200 Keep relay area designation 201 Reset retain choice of timer contents at a time of power failure 202 ON reset OFF reset choice for the counter instruction 203 Output hold address designation at a time of failure Program memory capacity designation 205 File register capacity designation 206 Station number registration during computer link 207 Station number registration during data l
26. B even if the program memory capacity is set to 4 5K 3 5K or 2 5K using the RAM module option NOTE 2 One of the following configurations can be established by the use of the ROM module 1 Program memory of 3 5KW without use of file register 2 Program memory of 2 5KW with 2KB of file register 3 Program memory of 2 5KW without use of file register The memory configuration established using the RAM module option ex program memory of 3 5KW with 4KB of file register is not applicable when the ROM module is used s Ps How to mount the memory module RAM module option can be mounted in the following manner CPU board 1 Shut off AC power to the control module 2 Remove two screws that secure the control module panel 2 and remove the control module panel 1 from the control module 3 Open the two board holding levers 20 in outward direction arrowhead and pull out the CPU board from the casing Push away two levers in the arrowhead direction using your middle fingers and hold the baord with your thumb and index finger a RAM module Q2Memory extension yf connector Memory board hs securing acre y ILR Y L A Sf C82 tenor module securing metal 4 Remove the memory board securing screw QD 5 Fasten the option RAM module 23 to the memory extension connector 2 of the CPU board 6 Put the memory board securing screw D through a cut in the RAM module option 3 and fasten it to
27. EB peoT 3IUBISTSII 94 JO ased 9479 UT se yonu se souewrogzed SIT sordup Aew 19TITA oxe aqeradoadde ue jo asn peo soueqstsaz uj3 upgu3a sjurod 7027000 2943 yeorq pue syeuw 03 3TnOTJIJTD 3104 oq 07 pouwnsse ATTewIOU ST peo SATIONPUT JUaeTAND JD91TP 383 Ysnouy UT pazojs 4319048 9q2 JO Junoooe uo peoT s squrod 2983002 2943 3UTyeu peoT qOB UCD 2q7 SUTABU UT SMOTI gt Tddns 19M04 4 JO QUE E Je O 07 SMOTI Ajddns 19mog se 38 3U9Iino 31045 e se 7Tou JuezTInND aSzeyo 2432 se 379u oa saurod 3o0e7u0 sy 3sneo 07 squrod 198qu09 y esneo o 09 TSATT ST AF mq Sur ezq 03 ATONTT ST IF Nq Suryeag _ SUTANP 23e TTY 07 DA4TID93J9 3UTINP IL TTT 02 3ATID9TJO E aiow St IENDATI STUL 3G SXOW ST ATMIATO STYL ABM BSUTMOTTOT 943 UL AST LY 918 991 FO ssn y proxy 50 7 External power supply Connection with the external power supply is required when the ZW 16S2 and ZW 32S2 DC output module and ZW 16S54 relay output module is used Base current is supplied for the DC output module and coil current is supplied for the relay output module If the DC output module is operated without external power supply it may result in unstable operation or the internal surge killer diode is invalidated which causes the output transistor to destruct The external power supply must be connected to the 24V terminal board of the rack when the ZW 16S2 or ZW 16S4 amp is connected It has to be connected through the connector for the
28. F due to a leak current On voltage 2V max 2A 2V max 2A OFF gt ON Ins max ON OFF Internal power OOmA max External power supply capacit Operational status LED active when ON LED active when ON aa ZW 8S1 100VAC ZW 16S1 LOOVAC output module output module l0 jack terminal board 18 jack terminal board Connections 8 outputs and 2 commons 16 outputs and 2 commons Common one common per Common one common per 4 points 8 points P 9 M3 5x8 Self locking screw in use Terminal board resin in red color 0 w 55 C Operating humidity 35 90 RH Insulation resistance 500VDC more than l0Mohms across output terminal and secondary circuit Dielectric strength L500VAC one minute across output terminal and secondary circuit Sane ee ZW 1682 12 24VDC ZW 3282 data output module output module Terminal SY Out put e lamp Circuit configuration 777777 lt Voltage regulator HETERO aa _ 12 24 NVo tage regulator N To 24VDC terminal board of the rack points Rated output voltage 12 24VDC 5 12 24VDC 1OWDC 30V 4 75VDC x 30V DC 2A 5A maximum per 8 points of 1 group gt zz Z e dul 20 DCS 112 24V External supply voltage 12 24VDC Simultaneous activation of one group consisting of 16 points Less than 8 points 0 5A point More than 9 points 0 3A point 5VDC external supply voltage 0 1A point
29. NSIA ZW 501CUD RAM Q eee CZW 501MO Pro CZWANPG1 Ladder grammer l Z 100LF2 o ZWA00CEDICE loader NOTE programmer Expansion power supply module ZW LOOPUL Ladder Len processor LCD pro grammer CZW 100P G2 IUOVAC input module Z2W 16N1 200VAC input module ZW 16N3 12 24VDC input module ZW 16N2 Data input module ZW 32N2 LOOVAC output module ZW 851 LOOVAC output module ZW 16S1 Z00VAC output module ZW 16S3 12 24VDC output module ZW 1652 Data output module ZW 32S2 Contact point output module ZW 16S4 12 24VDC 1 0 module gt ZW 32102 High speed counter module ZW 1HC5 Analog input module ZW 4AD2 Analog output module ZW 2DA2 LCD programmer data cassette a ZW 100PS3 ages Cassette loader O ee data cassette es ZW LOOMS3 CRT programmer data cassette ZW 100CS3 Contact your dealer for detail of the cassette loader and CRI 2 Total system by computer link data link and remote I 0 A Al RS Maximum 31 2370 e asp Computer link units of E 1 N 51 can be Converter sss interfaced Personal computer CRS422 Remote I O R5422 Data link H EU i Maximum 16 units of W 51 can be interfaced Maximum 7 units of remote terminals can be interfaced The following options are required to comprise the above system Computer RS232C RS422 Z 101HE To be installed near th
30. ON time Ton gt At ton OFF TOFF gt AEF toff At One scan time of PC Input device OFF time T ton Input module OFF to ON response time toff Input module ON to OFF response time Ton T OFF Input device contact point ton tort Input module logic lt 7 U U S i s al lt uses than At More than At In the 1 0 process at the beginning of each scan cycle the ON OFF state of the input logic side is stored in the data memory to be used for the input information required for the operation of the user program during that scan cycle Therefore if the ON OFF time of the input logic side should not continue for more than one scan time At the state of ON OFF may not be stored in the data memory NOTE 1 Response time of input module depends on the charge discharge characteristics of the integral circuit of the input module therefore it may vary according to the time that ON or OFF state continued PT s Charge discharge characteristics of integral circuit 2 3 Contact point of input device ho If the ON time of the input device were too long as shown with Threshold value at the logic side Logic side of input module a dotted line there is a difference in t ff than the case the ON time is shorter as shown with a solid line Worksheet example when the ZW 16N2 is used for the input module If one scan time is assumed to be
31. SH A EJ zje H TT BEY SHARP Programmable Controller Manual NEW SATELLITE W51 W51 Series Installation Manual SHARP CORPORATION Thank you very much for your purchase of Sharp Satellite W 51 Please be sure to read this manual thoroughly in order to attain correct operation of the W 51 This manual should be kept close at your hand for your quick reference Points of ZW 501CU2 operation 1 Please transfer the expression of ZW 501CU to ZW 501CU2 on every manuals 2 Available for 7 5KW ROM operation by using optional ROM module ZW 501M02 also 3 5KW ROM operation by using optional ROM module ZW 501M0 What must be cared for Table of contents a i i it ee 2 System configuration and general specification 2 E W351 series system Conti guration A 2 2 List of modules 2 3 General specification amam ic umama umaman r Qs m wa PU mm r m m u w s mm m ms A ee m uum umama amam mamn xm j mmm mm lt ass uma xm Qs um Cm ED mm mm a xm mm m mmm s sma G s 3 Configuration of each module and functions 3 ZW 50LCU control module 1 2 3 4 5 Parts identification and Dimensional view PP maman PP w ewe nr sr n eee Pune ELODS A a Tuz A m Performan
32. a ee 5 5 24VDC terminal board wiring When the DC output module ZW 16S82 or contact output module ZW 16S4 is used for the output module the external power supply source must be connected to the 24VDC terminal board of the CPU rack and I O rack 1 To drive a load of 12VDC or 24VDC using the DC output module L ETT A A IN FRA a BESO A C Output moguie 24V terminal board 1 Connect the positive side of the load driving power to the positive side of the 24V terminal board of the CPU rack 2 When the I O rack is used connect the positive side of the 24V terminal board of the CPU rack with the positive side of the 24V terminal board of I O rack RE Cnr Pp ee ETI De output modula 3 To drive a load of 12VDC by the DC output module the voltage of the external power supply source connected to the rack must be at least equal PEE GS bor or greater than the voltage of the E load driving power 12VDC 24VDC Ry NARS CPU rac Load driving power 12VDC or 24VYDC C 2 When the contact output module is used peat bee Pe SSR u 1 Provide 24VDC source separately as z a load driving source and connect it through the 24V terminal board of the CPU rack Load Eentact out puk Rea 24V terminal board E 2 When the I O rack is used connect the 24V terminal board of the CPU rack with the 24V terminal board of the I O rack 24VDC power a power CPU rack fate aTa a sp
33. and retention force If this delay time should be a problem after actual measurement the load should be driven via the magnet switch It makes the value relatively smaller than the use of the solenoid valve and Varister it improves the response time Protect fuse Fuse is used for protection of the printed circuit pattern and signal lines from burn out one each per 4 points with the ZW 8S1 8 points with the ZW 16S2 ZW 16S3 and ZW 1654 and 16 points with the ZW 32S2 But the fuse is not used for overcurrent protection of the output element or load 46 6 JA per 5A per 8 points 16 points 5A per 5A per 8 points 16 points power supply ZW 16S1 ZW 1682 ZW 1683 ZW 1684 Output module ZW 3252 Surge preventing means There is a possible generation of a several thousands volts surge in making and breaking the load L depending on the kind of the load Although output surge preventive means has been imple mented for the ZW 8S1 ZW 16S1 ZW 1682 ZW 1653 and ZW 3282 it requires a specific surge prevention for the ZW 1652 and ZW 32S2 when a long signal wire is used to the load Since the internal surge prevention has not been used for the relay output module ZW 1684 use of an external surge killer is required in order to extend the life of contact points to prevent noise to reduce generation of carbon by arc and raising of nitric acid However incorrect use of the arc killer may invite an adve
34. and fuse Printed circuit board 1 0 module cover card edge Address label I O terminal board 63 Guide pin 9 Rack securing screw Figure shows the ZW 1682 Rack securing screw 9 Fuse holder and fuse QD I O module cover 6 al Address label Le D Guide pin Printed circuit board card edge Rating plate I O connector Guide pin Rack securing screw Figure shows the ZW 3252 67 1 0 module cover Live portions of the fuse 40 and I O terminal board 62 are protected from casualty using the cover Guide pin two Used for easier mounting of I O module on the CPU and I O rack Rack securing screw two Used to secure the 1 0 module on the CPU and 1 0 rack Fuse holder and fuse not equipped on the input module Protect fuse is used for the I O module a O 2 ED 62 O Printed circuit board card edge For connection with the CPU or I O rack Rating plate I O terminal board For connection with I O device As it is removable it permits replacement of the I O module without removing the I O device cable from the terminal board I O connector For connection with the cable from 1 0 device Address label It comes with the control module as an accessory It has to be bonded on the location of the I O module installed The address label indicates the second and third digits of a relay number is used to represent 0230 0237 Installation and removal of the 1 0
35. applied during the output module OFF time b Insertion of current limit resistor Current must be limited with the current limit resistor Because it abates the voltage added to the lamp if the resistor is too large the resistor value should be determined on the basis of the brightness required for the lamp 5 3 Z2W 16S1 ZW 16S3 4 5 Output module ZW 1652 ZW 32S2 AC output module leak current During the OFF time of the AC output module a leakage current of less than 2mA flows through the ZW 8S51 ZW 16S1 and 3mA for the ZW 1683 In case the load that does not go OFF because of this leakage current a bleeder resistor should be inserted parallel to the load Bleeder resistor The value of resistor must be calculated on the basis of the load used it may possibly be about 10Kohms and 3 watts for LOOVAC or 6 watts for 200VAC To drive a large current inductive load with the DC output module A surge absorbing diode is implemented in the module to prevent destruction of the output transistor of the DC output module ZW 1682 ZW 3282 when connected with the load L Energy accumulated in the coil is consumed in the diode by the resistance of the inductive load as Joule heat when the output turns from ON to OFF Delay will be met for the restoration time until the energy goes below the load retention force The delay time is determined by the Magnetic switch value of L resistor value
36. ce specification V P Source power setup About memory module wan wau Ww Ww Q v m w w s w w v w i w x nn O PU yW X 3 2 CPU rack ZW 508KB 504KB and I O rack ZW 5087B 108ZB 1 2 Dimensional view Parts identification and functiong P Y 8 mam sa e e i 3 Precautions about the CPU and I O racks 3 3 Input modules and output modules 1 Parts identification and functions 2 Dimensional view 3 Input module specification 4 Output module specification 5 Precautions about input modules 6 Precautions about output modules 3 4 Expansion power supply module ZW 100PU1 lll Parts identification and functions 2 Dimensional view 9 3 Specification n 141 Supply voltage selection A A A A e en M Oo in G BH 10 10 10 13 13 17 18 21 21 2 26 29 29 31 32 35 41 44 oe 52 53 54 54 4 Installations 4 1 Installation 4
37. directly driving the output device such as the solenoid valve magnetic switch etc Rated Maximum Maximum rated 240VAC NOTE 1 2A NOTE 1 0 5A NOTE 2 SA 10ms max ae NOTE 1 If plural number of items 8 points or 4 points for the ZW 8S1 were to be ON at the same time within a group of the same common the total current should be less than 5A In the case of the ZW 1654 it is the value of the resistance load In the case of take the power factor NOTE 2 If the fuse is in the NOTE 3 2 up to 8 points are to current of up to 0 34 the solenoid valve and magnetic switch of the inductive load into consideration same one common group 16 points and actuate simultaneously it permits the per point If more than 8 points are to actuate simultaneously every point must be limited 0 3A at a maximum Im case the external supply voltage is 5VDC the limit is 0 1A per POTES Surge on current indicates the output element performance Lamp load and rush current For the incandescent lamp a rush current of 10 to 20 times the normal current flows for a period of about 10 milliseconds As a means to reduce the rush current there are two ways to insert a bleeder resistor or a current limit resistor a Insertion of bleeder resistor Bleeder resistor Current limit resistor Slight degree of the current that does not activate the lamp should be
38. dule I O rack ZW 108ZB I O module installation guide hole 2 Card edge connector 60 Module holding screw hole I O expansion connector 6D 24V terminal board 62 5V terminal board 5 Support hole I O module 8 modules I O rack ZW 508ZB E hy ae 25 26 6D Support hole It is an oval hole which support the rack on the control panel Use the M5 screw I O expansion connector It is the signal connector used to interface the CPU rack with the I O rack Use the I O expansion cable that comes with the I O rack or the control module The connector is protected by the cover when the machine is delivered Card edge connector It is the connector used to interface the control module I O module and expansion power supply module to the rack The CPU rack has two control module interfacing connectors and eight I O module interfacing connectors for the ZW 508KB or four connectors for the ZW 504KB The I O rack has eight I O module interfacing connectors and the ZW 108ZB has one expansion power supply module interfacing connector The connectors are protected by the cover when the machine is delivered The connector not used must be left protected with the cover Control module installation guide hole Used to hole the control module on its position 1 0 module installation guide hole Used to hold the 1 0 module on its position Moduie holding screw hole Used to secure the control module 1
39. e Securing screw Set im the AC100V mode Remove the lock plate securing screw 3 Remove the switch locking plate 4 Set the select switch 2 to the 200V side Use the switch lock plate 2 other side around during AC100V operation and fix it over the switch Fasten the lock plate securing screw 19 NOTE 1 When AC200V is supplied with the power source select switch set to the ACLOOV side damage may be done to the control module 17 5 About memory module The 3 5KW RAM is equipped standard for the program memory The ZW 501MA RAM module option must be used when the program is expanded above 3 5KW or the file register is expanded When the PROM is used for the program memory the ZW 501MO ROM module must be used Program memory File register Capacity RR Address capacity 2 5KW 2KB ZW 501MA expansion 7 5KW AAA A o RAM module in use 6 5KW 00000414777 5 5KW 00000412777 amp 5KW 00000410777 3 5KW 00000406777 2 5KW 00000104777 ZW 501MO ROM module 00000406777 Not usable in use 2 5KW 00000104777 2KB 30000433777 The capacity of the program memory and file register are assigned 4KB 30000 37777 after registration of the respective capacity in the system memory Program memory capacity File register capacity Not used system memory System memory 204 205 002 NOTE 1 The maximum capacity of the file registers will be 4K
40. e link converter personal computer Computer link ZW 501CL2 Installed in the ZW 501 U card control module Data link Data link card ZW 501DL1 Installed in the ZW 501CU ZW 501DL9 control module Remote Remote I O ZW 501RM1 Installed in the ZW 501CU 1 0 master card control module Remote I O ZW 5 gt 01RS1 installed in the CPU rack on slave module the remote slave side NOTE For details of computer link data link and remote I 0 refer to Instruction Manual related 2 2 List of modules Accessory Item Qty Module name Module name Model name Description Control ZW 501CU module Expansion ZW 100PU1 5VDC 7A power supply module ZW 100PU2 5VDC 12A Glass tube 250V mini fuse Glass tube 250V 3A mini fuse CPU rack ZW gt 08KB 2W 504KB Can be equipped with the control module and 4 I O modules ZW 108ZB CPU memory and power supply are fabricated Maximum 512 I 0 points can be installed 3 5KW program memory is incorporated Glass tube mini fuse Glass tube 250V 2A mini fuse Expansion I O cable 1m Expansion 5V supply cable 1m Installation Manual Programming Manual Address label 250V 1A Glass tube 250V 14 mini fuse Glass tube 250V 2A mini fuse Can be equipped with the control module and 8 1 0 modules I O rack Can be equipped Expansion signal cable with the 45cm 1 expansion
41. es to activate Not open Yes Short the 0020 terminal of the output No module with the common terminal to see if the TET I nsure py monitoring PL comes to activate the program that mno Yes change is met in the program Replace the output module with the new Monitor STRUOOO by the program to see if the Yes Check the external ON lamp is in wiring of the activation output module open wire open No To the CPU error lamp check procedure Check if the LED 0000 Yes is ON on the input module No Check if the predeter mined voltage is on to the 0000 terminal of the input module Replace the input module with the new one Check the external wiring of the input module open wire defective PB JO Ps The PL turns on without pushing the PB Check if the LED 0020 Confirm the specifi is ON on the output cation of the output moduie module if it is as in the specification In case a light load is used it may not Yes Monitor OUTOO20 by the programmer to check if O turn OFF due to the ON lamp activates F tei LL Yes Confirm by monitoring Replace the output the program that there module with the new is no change in the one program Monitor STROOOO by the No program monitor to check if the ON lamp activates To the CPU error check procedure Yes Check if LED 0000 is ON No on the input module Yes
42. etween the terminal board and the status lamp Cable Status lamp compartment Terminal board O b q yu POE Dad r gt cl N E E a gt Bottom view Since the terminal board used for the 1 0 module is detachable an entire terminal board may be removed with the cable fixed to the terminal board 67 2 Connector type 1 2 3 4 2 2N Use the flat e A screwdrivers Column Connecto pin number insert tube 1 Pay attention for the address numbers as they are arranged different from the connector pin numbers 2 Solder the signal wire to the connector pin with the cover inserted for insulation 3 Fasten the connector to the module using the flat tip screwdriver Recommended cable Multi pair vinyl insulated sheathed cable Use a larger common wire in case a large current is applied through the common line of the output module as the allowable current per line is 1 34 Pin number Pin number Power supply Address ha AR Address number e i O 4 O 1 2 4 3 2 4 3 4 15 5 4 5 5 6 7 6 7 O 1 0 4 2 _ 3 2 3 4 5 al fs 6 10 7 6 140 F 0 1 O 1 27h hi3 2 3 6 7 6 l 7 O 15 1 0 45 q 2 3 2 3 4 1 s 4a tk 5 6 7 6 gt i 120 1201 N No O Common Bpi L Open A ZW 32N2 ZW 3282 w
43. g 3 When both the DC output module and the contact output module are used Contact output module Load Contact output module DC output module Load O DC12V 1 When a load of 24VDC is driven by the DC output module both lines of the load driving power 24VDC must be connected to the 24V terminal board of the CPU rack 2 When a load of 12VDC is driven by the DC output module connect the 24VDC source to the 24V terminal board of the CPU rack apart from the load driving power 12VDC and connect the negative side of the load driving power line with the negative side of the 24V terminal board To drive the relay inside the contact output module it needs a 24VDC power NOTE Tighten the terminal board screw with a torque of less than 12Kg cm 70 5 6 Expansion power supply module wiring Remove the power supply module cover and make wires connected to the terminal board in the following manner Not used Class 3 ground Ground More than Kiv1 250 eee ACIOOV Or ACN AC power supply Make it connected serial with the stop output of the control module Stop output ese a a e E AC power supply E Ea a Stop output AC relay The coil rating must match ZW 501CU control module the supply voltage terminal board NOTE The terminal board screw must be fastened with a torque of less than 12Kg cm a e 5 Example of internal panel wirin
44. g 1 0 expansion W sienal cable jf 5VDC cable Use the cable BE OF k E E E E P that comes 0 A a Sas a with the 1 0 a E a q E NN E KE UE a rack a Conduit 2 x E y ie tee the module to module space and the conduit size so that there should be a N clearance of 30 to Q 50mm between the conduit and the module To external C 24VDC supply DC output module tela output module in use stop output Class 3 group pa 86 Maintenance and inspections 6 1 Routine maintenance 1 Check items In the following table are listed routine check items that required to be checked for operating the machine under an optimum conditions 1 General items Contents Criterion Note Ambient Check if it is within a 0 w 55 C temperature range specified in the ga specification f 35 x 90 RH Free of me In the case of in panel moisure humidity k i installation the condensation Ambient air Free of corrosive gas temperature inside the panel becomes the ambient temperature Vibration Not permitted Not permitted 2 Control module Input power Make voltage measure on 15 to 10 source the terminal board to of the rating check if the input voltage is within a range of the given rating Control Visually observe the Must be off module FATLURE lamp FAILURE lamp Battery Check if the battery Must be
45. gt Check if the End connector interfacing No the main module with the programmer is correctly connected No Set the switch to the correct position Make it correctly connected Yes To the main check End _ procedure BI aa Option module error check procedure Replace the option board Recovered Replace the CPU board 83 End All copyright is reserved by Sharp corporation
46. ink l 210 217 Store of error code For details of the system memory refer to Programming Manual System memory E TERJOP 103 Tenuew sATZoedser oy 07 13J0Y BIEP AUTT zoqnduco Sutsn usya AeTo1 TetToeds ey se pasn SF OSTE ECLVOOEL Beae Leoa SATUS AY yg eya FO uora3elodo oy BuTAnp pasoo aAT oe Sr qndano DPTAJ YT A00Z OOTOV 3SOTI ELE uo uo ug le e Of LOYST sal Tetoeds apod 101157 andano 3TEH ABTI WAMO ESATIVA NOY Tetoveds LOYROTPUT uUoTIBOTFTVads poo 9G UT pazuasaidol ST 9p09 10114 7 HION O0 T 2204091 pue YUTT T HLON doxp I PITOA SINTEF uny 397469 29748 Tnpou Teuotzdo San Tes UT 9ANTITRAI ur uorado do1p 1dn11970T 19M04 SANTTEOJ 19MOJ a npow O T sng eatp O T S1NTTYJ O T dois 3592 SIPMPAPH 1893 WO y y IFILT W M 2593 WY ABUT BopyuoIeM 10119 dd yooyo ARTaeg SANTTEJY TOUSH sue quo 1911 pe 1937 16 4 Source power setup Either ACLOOV or AC200V supply can be used for the control module drive power Before the products left the factory the power source switch has been set to the AC1LOOV side The switch must be turned to the AC200V side in the following manner when it has to be operated under AC200V 1 2 3 4 2 AC100V Power pes source select switch 4 US RES Switch Q locking 2 plate lag 1 a ss AC200V 200 v mode ue a EY setup Lock plat
47. itch photoelectric switch For those of the AC two wire type consumption current flows through the detect circuit during the OFF time which may not turn the input module OFF As it is noted as leak current for the specification of such as the photoelectric switch make sure that the value is below the OFF level of the input module 43 6 When the output circuit of the input device is of a triac output 10 1 t a voltage voltage current surge on curren ZW 851 LOOVAC 121VAC NOTE 1 80A one cycle ZW 16S1 2A _ ZW 16S2 12 24VDC 30VDC 2A NOTE 1 8A 10ms max ZW 16S3 200VAC 242VAC 2A NOTE 1 80A one cycle 2A A i ZW 168 ZW 32S2 5 12 2 amp VDC 30VDC or thyristor output Since a CR network is sometimes used as a surge killer for the triac or thyristor to prevent an arc error it may impede to turn the input module OFF due to a leak current caused by this CR network Though it is preferable to remove the CR network the value of C should be set below 0 033 microfarads for LOOVAC in case it is not possible to remove it In the case of 200VAC use a capacitor below 0 015 microfarads lriac output example Thyristor output example Input device CAC200V gt CAC200V ZW 16N4 ZW 16N1 CZW 16N3 gt ZW 16N3 Precautions about output modules Maximum voltage and current that can be broken and made at the output module Within the given rating every output module is capable of
48. l board or rack terminal board Dimensions of the I O module Dimensions of the control module terminal board and rack terminal board 77 M3 5X8 i self locking 8 m3 5x7 aia self locking up screw gt des 5 2 Control module wiring After removal of the control module panel wires must be connected to the terminal board in the following manner Optional rack dl h y E ee vaa Or wiring Or Lis To Li a _ Lo L3 refer to Instruction OB Manual of option module 5VDC supply cable Blue Power out attached to the z ua NOTE operational rack ro T Do not use terminals T Spare terminal To Li Lo and L3 for To be wired for a q other purpose Computer link ZW 501CL2 va Data link ZW 501DL1 9 lo Link Remote I O Es ZW 501RM1 al Class 3 ground Ground More APIO o x AC100V gt Ea power or AC200V When the DC output module is F used for the output module o connect the AC relay with Halt jale output the halt output and route the output contact to the emergency Stop CIECULES ee Make wires twisted NOTE Tighten the terminal board screw with a torque of less than 12Kg cm AC relay Use the AC relay whose rating is suitable for the power supply voltage 2 63 NOTE When 200VAC is used for the AC supply source the power source select switch of the control module must be set to the 200VAC side Refer to Section 3 1 4 Source power setup Supplying 20
49. mly 5 Others Verify the program on the cassette tape or PROM with the program currently in operation ee ee 6 2 Battery replacement procedure The memory backup battery must be replaced with the fresh one before its expiration date The expiration date is noted on the label posted on the control panel Contents of both the program memory and the data memory are retained by the backup battery during power failure Even if the ROM is used for the program memory it also need battery replacement The battery can be replaced while power is on to the control module 1 Parts code of the battery unit DUNT 5211NCZZ 2 Battery replacement procedure Get the fresh battery ready Loosen two screws 2 that_secure the panel then remove the control module panel 1 Unfasten the connector 2 of the used battery on the CPU board and put the connector of the fresh battery into connection within one minute Take out the used battery from the battery holder 8 and replace it with the fresh battery Replace the control module panel 1 back into its original place Revise the battery expiration label Battery expiratio data iabe Battery holder securing screw Control module panel Lift Locking Panel securing springs upright screw aye 6 3 Error checks Shown next are basic error check procedures Main check out procedure Every lamps of all modules are out The
50. n Eo r remove if it is hard to remove nyaya 9994895994 y Si IET AS How to install the I O module cover How to remove the 1 0 module NOTE Be sure to shut off AC power to the control module before mounting and dismounting the I O module to from the rack 5G 4 5 Installation of input output module side panel When the I O rack is used the side panel attached to the I O rack must be fitted to the I O module on the left side f uhi ciki y yx AAAARAAALR YY dd Attached self locking y screw 3 M3 x 8 H eh ot ARAS AA R sfl mi AAA dage Engage this tab to close Side panel e Tighten the self locking screw with a torque less than 5kg cm 60 4 6 Installation of expansion power supply module Guide hole Cover securing screw hole Module securing screw hole securing screw 1 Loosen the cover securing screw G of the power supply module cover 46 with the phillips screwdriver and remove the power supply module cover 2 Insert four guide tabs of the expansion power supply module into the guide holes of the ZW 108ZB I O rack and install the expansion power supply module to the ZW 108ZB 1 0 rack 3 Tighten four rack securing screws 69 of the expansion power supply module through the module securing screw holes of the ZW 108ZB I O rack Ze ES b Wirings 3 1 1 2 3 4 5 6 1
51. nmental conditions 1 2 3 4 5 6 7 Because the module is made neither dustproof not waterproof it is recommended to install inside the enclosed type cabinet so far as condition allows Never install the module in such a location where strong vibration and impact are existing Do not allow any other equipment installed close to the unit and avoid installing directly above a heat generating source like heater transformer and large capacity resistor Do not share the cabinet with that of a high tension equipment Keep away from a high tension line and power line as much as condition allows Install the module on the surface that covered with an electrically conductive material for the purpose of insuring positive ground connection and for better noise immunity Avoid installation on a paint finished board Use the galvanized M5 screw for securing the module O Q A Surface must be aa House in the enclose covered with ies type cabinet electrically Tans conductive material 501 lg EES U This module is Ha Al neither made mE Eo waterproof not Hed dustproof E ae 4 gl Le a El n TOPTA TE Ange yt et t Avoid installation close a Neat generatie 119 9 Ej to a high tension line source like heater al and transformer l I I i F I and power line as much as situation allows m wv n 55 4 2 Installation of the 1 0 rack on the panel Conduit 1 fot C
52. nual 11 lines of LCD segments with 11 contacts 1 coil per line Module name Ladder processor Ladder processor I NOTE Model name Z LOOLP1 Z 1LOOLP2 ZW 100CFL Description EL display 6 relay lines 2 message lines with l master control 12 relay contacts 1 coil per line EL display 11 relay lines 2 message lines with 11 relay contacts 1 coil per line Two sided 3 inch 312KB compact floppy disk with 16 column 2 row display unit Item AC cord Ground cord Printer interfacing cable Shoulder strap installation Manual AC cord Ground cord Printer interfacing cable CF loader interfacing cable 25 p connector Glass tube 125VAC 3A mini fuse Installation Manual AC cord Ground cord Glass tube 125VAC 2A mini fuse Soft case Shoulder strap Installation Manual The ZW 100PS3 LCD display programmer data cassette tape recorder is required when the LCD programmer is used 2 5 General specification Item specification Supply voltage LS VAC a or 200VAC eZ Power source 50 60Hz frequency Allowable power failure time Normal operation is ensured for an instantaneous power failure of less than 10ms Insulation resistance More than 1OMohms with 500VDC megger external high tension terminal vs chassis ground Dielectric strength 1500VAC 50 60Hz one minute external high tension terminal vs chassis ground
53. onduit i ws et Fe ees Ct Cy ee oe ane 3 i 50 100mm Conduit For the installation of the ZW 100PG1l programmer Reserve an open area of 50 to 100mm between racks It should have a space of 50mm to avoid heat rising e The left side of the CPU rack must have a clearance of more than 50mm against other panel or device 5G e When both racks are to be installed side by side it must have a clearance of more than 50 to 100mm NOTE 1 Use the I O expansion signal cable Im and I O expansion 5V power supply cable lm when both racks are arranged side by side Cables come with the ZW 501CU control module Since one each of cables is supplied it is not possible to lay more than three modules side by side 250 100 250 250 w me w eee ee Bore locations for the ZW 504KB 480 1 tapping screw Panel bore locations when the Dimension of the rack to rack space is set to 100mm rack support hole _ 57 4 3 1 2 3 4 Installation of control module Guide hole CPU rack Module securing securing screw Panel securin gt screw ds 30 Module securing screw hole Control module panel 28 Guide hole 45 CPU rack Peripheral module interfacing securing connector locking spring screw Loosen two panel securing screws 2 of the control module panel O using the flat tip screwdriver NOTE Since the screw is fixed to
54. ower consumption 5VDC External power supply x Operational status Connections Operating temperature Operating humidity Dielectric strength Insulation resistance NOTE 1 1 0 module ZW 1654 relay contact output module o 24VDC terminal board of the rack 16 points 240VAC 30VDC 2A resistance load 5A maximum per 8 points of 1 group 5V imA Mechanical 20 000 000 times minimum Electrical 1 Maximum make break voltage current resistance load More than 100 000 times 2 Electromagnetic relay load More than 200 000 times at 10 5A of 200VAC normally 0 5A coso 0 2 250VAC 5A anti surge mini fuse one piece per 8 points None l5ms max 20ms max 180mA max 24VDC 10 all waveform pulse usable 20mA maximum per point l common per 8 points LED active when ON Connector terminal board 16 outputs 2 commons 18P P 9 M3 5x8 Self lock screw in use Terminal board resin in red color 35 x 90 RH without moisture condensation L500VAC one minute across output terminal and secondary circuit 500VDC more than 10Mohms across output terminal and secondary circuit Refer to the instructions of the respective module for a special A Or 5 Precautions about input modules 1 Input signal ON OFF timings There is a need of satisfying the following condition in order to positively reflect the ON OFF state of the input device such as limit switch to the operation of the PC Input device
55. panel not to be open during operation When the power supply halt output cable etc is connected to the terminal board When source voltage is selected When the optional RAM module or ROM module is mounted or dismounted When the fuse is replaced When the battery is replaced Panel securing screw Not only this screw is used to secure the control module panel but it also is used to hold the programmer holding screw when the ZW 101PG1 programmer is installed to the control module Battery expiration label On this label is indicated the expiration data of the memory backup battery installed on the CPU board The battery therefore has to be replaced with the fresh one before the data After the replacement the label has to be replaced with the label indicated with a new expiration date POWER lamp green Lights up when 5V source is supplied to the control module RUN lamp green Lights up under the normal operation o Flickers during programming with the support tool in connection but the programmable controller halts Goes out when an error is established by the selfcheck Support tool IN USE IDLE lamp This switch has to be turned to the IDLE side when such as the programmer is connected to or disconnected rom the support tool connector When it set to the IN USE side after completion of connection or disconnection it enables communication between the support tool and the control module
56. power Expansion 5V supply supply module and cable 60cm 1 8 I O modules I O module side plate 1 Side panel securing Screw we Expansion signal cable 45cm 1 Expansion 5V supply cable 60cm I O module side plate Side panel securing screw ZW 104ZB Can be equipped with the expansion power supply module and 4 I O modules Ep Accessory Item Module name Model name Description I O rack ZW 102ZB Can be equipped with the expansion power supply module and 2 1 0 modules Expansion signal cable 45cm Expansion 5V supply cable 60cm I O module side plate Side panel securing screw ZW 508ZB Can be equipped with 8 I O modules Expansion signal cable 45cm Expansion 5V supply cable 60cm 1 0 module side plate Side panel securing ZW 501MA 4KW expansion program memory Expansion RAM module ROM module ZW 501MO 32 input points Interfacing connector Input ZW LONL module ZW 16N2 ZW 16N3 ZW 32N2 12 24VDC Output ZW 8S1 8 triac output Glass tube i25VAC 5A module points LOOVAC 2A mini fuse ZW 1651 16 triac output Glass tube 125VAC 5A points LOOVAC 2A mini fuse ZW 1682 16 transistor Glass tube 125VAC 5A output points mini fuse 12 24VDC 2A ZW 16S3 16 transistor Glass tube 250VAC 5A output points mini fuse 200VAC 2A ZW 1684 16 contact output Glass tube 250VAC 5A points 240VAC anti surge mini fuse 30VDC
57. rse effect Also it must be noted that the use of the arc killer causes the restoration time to prolong in some degree ee Pa A3T1BTOA noya 103IT0edey ogy sy ssn SJENOATO OV 247 JO SL BYR UT AOOE 03 A007 JNoge Surpue3s UJIM 2323 04 94 eAeU 3snu y 3582 Ten oe 243 UT UOTIRUATJUOD qeu 3x9u squrod 30e73u09 u wm3a q PROT pettdde sr zemod u um Zup pupT aq pTnous IF ADOZ 02 ADOT JO endless JU9114n9 103 y pue s3urod SL 9Y1 UT speoT u mq q ds Jopquoo ua FO 3UTAR9AQ ZUTINP p9219SUT oq Tqetiejead pTnous 9BIPUISTP Sutsseaddns 103 Y1OMJ9U YO sur SAQyY AO APZ O p uZrsse ST 9 1892 BSUTI19PTSUO st e8eiatoa Atddns y u umM S9TIST1979B4e8ug0 KeT r pue SUT UOT IeTO Se uji ut aQoueUZOZIed PROT 941 FO UOT ieedde Aew AeTap e ptoustos Pons 49 TARA e uo 3urpuadap TTIBS pue BT9I1 p ST peog ayy USUM s 5S u pro5uroo jou Aew Adu DEOT sq3utod Joe quoS SAT JONpuyT 4 JO AT 19d swyo 7 01 50 Y y JUSI1Ano jurod 329e3u02 jo VT J10MJ9U YO oy JO 1871 e ted SPeie3oroTua 9 02 T 9 uey zeT Tews AyRUSTOTFINsS oq SOnTVA o3eurxoxdde 247 prnoys peo 243 JO 2D0UBpadur sayy 103 pesn oq Kew BUTMOTTOF saul zemod Jy xepun pajexedo u umMx J yu usT FO DITOUYD 239 Sseanqeeg POC ov 97duexo ITNIDITO s Tdurex I TTT 212 Teord z oe h 2 peoT SAT3ONPUuT 4 Ajddns 19mog e poy73au 2POTP 19097 pora 293271104 ATddns 2197 Se oues 243 n0qe oq pTnous poTp 1
58. s are used the second unit must be equipped with the ZW 100PUl expansion power supply module NOTE 1 Do not install the expansion power supply module to the first and third ZW 108ZB ZW 100PU1 Z W 108Z B ZW 95082 B Z EZ lt ZW 108ZB ZW 108Z B L L ee aee s ISSN l 7W 508K B ZW 504K B ZW 508K B CZW 504K B 2 5 6 L 8 Use the 5VDC I 0 expansion signal cable for connection of the I O rack with the control module or other I O rack The cable comes with the I O rack or the control module Do not allow existence of any unoccupied space when the input module or output module is to be installed on the CPU rack or the I O rack All modules must be installed successively without any unoccupancy The I O module installed next to an unoccupancy will not operate Existence of an open space in the CPU rack will not permit all 1 0 modules installed after the open space to operate Open space gt I O modules after this will not operate Actuation of the power indicator 62 must be confirmed before the operation when the ZW 108ZB is used for the I O rack If the power indicator is not active check the wiring as 5VDC is not in supply to the I O rack See SA Installation and 85 Wirings for installation and wiring of racks and modules a as 4 5 Input modules and output modules 13 Parts identification and functions CPU rack securing screw Fuse holder
59. terminal board Terminal board securing screw Terminal board securing screw Loosen two screws of the terminal board and remove the terminal board from the cabinet NOTE Because the screw is retained by the stopper it cannot be removed from the terminal board 80 Dimensional view 2 Includes the rack Includes the rack Connector type Jack type 31 3 ZW 16N1 115VAC input module Input lamp Circuit configuration Input module specification ZW 16N3 200VAC input module SYinput Lamp de lt gt j lt input lamp i ra oe AC100V Le Input lamp Numb i t A apas sa 16 points 16 points points LOOVAC 50 60Hz with less Rated input voltage 200VAC 50 60Hz with less than 54 of waveform distortion than 5 of waveform distortion NOTE 2 Pay attention for the OFF level when such as the proximity switch and photoelectric switch is used as it may not turn OFF properly sometimes Input voltage range OVAC x 132V OVAC x 242V Input oN level 160V max voltage Input ON Level LOmA max current level _ OFF level 3 5mA min Input impedance Abt 8 3Kohms Abt 16Kohms e OFF gt ON 15ms max 115VAC 15ms max 200VAC time ON gt OFF 20ms min 115VAC 20ms min 200VAC internal power consumption 5VDC Operational status Connections _Operating temperature Operating humidity Insulation registance Dielectric strength
60. ts at a time of power failure even if the ROM is used for the memory 12 Relay numbers of input and output modules are determined by serial number Pay special attention for the location of the input output module and relay number when a special module other than the 1l6 point module such as the 32 point module is used For detail of serial number determination refer to Section 2 3 of Programming Manual 13 No vacant slot should be existing in a midway when the input output module is installed in the CPU rack and 1 0 rack In other words input output modules after the vacant number can not be controlled to operate 14 As the maximum I O point of the W 51 is 512 points and the maximum I O slot is 32 don t exceed the 512 points I O when using the 32 points I O for example ZW 32N2 or the special 1 0 for example ZW 4AD2 which occupies 32 points 1 0 relay erea 15 As the watch dog timer of the W 51 for the self diagnosis is seted at 150 ms don t exceed 150 ms for the scan time of the programming If the scan time exceeds 150 ms the Halt Output of the control module makes OFF OPEN 82 System configuration and general specification 2 1 W gt 1 series system configuration 1 Basic system configuration I O rack ZW 508Z B 1 0 el ZW 108Z B ZW 102Z B x ail 1 0 expansion signal cable ZW 10628 I O expansion 5V power supply cable CPU rack El CZW 508KB ZW 50K B Control module A
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