1

DEVELOPMENT OF A TRAFFIC LIGHT CONTROL SYSTEM USING

PROGRAMMABLE LOGIC CONTROLLER

AZRULNOR BIN AHMAD

UNIVERSITI MALAYSIA PAHANG

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UNIVERSITI MALAYSIA PAHANG

BORANG PENGESAHAN STATUS TESIS♦

JUDUL: DEVELOPMENT OF A TRAFFIC LIGHT CONTROL SYSTEM

USING PROGRAMMABLE LOGIC CONTROLLER
SESI PENGAJIAN:________________
2007/2008

Saya ________________________________________________________________
AZRULNOR BIN AHMAD ( 840418-09-5011 )
(HURUF BESAR)

mengaku membenarkan tesis (Sarjana Muda/Sarjana /Doktor Falsafah)* ini disimpan di

Perpustakaan dengan syarat-syarat kegunaan seperti berikut:

1. Tesis adalah hakmilik Universiti Malaysia Pahang (UMP).

2. Perpustakaan dibenarkan membuat salinan untuk tujuan pengajian sahaja.
3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran antara institusi
pengajian tinggi.
4. **Sila tandakan ( √ )

(Mengandungi maklumat yang berdarjah keselamatan

SULIT atau kepentingan Malaysia seperti yang termaktub
di dalam AKTA RAHSIA RASMI 1972)

TERHAD (Mengandungi maklumat TERHAD yang telah ditentukan

oleh organisasi/badan di mana penyelidikan dijalankan)

√ TIDAK TERHAD

Disahkan oleh:

___________________________ ___________________________
(TANDATANGAN PENULIS) (TANDATANGAN PENYELIA)

Alamat Tetap:

NO. 55 KAMPUNG LAHAR, NOR MANIHA ABD. GHANI

MUKIM MALAU, 06000 ( Nama Penyelia )
JITRA, KEDAH

Tarikh: 30 NOVEMBER 2007 Tarikh: : 30 NOVEMBER 2007

CATATAN: * Potong yang tidak berkenaan.

** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak
berkuasa/organisasi berkenaan dengan menyatakan sekali tempoh tesis ini perlu
dikelaskan sebagai atau TERHAD.
♦ Tesis dimaksudkan sebagai tesis bagi Ijazah doktor Falsafah dan Sarjana secara
 I

DEVELOPMENT OF TRAFFIC LIGHT CONTROL SYSTEM USING

PROGRAMMABLE LOGIC CONTROLLER

AZRULNOR BIN AHMAD

This thesis is submitted as partial in fulfillment of the

requirements for the award of the
Bachelor of Electrical Engineering (Electronics)

FACULTY OF ELECTRICAL & ELECTRONIC ENGINEERING

UNIVERSITY MALAYSIA PAHANG

NOVEMBER 2007
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I declare that this thesis entitled “Development of a traffic light control system“ is
the result of my own research except as cited in the references. The thesis has not
been accepted for any degree and is not concurrently submitted in candidature of any
other degree.

Signature : ....................................................

Name : AZRULNOR BIN AHMAD

Date : 30 NOVEMBER 2007

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To my beloved father, mother, brother and my sisters.

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ACKNOWLEDGEMENT

I would like to take this opportunity to acknowledge my supervisor, Madam

Nor Maniha Abd. Ghani who always being supportive to this project. His
encouragement, guidance, critics and friendship makes me feel enthusiasm to finish
this thesis.

I also like to acknowledge the lectures and staff who gave invaluable tips and
helps to me. Also to my fellow friends who was sharing the opinions to me. Not to
forget to my beloved and respected dad, mom, brother and sisters who constantly
gave morale support to me when I’m really needed.
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ABSTRACT

Development of a traffic light control system using PLC (Programmable

Logic Controller) is the title of this project. This project is divided into two parts
which are hardware and software. The hardware part for this project is a model of
four way junction of a traffic light. Each lane has two limits switch (input) function
as a sensor. Three indicator lamps with different colours (Red, Yellow and Green)
are installed at each lane for represents as traffic light signal. This limit switches and
indicator lamps are connected to Omron PLC CQM1H-CPU51. The PLC controls
every signal which is coming from the inputs (Limit switch) to software and display
to the outputs (Indicator lamps). The software part operates with Omron PLC is CX-
Programmer. With using this software, the ladder logic diagram is programmed to
control the traffic light base on the flow chart. At the end of this project, the traffic
light successfully control by PLC.
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ABSTRAK

Pembangunan sistem kawalan lampu isyarat menggunakan PLC

(Programmable Logic Controller) adalah tajuk projek ini. Projek ini terbahagi
kepada dua bahagian software dan hardware. Hardware projek ini adalah model
simpang empat berlampu isyarat. Setiap lorong menpunyai dua suis (masukkan)
berfungsi sebagai penderia. Tiga lampu penanda yang berlainan warna (Merah,
Kuning, Hijau) dipasang pada setiap lorong sebagai lampu isyarat. Suis dan lampu
penanda bersambung pada PLC Omron CQM1H-CPU51. PLC mengawal setiap
isyarat yang datang dari masukan (Suis) ke software dan dipaparkan ke keluaran
(lampu penanda). Software yang beroperasi dengan PLC Omron ialah CX-
Programmmer. Dengan menggunakan software ini, ladder logic diagram
diprogramkan untuk mengawal lampu isyarat berpandukan carta aliran yang telah
dipersetujui. Di akhir projek ini, lampu isyarat berjaya dikawal sepenuhnya
menggunakan PLC.
 VII

TABLE OF CONTENTS

CHAPTER TITLE PAGE

DECLARATION II
DEDICATION III
ACKNOWLEDGEMENT IV
ABSTRACT V
ABSTRAK VI
TABLE OF CONTENTS VII
LIST OF FIGURES IX
LIST OF TABLES X

1 INTRODUCTION
1.1 Overview of traffic light system 1
1.2 Overview of Programmable Logic Controller 2
1.3 Project Objectives 4
1.4 Project Scopes 5
1.5 Problem statement 5
1.6 Thesis outline 6

2 SYSTEM HARDWARE
2.1 Introduction 8
2.2 Programmable Logic Controller 9
2.2.1 PLC configuration 9
2.2.2 Basic PLC schema 11
2.2.3 PLC operation 13
2.2.4 Internal PLC 14
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2.3 CQM1H configuration 14

2.4 Traffic light model 15
2.5 Hardware wiring diagram 17

3 SYSTEM SOFTWARE
3.1 Introduction to CX-Programmer 21
3.2 Diagram workspace 22
3.3 Program development 23

4 RESULT AND ANALYSIS

4.1 Introduction 28
4.2 Inputs and outputs testified 28
4.3 Traffic light control system analysis 30
4.4 Simulation in the real world 32

5 CONCLUSION AND RECOMMENDATIONS

5.1 Conclusion 33
5.2 Recommendations 34
5.2.1 Costing and commercialization 34

REFFERENCE 35

APPENDICES
APPENDIX A – CQM1H Manual 36
APPENDIX B – Dedicated I/O Units 59
APPENDIX C – Traffic light program 70
 IX

LIST OF FIGURES

FIGURE NO. TITLE PAGE

2.1 PLC system overview 11

2.2 PLC operation 13
2.3 CQM1H configuration 15
2.4 Traffic light model 16
2.5 Traffic light hardware 17
2.6 PLC cabinet box wiring diagram 18
2.7 Inputs wiring diagram 19
2.8 Outputs wiring diagram 20
3.1 Programming section 23
3.2 Traffic phase flowchart 24
3.3 Lane phase ladder diagram 25
3.4 Program flowchart 26
3.5 Program ladder diagram 27
4.1 Testing input/output ladder diagram 30
 X

LIST OF TABLE

TABLE TITLE PAGE

4.1 Input addresses 29

4.2 Outputs addresses 29
4.3 Preset cycle time lane & phase duration 30
4.4 New traffic light control system phase
& lane duration 31
4.5 Sensor distance 32
5.1 Cost of project 34
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CHAPTER 1

INTRODUCTION

1.1 Overview of traffic light system

Ever since Roman times, society has tried to control traffic. Even the fabled
Roman road system created a conflict between pedestrian and equine travelers.
However, a practical solution was not developed until the mid-nineteenth century,
when J. P. Knight, a railway signaling engineer, created the first traffic signal, which
was installed near Westminster Abbey in London, England in 1868. Unfortunately,
the device exploded, killing a police officer, and its use was discontinued after being
in operation for only a short time.

The modern traffic light was invented in America. New York had a three-
color system in 1918 that was operated manually from a tower in the middle of the
street. Other cities soon adopted the idea of having someone on the scene to control
the lights. Garrett Morgan, inventor of the gas mask, also developed traffic signaling
devices. Having witnessed an accident between a car and a carriage, Morgan felt
compelled to devise a system to prevent such collisions at street intersections. In
1923 he patented an electric traffic light system using a pole with a cross section on
which the words STOP and GO were illuminated.
 2

These basic designs were soon improved. In 1926 the first automatic signals
were installed in London; they depended on a timer to activate them. In the 1930s
vehicle-activated lights were created in which cars rolled over half-buried rubber
tubes. Air in the tubes was displaced by the weight of the car rolling over them, and
the increased pressure operated an electric contact, activating the lights. But these
tubes wore out quickly. A better idea was the inductive-loop device: a loop of wire
was imbedded in the road itself and connected to a box controlling the lights; a
current of electricity passed through the loop, and when the steel body of a car
passed overhead, it produced a signal that activated the light.

Today, traffic is automatically routed onto limited access highways courtesy

of a computer activated guidance system that determines traffic volume on the
highway. Global positioning satellite systems (GPS) are installed in many cars.
These systems connect with a satellite and inform drivers where they are and
possible routes to their destination. Such systems will eventually enable a drive to
determine the best route to a destination given prevailing traffic conditions.

1.2 Overview of Programmable logic controller (PLC)

A programmable logic controller (PLC) is an industrial computer used to

control and automate complex systems. Programmable logic controllers are a
relatively recent development in process control technology. It is designed for use in
an industrial environment, which uses a programmable memory for the integral
storage of user-oriented instructions for implementing specific functions such as
logic, sequencing, timing, counting, and arithmetic to control through digital or
analog inputs and outputs, various types of machines or processes.
 3

Programmable logic controllers are used throughout industry to control and

monitor a wide range of machines and other movable components and systems. PLC
is used to monitor input signals from a variety of input points (input sensors) which
report events and conditions occurring in a controlled process. Programmable logic
controllers are typically found in factory type settings. PLCs are used to control
robots, assembly lines and various other applications that require a large amount of
data monitoring and control.

A typical programmable logic controller employs a backplane to serve as the

communications bus for interconnecting the PLC processor with the array of
individual input/output devices with which the processor interacts in terms of
receiving input data for use in executing the control program and transmitting
control data for use in controlling the targeted objects. A PLC includes a rack into
which a plurality of input/output cards may be placed. A rack includes several slots
into which these input/output cards are installed.

Each input/output card has a plurality of I/O points. The I/O modules are
typically pluggable into respective slots located on a backplane board in the PLC.
An I/O bus couples the cards in the slots back to the processor of the programmable
logic controller. The slots are coupled together by a main bus which couples any I/O
modules plugged into the slots to a central processing unit (CPU).

The CPU itself can be located on a card which is pluggable into a dedicated
slot on the backplane of the PLC. The particular processor employed in a PLC
together with the particular choice of input and output cards installed in the PLC
rack are often referred to as the hardware configuration of the programmable logic
controller. The hardware configuration also includes the particular addresses which
the I/O cards. Each option module typically has a plurality of input/output points.
 4

The option modules are coupled through an interface bus, for example via a
backplane, to a main controller having a microprocessor executing a user program.
Option modules may also include a microprocessor and a memory containing
separate user programs and data directed to a particular operation of the PLC
system. During the execution of a stored control program, the PLC's read inputs
from the controlled process and, per the logic of the control program, provide
outputs to the controlled process. The outputs typically provide analog or binary
voltages or "contacts" implemented by solid state switching devices.

PLC's are normally constructed in modular fashion to allow them to be easily

reconfigured to meet the demands of the particular process being controlled. The
processor and I/O circuitry are normally constructed as separate modules that may
be inserted in a chassis and connected together through a common backplane using
permanent or releasable electrical connectors.

1.3 Project objectives

This project is about develop a new practical traffic light control system
which the system will solve the traffic congestion issue. To develop the project,
there are two objectives that must be accomplished which are:-

i. Develop a new traffic light control system controlled by programmable logic

controller (PLC).

ii. Implement the system on a model of a traffic light.

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1.4 Project scope

i. Construct a model of four way junction of a traffic light model.

ii. Programmed a ladder logic diagram to control the traffic light.

iii. Combine the software part and the hardware part to simulate a traffic light
system.

1.5 Problem statement

The monitoring and control of city traffic light is becoming a major problem
in many countries. The increasing number of vehicles and the lower phase of
highways developments have led to traffic congestion problem especially in major
cities such as Kuala Lumpur, Georgetown, Johor Bahru, and Ipoh. Travel time,
environment quality, life quality, and road safety are all adversely affected as a
result of traffic congestions. In addition, delays due to traffic congestions also
indirectly affect productivity, efficiency, and energy losses.

There are many factors that lead to traffic congestion such as the density of
vehicles on the roads, human habits, social behavior, and traffic light system. One
major factor is due to the traffic lights system that controls the traffic at junction.
Traffic policeman are deployed at traffic intersection everyday in order to overcome
these congestion during peak hour, thus one of the roots of the problem is due to
ineffective traffic lights controllers. With effective control the intersection, it is
 6

believed that the overall capacity and performance of urban traffic network could be
resolve.

There are several types of conventional methods of traffic light control;

however they fail to deal effectively with complex and time varying traffic
conditions. Currently, two types of traffic light control are commonly installed in
Malaysia and many parts of the world: the preset cycle time (PCT) and vehicle-
actuated (VA). Due the deployment of a large number of traffic police in the city
during peak hours, it is evident that these types of traffic lights controllers are
inadequate. There is a need to research on new types of highly effective practical
traffic light controllers.

In this paper, the proposed of a new development of a traffic light control

system controlled by PLC. This system will decreased the traffic congestion at
traffic light by extend the time for the green signal if traffic density at that lane are
high and give the priority to who first arrive at the junction to get a green signal.

1.6 Thesis outline

Chapter 1 is introduction to programmable logic controller and traffic light

system. This chapter also explains about project objectives and scopes and discuss
about problem statement.

Chapter 2 focuses on hardware development and configuration. This chapter

explains every detail about PLC Omron CQM1H and traffic light model. The wiring
diagram for this hardware also will be discussed in this chapter
 7

Chapter 3 deals with the software development using software CX-

Programmer. These chapters also discuss the flowchart and development program
for traffic light system.

Chapter 4 presents all the results obtained and the configuration of doing
simulation in the real world.

Chapter 5 discusses the conclusion of this project development traffic light

control system using Programmable Logic Controller. This chapter also explains the
problem and the recommendation for this project and for the future development or
system modification.
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CHAPTER 2

SYSTEM HARDWARE

2.1 Introduction

The hardware part of this project is Programmable logic controller (PLC) and
a traffic light model. Omron CQM1H-CPU51 is the type of PLC used in this project
as the processor to control the traffic light. This type of PLC was been chosen
because the characteristic is fully necessary by the development of traffic light
system.

The four ways traffic light model is constructed to display how this traffic
light control system is running. This traffic light model has a complete set of traffic
light signal which are red, yellow and green as a traffic signal for each lane. Each
lane also has two limit switches represent as a sensor on the road. The first sensor
placed in front of the lane to detect the presence of a car at the junction and the
second sensor placed at certain length from first sensor to determine the volume of
car at that lane. The right connection between PLC and traffic light model is very
important because it can avoid the problem or conflict when the program is
transferred to PLC.
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2.2 Programmable Logic Controller

2.2.1 PLC configuration

i. Many PLC configurations are available, even from a single vendor. But each
of these has common components and concepts. The most essential
component is are:

ii. iPower supply – This can be built into the PLC or be an external unit.
Common voltage levels required by the PLC are 24Vdc 120Vac 220Vac.

iii. CPU (central Processing Unit) – This is a computer where ladder logic is
stored and processed.

iv. I/O (Input/output) – A number of input/output terminals must be provided so

that the PLC can monitor the process and initiate actions. Inputs to, and
outputs from, a PLC is necessary to monitor and control a process. Both
inputs and outputs can be categorized into two basic types: logical or
continuous. Consider the example of a light bulb. If it can only be turned on
or off, it is logical control. If the light can be dimmed to different levels, it is
continuous.

v. Indicator lights – These indicate the status of the PLC including power on,
program running, and a fault. These are essential when diagnosing problems.

vi. Rack Type : A rack can often be as large as 18” by 30” by 10”
 10

vii. Mini: These are similar in function to PLC racks, but about the half size.
Dedicated Backplanes can be used to support the cards OR DIN rail
mountable with incorporated I/O bus in module.

viii. Shoebox: A compact, all-in-one unit that has limited expansion capabilities.
Lower cost and compactness make these ideal for small applications. DIN
rail mountable.

ix. Micro: These units can be as small as a deck of cards. They tend to have
fixed quantities of I/O and limited abilities, but costs will be lowest. DIN rail
mountable
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2.2.2 Basic PLC schema

The basic PLC schema include CPU, power supply, memory, Input block, output
block, communication and expansion connections. Figure 2.1 shows the PLC system
overview.

Figure 2.1 PLC system overview

CPU modules - The Central Processing Unit (CPU) Module is the brain of
the [Link] role to read inputs, execute the control program, update outputs.
The CPU consists of the arithmetic logic unit (ALU), timing/control circuitry,
accumulator, scratch pad memory, program counter, address stack and instruction
register. A PLC works by continually scanning a program.

Memory - The memory includes pre-programmed ROM memory containing

the PLC’s operating system, driver programs and application programs and the
RAM memory. PLC manufacturer offer various types of retentive memory to save
user programs and data while power is removed, so that the PLC can resume
 12

execution of the user-written control program as soon as power is restored. Some

types of memory used in a PLC include:

i. ROM (Read-Only Memory)

ii. RAM (Random Access Memory)

iii. PROM (Programmable Read-Only Memory)

iv. EPROM (Erasable Programmable Read-Only Memory)

v. EEPROM (Electronically Erasable Programmable Read-Only Memory)

vi. FLASH Memory

vii. Compact Flash – Can store complete program information, read & write text
files

viii. I/O Modules - Input and output (I/O) modules connect the PLC to sensors
and actuators. Provide isolation for the low-voltage, low-current signals that
the PLC uses internally from the higher-power electrical circuits required by
most sensors and actuators. Wide range of I/O modules available including:
digital (logical) I/O modules and analogue (continuous) I/O modules.
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2.2.3 PLC Operation

CHECK INPUT STATUS-First the PLC takes a look at each input to

determine whether it is on or off condition.

EXECUTE PROGRAM-Next the PLC executes a program by one

instruction at a time. If the first input is on then it should turn on the first output.
Since it already knows then it will be able to decide whether the first output should
be turned on based on the state of the first input. It will store the execution results
for use later during the next step.

UPDATE OUTPUT STATUS-Finally the PLC updates the status of the

outputs. It updates the outputs based on which inputs are on during the first step and
the results of executing your program during the second step. Based on the example
in step 2 it would now turn “ON” the first output because the first input is “ON” and
your program said to turn “ON” the first output when this condition is true.

Figure 2.2 PLC operation block diagram

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2.2.4 Internal PLC

INPUT RELAYS-(contacts) These are connected to the outside world. They

physically exist and receive signals from switches, sensors, etc.

INTERNAL UTILITY RELAYS-(contacts) These do not receive signals

from the outside world nor do they physically exist. They are simulated relays and
are what enables a PLC to eliminate external relays.

OUTPUT RELAYS-(coils) These are connected to the outside world. They

physically exist and send on/off signals to solenoids, lights, etc.

DATA STORAGE -Typically there are registers assigned to simply store

data. They are usually used as temporary storage for math or data manipulation.
They can also typically be used to store data when power is removed from the PLC.

2.3 CQM1H configuration

Figure 2.3 shows the Omron PLC CQM1H configuration. The main body of
this PLC is power supply unit, Central processor unit and input/output slot. The
power supply unit receive the required PLC voltage is 240Vac. For safety the
voltage to PLC must connect to automatic circuit breaker before connect to the PLC
because to protect the PLC from overload. The CPU covered by Analog input/output
slot, RS232 port, and processor. The inputs/outputs slot uses for system are using
digital input and digital output. There are not limited slot for input and output port
and can use for multiple inputs/outputs card.
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Figure 2.3 CQM1H configuration

2.4 Traffic light model

The four ways junction is developed to display the simulation the

development of the new traffic light control system. Figure 2.4 and 2.5 show the
design of traffic light model. Every lane and traffic light signals have been labeled
with alphabet A, B, C and D to separate each lane and traffic light. Each traffic light
lane has their set of traffic light signal “Red, Yellow, and Green”. This traffic light
signal operates similar like common traffic light signal. It changes from red to green
and then yellow and after that back to red signal.
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Each lane also has two limit switches represent as a sensor on the road. The
suitable sensor for design a real traffic light system is type of linear sensor or
electromagnetic sensor. The first sensor placed in front of lane to detect the presence
car at the junction and the second sensor placed at certain length from first sensor to
determine the volume of the car at that lane. From this combination of sensor, we
will know the expected time for green signal on when each lane change to the green
signal.

Figure 2.4 Traffic light model

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Figure 2.5 Traffic light hardware

2.5 Hardware wiring diagram

Once hardware is designed ladder diagrams are constructed to document the

wiring. For this project, existed PLC cabinet box are use and connect with the traffic
light model. A basic wiring diagram is as shown in figure 2.6. The PLC would be
supplied with AC power 240V and then I/O card supplied with DC power 12V to
24V. The common for input card is 24Vdc and for output card is 0Vdc. A fuse is
used after disconnect to limit the maximum current drawn by the system.
 18

Figure 2.6 PLC cabinet box wiring diagram

.

The PLC input wiring address start with number 0.00 to 0.15 for every input
card. When the other input card is install to the PLC socket the address for this input
card will start with number 1.00 to 1.15 and so on. Figure 2.7 shows the wiring
diagram for input card which this input card connects to sensor (limit switch) at
traffic light model.
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Figure 2.7 Input wiring diagram

The PLC outputs wiring address start with number 100.00 to 100.07 for
every output card. When the other output card is install to the PLC socket the
address for this output card will start with number 101.00 to 101.07 and so on. The
figure 2.8 show the wiring diagram for output card which output card connect to
sensor (limit switch) at traffic light model.
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Figure 2.8 Output wiring diagram

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CHAPTER 3

SYSTEM SOFTWARE

3.1 Introduction to CX-Programmer software

CX-Programmer is a PLC programming tool for the creation, testing and

maintenance of programs associated with Omron CSI-series PLCs, CV-series PLCs
and C-series PLCs. It provides facilities for support of PLC device and address
information and for communications with OMRON PLCs and their supported
network

CX-Programmer operates on IBM compatible personal computers with

Pentium or better central processors, including Pentium II. It run in a Microsoft
windows environment. The information within a CX-Programmer project consists of
ladder programs, operands, required PLC memory content, I/O table, expansion
instructions (if applicable) and symbols. Each CX-Programmer project file is
separate and is a single document.
 22

CX-Programmer can only open a single project at a time. However, it is

possible to deal with many project files by using CX-Programmer at once. A CX-
Programmer project has a CXP or CXT file extension (normally the CXP file is used
and is a compressed version of the CXT file).

3.2 Diagram workspace

The diagram workspace can display a ladder program, the symbol table of
that program or the Mnemonic view. The details displayed depend upon the
selection made in the project workspace.

When a new project is created or a new PLC added to a project, an empty

ladder is automatically displayed on the right-hand side to the project workspace.
The symbol table and Mnemonics view must be explicitly selected to be displayed.
All views can be opened at the same time and can selected via option associated
with the window menu.

PLC program instruction can be entered as a graphical representation in

ladder form. Programs can be created, edited, and monitored in this view. The 3.1
shows the diagram workspace appearance.
 23

Figure 3.1 Programming section

3.3 Program development.

Before construct a ladder logic diagram, program flowchart is ideal for a

process that has sequential process steps. The steps will be executed in a simple
order that may change as the result of some simple decisions. The block symbol is
connected using arrow to indicate the sequence of the steps and different types of
program actions. The other functions may be used but are not necessary for most
PLC applications.

A flowchart in figure 3.2 shows about how the lane changes to the other lane
for a green signal. This traffic light system is working independently to change from
one lane to the other lane based on which lane can activate sensor 1 fast. This traffic
light system give the priority to the lane which have a car and followed by the other..
 24

This traffic light control system operate similar to intelligent traffic light system
which it only give a green signal to the lane which have a vehicles and not like a
common traffic light control system which have a fix rotation for each lane.

Figure 3.2 Traffic phase flowchart

Figure 3.3 shows a sample ladder logic diagram that has been constructed for
the flowchart is shown in figure for the lane A. The ladder diagram for the other
lanes is similar with this ladder diagram but the memories for the contacts are
different.
 25

Figure 3.3 Lane phase ladder diagram

Figure 3.4 shows a program flowchart for changing traffic light signal at the
specific lane. A red signal will turn to green signal if a sensor 1 is activated. If the
sensor 2 is activated before a red signal turn to a green signal, a green signal will
hold for a 20s and if not a green signal only hold for a 10s. A green signal will hold
the that time or extend more than time if sensor 1 from other lanes are not activated.
When the sensor 1 from the other lanes activate, a green signal will turn into a
yellow signal for 2s and then back to red signal. For safety, the other lanes will
change to a green signal after 2s.
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Figure 3.4 Program flowchart

Figure 3.5 shows a sample ladder logic diagram has been constructed for the
lane A. The ladder diagram for the other lanes is similar with this ladder diagram but
the memory for the contacts is different. The address for every traffic signal are
different based on hardware design when wiring the indicator lamp from traffic light
model to output card at PLC cabinet box. The set value of the timer can change for a
desired value based on distance between sensor 1 and sensor 2.
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Figure 3.5 Program ladder diagram

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CHAPTER 4

RESULT & ANALYSIS

4.1 Introduction

This chapter will discusses all the finding results after hardware and software
development. This chapter also includes the analysis from the simulation of this
project and setup configuration for simulation in the real world.

4.2 Input and Output testing

Input and Output of the traffic light could be tested to know either the
address from PLC is similar with the sensor and indicator lamp from hardware or
not. To check the address between PLC and traffic light model is similar with the
wiring diagram made before, a ladder logic diagram from software may testify either
the connection between PLC and sensor and traffic signal are correct. The table 4.1
and 4.2 show the address connection between PLC and input/output on traffic light
model.
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Table 4.1 Input addresses

INPUT ADDRESS
SENSOR 1A 0.12
SENSOR 2A 0.14
SENSOR 1B 0.05
SENSOR 2B 0.06
SENSOR 1C 0.07
SENSOR 2C 0.08
SENSOR 1D 0.09
SENSOR 2D 0.1

Table 4.2 Output addresses

\
OUTPUT ADDRESS
A RED 101.02
A YELLOW 101.01
A GREEN 101
B RED 101.05
B YELLOW 101.04
B GREEN 101.03
C RED 102.02
C YELLOW 102.01
C GREEN 102
D RED 102.05
D YELLOW 102.04
D GREEN 102.03

Figure 4.1 shows the ladder diagram for testing the every input and output of
the system. This figure shows the example to testify input sensor 1A and output A
Red. The indicator lamp A Red will on. By using this ladder diagram all input and
output will be tested.
 30

Figure 4.1 Testing input/output ladder diagram

4.3 Traffic light control system analysis

Since in the beginning, this project objective is to develop a new traffic light
control system and reduce traffic congestion at the junction. At the end, a new traffic
light system is well developed by using two sensors. This sensors is to determine the
traffic volume at the lane when waiting a green signal to go through the junction.
With this sensors the volume of traffic can be determined and the system can choose
a suitable time for green signal once get their turn.

The common traffic light system have fix their time for every signal of traffic
light, it cause the traffic congestion when each lane have a high volume of vehicles.
It also wastes time for waiting at traffic light when the lower volume of traffic at
certain time. The tables 4.3 show the comparison about time between this project
traffic light control system and preset cycle time system.

Table 4.3 Preset Cycle Time lane and phase duration

LANE RED YELLOW GREEN
A 66s 2s 20s
B 66s 2s 20s
C 66s 2s 20s
D 66s 2s 20s
 31

Table 4.3 shows time duration for preset cycle time traffic control system.
This type of traffic light system has fix duration for traffic signal and rotation lane.
So the time for waiting for the next lane to turn green signal is about 22 second to 66
second. If now the lane A get a green signal and then only lane D have a vehicle
waiting at the junction, it must wait for 66 second before the lane D change to a
green signal. This type of traffic light control system is not effective and cost wasted
time and energy. It also causes the traffic congestion when waiting too long at traffic
light junction.

Table 4.4 New traffic light control system phase and lane duration
GREEN
SENSOR SENSOR
LANE RED YELLOW 1 2
A - 2s 10s 20s
B - 2s 10s 20s
C - 2s 10s 20s
D - 2s 10s 20s

Table 4.4 shows time duration for this project development a traffic light
control system. This type of traffic light system is freely changing the lane to the
other lane based on the priority if any of 1st vehicles presence at traffic light
junction. This traffic light system not depends on lane rotation and effective and
reduces time and energy. It effective when the volume of traffic is low at certain
time because the time for a green signal is different depends on volume of traffic at
lane.
 32

4.4 Simulation in the real world.

In order to apply this project traffic light control system, there had some
criterion that had to be determined. Firstly, the situation of traffic condition at
junction. The average volume of traffic at junction must be verified because from
this data we know where sensor 2 will place at that lane. This criterion is very
important because the efficient and effective of this traffic light system depend with
these sensors. The other criterion is time for a green signal on when only sensor 1
activates or sensor 2 also activate. The table 4.5 is the suggestion times for a green
signal depend on distance from sensor 1 to sensor 2.

Table 4.5 Sensor distance

SENSOR SENSOR
DISTANCE 1 2
50M 10s 20s
100M 25s 50s
150M 55s 110s
200M 120s 250s
 33

CHAPTER 5

CONCLUSION AND RECOMMENDATION

5.1 Conclusion

At the end of this project, the traffic light successfully controlled by PLC.
The software and hardware part can operate together without any problem. The
design of ladder logic diagram is based on program flow chart. This intelligent
traffic light control system operate smoothly without any conflict or error coming
from input or output in many condition when running the simulation. It is better
running a simulation of this traffic light control system in the real world to discover
any weakness of this system.
 34

5.2 Recommendation

For the future development, this traffic light controller can be upgrade by
replace the sensor with using any suitable type of vision sensor. It can reduce
applied more sensor because only one sensor enough to detect any distance vehicles
at the lane. It is more accurate to determine a volume of traffics than any type of
sensors use for this project. By using this vision sensor, it easier to apply a fuzzy
logic method on this traffic light control system.

5.2.1 Costing and commercialization

Table 5.1 shows the cost that use for this project.

Table 5.1 Cost of project

Cost per
No Component unit Quantity Total cost
1 Limit switch RM 1.20 8 RM 9.60

This project is very valuable to commercial because the traffic congestion

problem have an effect on our life everyday. In addition, delays due to traffic
congestions also indirectly affect productivity, efficiency and energy losses. This
traffic light controller is new types of highly effective practical traffic light
controllers because this system will decrease the traffic congestion at traffic light.
By applied this traffic light controller the traffic congestion issue can be solved.
 35

REFERENCES

[1] [Link]
Traffic light summary

[2] [Link]/trafficlight
Traffic light: definition

[3] [Link]

[4] John K. Hackworth and Federick D. Hackworth “Programmable logic

controllers: Programming methods & applications

[5] Hugh Jack ”Automating manufacturing system with PLC”

[6] FKEE PLC notes

 [Program Name : Section1]

[Section Name : Section1]

000000
253.13 0.01 101.00 101.01 101.02 AR ON
(000000)
P_On a170 a251 a332
...
Always stop PB AG ON AY ON AR ON

101.03 101.04 101.05 BR ON

a090 a171 a252

...
BG ON BR ON

102.00 102.01 102.02 CR ON

a091 a172 a330

...
CG ON CY ON CR ON

102.03 102.04 102.05 DR ON

a092 a250 a331

...
DG ON DY ON DR ON

0.12 45.01 KEEP

000001
(11)
(000018)
45.00
1A
b026 b033 b040
...
a046 a080 b183
...
a197 b263 a277
...
b343 a357
...
45.02

45.03

TIM003

0.05 45.00 KEEP

000002
(11)
(000025)
45.01
1B
b019 b034 b041
...
b101 a117 b182
...
a198 b262 a278
...
a287 a320
...
45.02

45.03

TIM007
 0.07 45.00 KEEP
000003
(11)
(000032)
45.02
1C
b020 b027 b042
...
b102 a118 b181
...
a199 a207 a240
...
b342 a358
...
45.01

45.03

TIM011

0.09 45.00 KEEP

000004
(11)
(000039)
45.03
1D
b021 b028 b035
...
b103 a119 a127
...
a160 b261 a279
...
b341 a359
...
45.01

45.02

TIM015

45.00 41.03 41.02 41.01 TIM

000005
(000046)
100

#20

a073
41.01 41.02

41.02 41.03 41.01

41.01 41.03
 41.01 41.03 41.02

41.02 41.03

0.00

START

TIM100 KEEP
000006
(11)
(000073)
41.00

a078 b128 b136

...
a139 b144 a147
...
b208 b216 a219
...
b224 a227 b288
...
b296 a299 b304
...
a307
TIM003

40.00 JMP
000007
(04)
(000076)
#1

40.01

41.00

45.00 40.01 KEEP

000008
(11)
(000080)
40.00

a076 a094 a099

...
a109
TIM003

TIM000

0.14 TIM
000009
(000085)
000
2A
#30

a083 a087
...
 TIM000 KEEP
000010
(11)
(000087)
40.01

a077 b081 b095

...
a097 a100 a112
...
TIM003

101.05 102.02 102.05 IL

000011
(02)
(000090)

BR ON CR ON DR ON

000012
40.00 40.01 TIM001 TIM002 TIM070 101.00 AG ON
(000094)
b003
AG ON

40.01 TIM071

40.00 45.01 45.02 45.03

40.01

40.00 TIM
000013
(000109)
001

#120

b096 a115
...
TIM

070

#20

a105
40.01 TIM
000014
(000112)
002

#220

b098 a116
...
TIM

071

#20

a106
TIM001 45.01 40.02
000015
(000115)
a122
 TIM002 45.02

45.03

40.02 TIM
000016
(000122)
003

#20

a023 a074 a082

...
a088
101.01 AY ON

b004
AY ON

000017 ILC
(03)
(000125)

000018 JME
(05)
(000126)
#1

45.03 41.00 41.03 41.02 TIM

000019
(000127)
101

#20

a153
41.02 41.03

41.03 41.00 41.02

41.02 41.00

41.02 41.00 41.03

41.03 41.00

TIM101 KEEP
000020
(11)
(000153)
41.01

a049 b050 a056

...
b057 b062 a158
...
a210 b211 a217
...
b218 b223 a290
...
b291 a297 b298
...
b303
 TIM015

40.09 JMP
000021
(04)
(000156)
#2

40.10

41.01

45.03 40.10 KEEP

000022
(11)
(000160)
40.09

a156 a174 a179

...
a189
TIM015

TIM012

0.10 TIM
000023
(000165)
012
2D
#30

a163 a167
...
TIM012 KEEP
000024
(11)
(000167)
40.10

a157 b161 b175

...
a177 a180 a192
...
TIM015

101.02 101.05 102.02 IL

000025
(02)
(000170)

AR ON BR ON CR ON

000026
40.09 40.10 TIM013 TIM014 TIM073 102.03 DG ON
(000174)
b015
DG ON

40.10 TIM072
 40.09 45.02 45.01 45.00

40.10

40.09 TIM
000027
(000189)
013

#120

b176 a195
...
TIM

072

#20

a186
40.10 TIM
000028
(000192)
014

#220

b178 a196
...
TIM

073

#20

a185
TIM013 45.00 40.11
000029
(000195)
a202

TIM014 45.01

45.02

40.11 TIM
000030
(000202)
015

#20

a044 a154 a162

...
a168
102.04 DY ON

b016
DY ON

000031 ILC
(03)
(000205)
 000032 JME
(05)
(000206)
#2

45.02 41.00 41.03 41.01 TIM

000033
(000207)
102

#20

a233
41.01 41.03

41.03 41.00 41.01

41.01 41.00

41.01 41.00 41.03

41.03 41.00

TIM102 KEEP
000034
(11)
(000233)
41.02

b048 a051
... b054
a064 b065
... a130
b131 a137
... b138
b143 a238
... b289
a292 b295
... a305
b306
TIM011

40.06 JMP
000035
(04)
(000236)
#3

40.07

41.02

45.02 40.07 KEEP

000036
(11)
(000240)
40.06

a236 a254 a259

...
a269
 TIM011

TIM008

0.08 TIM
000037
(000245)
008
2C
#30

a243 a247
...
TIM008 KEEP
000038
(11)
(000247)
40.07

a237 b241 b255

...
a257 a260 a272
...
TIM011

102.05 101.02 101.05 IL

000039
(02)
(000250)

DR ON AR ON BR ON

000040
40.06 40.07 TIM009 TIM010 TIM074 102.00 CG ON
(000254)
b011
CG ON

40.07 TIM075

40.06 45.03 45.01 45.00

40.07

40.06 TIM
000041
(000269)
009

#120

b256 a275
...
TIM

074

#20

a265
 40.07 TIM
000042
(000272)
010

#220

b258 a276
...
TIM

075

#20

a266
TIM009 45.00 40.08
000043
(000275)
a282

TIM010 45.01

45.03

40.08 TIM
000044
(000282)
011

#20

a037 a234 a242

...
a248
102.01 CY ON

b012
CY ON

000045 ILC
(03)
(000285)

000046 JME
(05)
(000286)
#3

45.01 41.00 41.02 41.01 TIM

000047
(000287)
103

#20

a313
41.01 41.02

41.02 41.00 41.01

41.01 41.00
 41.01 41.00 41.02

41.02 41.00

TIM103 KEEP
000048
(11)
(000313)
41.03

b047 b055 a058

...
b063 a066 b129
...
a132 b135 a145
...
b146 b209 a212
...
b215 a225 b226
...
a318
TIM007

40.03 JMP
000049
(04)
(000316)
#4

40.04

41.03

45.01 40.04 KEEP

000050
(11)
(000320)
40.03

a316 a334 a339

...
a349
TIM007

TIM004

0.06 TIM
000051
(000325)
004
2B
#30

a323 a327
...
TIM004 KEEP
000052
(11)
(000327)
40.04

a317 b321 b335

...
a337 a340 a352
...
 TIM007

102.02 102.05 101.02 IL

000053
(02)
(000330)

CR ON DR ON AR ON

000054
40.03 40.04 TIM005 TIM006 TIM077 101.03 BG ON
(000334)
b007
BG ON

40.04 TIM076

40.03 45.03 45.02 45.00

40.04

40.03 TIM
000055
(000349)
005

#120

b336 a355
...
TIM

076

#20

a346
40.04 TIM
000056
(000352)
006

#220

b338 a356
...
TIM

077

#20

a345
TIM005 45.00 40.05
000057
(000355)
a362

TIM006 45.02
 45.03

40.05 TIM
000058
(000362)
007

#20

a030 a314 a322

...
a328
101.04

b008

000059 ILC
(03)
(000365)

000060 JME
(05)
(000366)
#4

000061 END
(01)
(000367)
Nomenclature Section 2-1

CQM1-B7A12
Front View

Indicators (see following table)

B7A Link Terminal connection terminals 1

For connection of a 16-point Input B7A Link Terminal.

External power terminals

Required for transmission with the B7A Link Terminal. Con-
nect a 12- to-24 VDC power supply.

Terminal screws: M3
(Optimum tightening torque: 0.5 N S m)

Indicators Name Color Function

RDY Unit ready Green Lit while the CQM1H/CQM1 is supplied
with power.
ERR Input Red Lit if the B7A Link Terminal for input is
transmission malfunctioning or the B7A Link Terminal
error for input is disconnected.
3ms Transmission Orange Lit while transmission delay time is set
delay time to RAPID (3 ms). Not lit when set to
STANDARD (19.2 ms).
LOAD OFF Transmission Orange Lit while transmission error processing
error is set to LOAD OFF. Not lit when set to
processing HOLD.
15IN+ERR Input mode Orange Lit while input mode is set to 15IN+ERR.
Not lit when set to 16IN.
Nomenclature Section 2-1

CQM1-B7A02
Front View

Indicators (see following table)

B7A Link Terminal connection terminals 1

For connection of a 16-point output B7A Link Terminal.

External power terminals

Required for transmission with the B7A Link Terminal. Con-
nect a 12- to 24-VDC power supply.

Terminal screws: M3
(Optimum tightening torque: 0.5 N S m)

Name Color Function

RDY Unit ready Green Lit while the CQM1H/CQM1 is supplied
with power.
19ms/3ms Transmission Orange Lit while transmission delay time is set
delay time to RAPID (3 ms). Not lit when set to
STANDARD (19.2 ms).

Left-side View
Common to all models.

Operation setting DIP Switch

Sets to the operation of the
B7A Interface Unit (see page
15). Set the switches before
mounting the B7A Interface
Unit in CQM1H/CQM1. To set
after mounting, remove the ter-
minal block and make the set-
ting from the front face.
Switch Settings Section 2-2

2-2 Switch Settings

Remove the terminal block to expose the DIP switch underneath. Refer to the
CQM1H Operation Manual (W363) or the CQM1 Operation Manual (W226) for
the method of removing the terminal block.
Use a thin-tipped object, such as a small screwdriver, to set the pins.

DIP switch

CQM1-B7A21/CQM1-B7A12
Pin no. Setting OFF ON
4 Transmission delay STANDARD (19.2 ms) RAPID (3 ms)
time
3 Transmission error HOLD LOAD OFF
processing
2 Input mode 16IN 15IN+ERR
1 ERR indicator Not lit Lit

Note On delivery from the factory, pin 1 is set ON and all others OFF.
CQM1-B7A03/CQM1-B7A02
Pin no. Setting OFF ON
4 Transmission delay STANDARD (19.2 ms) RAPID (3 ms)
time
3 Not used (set OFF) ––– –––
2 Not used (set OFF) ––– –––
1 Not used (set OFF) ––– –––

Note On delivery from the factory, all pins set OFF.

CQM1-B7A13
Pin no. Setting OFF ON
6 Transmission delay STANDARD (19.2 ms) RAPID (3 ms)
time
5 Transmission error HOLD LOAD OFF
processing
4 Input mode 16IN 15IN+ERR
3 ERR1 indicator Not lit Lit
2 ERR2 indicator Not lit Lit
1 Not used (set OFF) ––– –––

Note On delivery from the factory, pins 2 and 3 are set ON and all others OFF.

! Caution Turn off the CQM1H/CQM1 power before setting the pins.
Switch Settings Section 2-2

Transmission Delay Time Sets the transmission delay time for the B7A Interface Unit.
Setting
Setting Transmission Delay Time
ON RAPID (3 ms)
OFF STANDARD (19.2 ms) (factory setting)

Set the transmission delay time to RAPID to enable transmission with high-
speed B7A Link Terminals with a transmission delay time of 3 ms. Set the trans-
mission delay time to STANDARD to enable transmission with standard B7A
Link Terminals with a transmission delay time of 19.2 ms.
Set the pin to match the transmission delay time of the type of B7A Link Terminal
connected. A transmission error will occur if the setting does not match the trans-
mission delay time of the B7A Link Terminal.
The transmission delay time setting is made for the entire Unit. It is not possible
to make separate settings for each word if multiple words are used.
Transmission Error This setting determines whether the input bit status immediately prior to the error
Processing Setting is held when a transmission error occurs (HOLD) or whether all input bits turn off
(LOAD OFF).
Setting Transmission error processing
ON LOAD OFF
OFF HOLD (factory setting)

Input Mode Setting Set the input mode (the use of bit 15) from the Input B7A Link Terminal to one of
the modes shown in the table below. Match the pin setting to the Input B7A Link
Terminal.
Setting Input mode Description
ON 15-point input + 1 error Bit 15 used as transmission error bit. The
(15IN+ERR) bits available for input are the 15 bits from
00 to 14.
OFF 16-point input (16IN) Bit 15 also used as a normal input bit. The
bits available for input are the 16 bits from
00 to 15. (factory setting)

ERR Indicator Lighting Sets whether the ERR indicator lights when an input transmission error occurs.
Setting
Setting Description
ON ERR indicator lights (factory setting)
OFF ERR indicator does not light

To avoid indicator lighting unnecessarily, set pin OFF if the input side of the B7A
Interface Unit is not used.
 SECTION 3
Connections
This section describes the connections between the CQM1-B7Ajj Interface Units and B7A Link Terminals.

3-1 Connections to B7A Link Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3-1-1 Recommended Cables .............................................. 18
3-1-2 Connecting Terminals .............................................. 18
3-2 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Connections to B7A Link Terminals Section 3-1

3-1 Connections to B7A Link Terminals

3-1-1 Recommended Cables
The B7A Interface Unit can be connected to the input and output B7A Link Termi-
nals using the following cables.

Standard Transmission Delay-time Type

Cabtire Cable Use a VCTF 0.75 x 3 C cabtire cable (100 m max.) if a power supply is shared
and a VCTF 0.75 x 2 C cabtire cable (500 m max.) if power is supplied indepen-
dently.

Rapid Transmission Delay-time Type

Shielded Cable Use a 0.75 x 3 C shielded cable (50 m max.) if a power supply is shared and a
0.75 x 2 C shielded cable (100 m max.) if power is supplied independently.

! Caution If shielded cable is not used for the high-speed transmission delay-time Link Ter-
minal, the transmission distance is not to exceed 10 m regardless of whether
power supply is shared or wired separately.

3-1-2 Connecting Terminals

Connect the input and output B7A Link Terminals to the B7A Interface Unit via
the following terminals using crimp-style terminals used for CQM1H/CQM1 I/O
Units.
CQM1-B7A21

Connect to the SIG terminal of

the output B7A Link terminal.
B0 Word m
A0 Connect to the negative power supply ter-
B1 minal of the output B7A Link Terminal.
A1
B2
Unused
A2 Connect to the SIG terminal of
B3 the input B7A Link Terminal.
A3
Word n
Connect to the negative power supply ter-
minal of the input B7A Link Terminal.

CQM1-B7A13

Connect to the SIG terminal of

the input B7A Link terminal.
B0 Word n
A0 Connect to the negative power supply ter-
B1 minal of the input B7A Link Terminal.
A1
Unused B2
A2 Connect to the SIG terminal of
B3
the input B7A Link Terminal.
A3
Word n + 1
Connect to the negative power supply ter-
minal of the input B7A Link Terminal.
Connections to B7A Link Terminals Section 3-1

CQM1-B7A03

Connect to the SIG terminal of

the output B7A Link terminal.
B0 Word m
A0 Connect to the negative power supply ter-
B1 minal of the output B7A Link Terminal.
A1
B2
Unused
A2 Connect to the SIG terminal of
B3 the output B7A Link Terminal.
A3
Word m + 1
Connect to the negative power supply ter-
minal of the output B7A Link Terminal.

CQM1-B7A12

Connect to the SIG terminal of

the input B7A Link terminal.
B0 Word n
A0 Connect to the negative power supply ter-
B1 minal of the input B7A Link Terminal.
A1
B2
Unused
A2 Unused
B3
A3

CQM1-B7A02

Connect to the SIG terminal of

the output B7A Link terminal.
B0 Word m
A0 Connect to the negative power supply ter-
B1 minal of the output B7A Link Terminal.
A1
B2
Unused
A2 Unused
B3
A3

Connectors Crimp connectors for I/O Unit wiring should be less than 6.2 mm wide (M3), and
the wire should be AWG22 to 18 (0.3 to 0.75 mm2).
Terminal screws should be tightened with a torque of 0.5 N S m.

6.2 mm max. 6.2 mm max.

! Caution Forked crimp connectors are required by UL and CSA standards.

Wiring Section 3-2

3-2 Wiring
Wiring between the B7A Interface Unit, input B7A Link Terminal, and output B7A
Link Terminal sharing a single power supply differs from wiring between Units
using independent power supplies as shown in the following diagrams.

Standard Transmission Delay-time Link Terminal

Single Power Supply

Terminal screws: M3.5

B7A Interface Unit

Terminal screws: M3
B7A Link Terminal
Transmission distance: 100 m max.

B7A Link Terminal

Transmission cable: VCTF 0.75 mm2 min.

+

12 to 24 VDC

Independent Power Supplies

Terminal screws: M3.5

B7A Interface Unit

12 to 24 VDC
Terminal screws: M3 +
B7A Link Terminal
Transmission distance: 500 m max.

12 to 24 VDC
+
B7A Link Terminal

+
Transmission cable: VCTF 0.75 mm2 min.

12 to 24 VDC

Note 1. The transmission distance depends on the type of wiring used.

2. The size of terminal screw differs for the B7A Interface Unit and B7A Link
Terminal. Consider the size of the terminal screws when using crimped ter-
minals.
3. Locate transmission cables away from power cables and high-voltage
cables to eliminate the effects of noise.
Wiring Section 3-2

Rapid Transmission Delay-time Link Terminal

Single Power Supply

Terminal screws: M3.5

B7A Interface Unit

Terminal screws: M3
Transmission distance: B7A Link Terminal
50 m max.

–
Shielded cable:
– Ground 0.75 mm2 min.

B7A Link Terminal

Transmission cable:
+
shielded, 0.75 mm2 min.
Ground

12 to 24 VDC

Independent Power Supplies

Terminal screws: M3.5

B7A Interface Unit
12 to 24 VDC
Terminal screws: M3 +
B7A Link Terminal
Transmission distance:
50 m max.

– Shielded cable:
0.75 mm2 min.
Ground
–

12 to 24 VDC
+
B7A Link Terminal

+
Transmission cable:
shielded, 0.75 mm2 min.
Ground
12 to 24 VDC

Note 1. The transmission distance depends on the type of wiring used.

2. The size of terminal screw differs for the B7A Interface Unit and B7A Link
Terminal. Consider the size of the terminal screws when using crimped ter-
minals.
3. It is recommend that the shield wire be grounded.
4. If shielded cable is not used, the transmission distance is not to exceed 10 m
regardless of whether power supply is common or wired separately (using
VCTF 0.75 mm2 min.).
5. Locate transmission cables away from power cables and high-voltage
cables to eliminate the effects of noise.
Standard Specifications
The standard specifications of the B7A Interface Unit conform to those of the CQM1H/CQM1 PC.

Performance Specifications
Item Specification
I/O points B7A21: 16 input points (see note 1), 16 output points
B7A13: 32 input points (see note 2)
B7A03: 32 output points
B7A12: 16 input points (see note 1)
B7A02: 16 output points
I/O word allocation B7A21: 1 word each for input and output (2 words in total)
B7A13: 2 words for input
B7A03: 2 words for output
B7A12: 1 word for input
B7A02: 1 word for output
Communication method Unidirectional, time-division multiplex
Transmission distance STANDARD: 500 m max.
(see note 3) RAPID: 100 m max.
Transmission delay time STANDARD: 19.2 ms (rated delay), 31 ms max.
RAPID: 3 ms (rated delay), 5 ms max.
Minimum input time STANDARD: 16 ms
(see note 4) RAPID: 2.4 ms
Power consumption 100 mA at 5 VDC
External power supply 12 to 24 VDC ±10% (excluding the power required by the B7A Link Terminals)
B7A21: 0.11 A min.
B7A13: 0.07 A min.
B7A03: 0.10 A min.
B7A12: 0.05 A min.
B7A02: 0.04 A min.
Weight 200 g max.
Dimensions 32 x 110 x 107 (W x H x D) mm

Note 1. Input mode setting allows selection between 16-point input and 15-point+1 error input.
2. Input mode setting allows selection between 32-point input and 30-point+2 error input. Refer to 2-2
Switch Settings.
3. The maximum transmission distance of the B7A Interface Unit varies with the transmission delay time
and the method of wiring. Refer to 3-1 Connections to B7A Link Terminals for details.
4. Minimum input time is the minimum required time to read an input signal from the CPU. The ON/OFF
signal range from the CPU to the B7A Interface Unit’s output bit should be larger than the minimum input
time.
Specifications

Dimensions
These dimensions are the same for all B7A Interface Unit models.

(Unit: mm)
Modular PLC Series CQM1H

General

The SYSMAC CQM1H redefines the modular structure of controllers

with up to 512 inputs and outputs. In contrast to traditional modular
controllers, it does not require a rack that establishes the space
requirements in advance. The individual I/O Units are simply
connected to the CPU Unit and snapped onto the DIN rail.
Programming is carried out via the programming interface and a PC
using the CX−Programmer programming software.
PLC program written for the CQM1 are also compatible with the
CQM1H.
For programming software, see page 434.

Performance Data

CQM1H–CPU11/–CPU21 CQM1H–CPU51 CQM1H–CPU61

Local inputs/outputs 256 512 512

Remote inputs/outputs 224 480 480

Execution time (bit instruction) 0.4 ∝s 0.4 ∝s 0.4 ∝s

Program memory 3.2 kwords 7.2 kwords 15.2 kwords
Data memory 3 kwords 6 kwords 12 kwords

Input interrupts 4 4 4

Time–controlled interrupts 3 (0.5 ms..5 min) 3 (0.5 ms..5 min) 3 (0.5 ms..5 min)
Special I/O Module − 2 slots 2 slots

Networks and Communication

Networks, see page 213
Ethernet (open network) − − −

Controller Link (network) − Yes Yes

Host Link SYSMAC WAY (network) Yes Yes Yes

DeviceNet (open fieldbus) Yes (slave) Yes (slave) Yes (slave)

CompoBus/S (fieldbus) Yes Yes Yes

ASI–Interface (open fieldbus) Yes Yes Yes

PROFIBUS–DP (open fieldbus) Yes (slave) Yes (slave) Yes (slave)

Modular PLC Series CQM1H

Programmable
System Configuration

Logic Contr .
The individual Units of the CQM1H system are plugged in to one
another and secured using 2 locking sliders. The system must be
mounted on a DIN rail.
To make installation easier, the I/O Unit terminal blocks can be
removed.

The following information should be noted when selecting I/O Units:

DIN
CPU type Number of free Max. number of track
I/O* Units*
CQM1H−CPU11/−CPU21 240 (15 words) 11 Power Controller CPU Unit Function End plate
supply Link Unit
CQM1H−CPU51/−CPU61 496 (31 words) 11 Unit Network
Unit
(5+11 with exp.)

* Excluding the 16 transistor inputs integrated into the CPU

I/O expansion
It is possible to expand the CQM1H system by one I/O Unit block
(system) using interface units and a bus cable. This allows a maximum
configuration of 5 I/O Units on the CPU and 11 I/O Units on the
expansion block (system) to be achieved.
The power consumption of all CPU Units may not exceed 3.0 A and
that of the Expansion Block (system) Units may not exceed 2.0 A.

CPU Unit and

max. 5 I/O Units Interface
Unit

Interface Expansion block (system)

Unit max. 11 I/O Units

Special features of the CQM1H CPU

Each CPU has 16 transistor inputs. Four of these inputs can be
configured as interrupt inputs. The response time before the interrupt
subroutine is called up is max. 0.1 ms. Buffer battery
Furthermore, three inputs can be used to connect an encoder as a
high−speed counter input. Pulses of up to 5 kHz are counted. DIP
Each CQM1H CPU can output pulses up to 1 kHz via a Transistor switch
Output Unit.

Memory
Unit

Removable terminal block

Miniature 16 integrated
peripheral transistor inputs
port
RS−232C Slot 2
port Slot 1
for inner boards
Modular PLC Series CQM1H

System Configuration (Continued)

Programmable
Logic Contr .
Inner Boards
A further special feature of the CQM1H CPU51/CPU61 is slots 1 and 2.
Slots 1 and 2 can hold inner boards with various functions. It should be
noted that some inner boards may only be used in slot 1 and others
may only be used in slot 2.

Protocol macro function

The special I/O Module CQM1H−SCB41 with one RS−232C and one
RS−422/485 port supports the protocol macro function.
This function provides a simple method of generating transmission
protocols for other devices, such as a modem, barcode reader or
printer. Using the CX−Protocol software, ASCII character strings can
be assigned to different sequence numbers. The PLC program only
has to call up the sequence number.
The reference data for the response can be automatically filtered.
For CX−Protocol software, see page 438.

CPU Units

CPU Unit Model code CQM1H–CPU11

− Peripheral port Local I/O 256
− 16 built−in transistor inputs
Program memory 3.2 kwords
Data memory 3 kwords
Current consumption 820 mA

CPU Unit Model code CQM1H–CPU21

− Peripheral port Local I/O 256
− RS−232C port
Program memory 3.2 kwords
− 16 built−in transistor inputs
Data memory 3 kwords
Current consumption 820 mA

CPU Unit Model code CQM1H–CPU51

− Peripheral port Local I/O 512
− RS−232C port
Program memory 7.2 kwords
− Controller Link network capable
− Inner boards possible Data memory 6 kwords
16 i t tdt it i t
Current consumption 820 mA

CPU Unit Model code CQM1H–CPU61

− Peripheral port Local I/O 512
− RS−232C port
Program memory 15.2 kwords
− Controller Link network capable
− Inner boards possible Data memory 12 kwords
16 i t tdt it i t
Current consumption 820 mA
Modular PLC Series CQM1H

Specifications (CPU Units)

Designation CQM1H CPU11 CPU21 CPU51 CPU61

CPU integrated I/O 16 inputs 16 inputs 16 inputs 16 inputs

1 circuit 1 circuit 1 circuit 1 circuit
Max. local I/O 256 256 512 512
Max. remote I/O 224 224 480 480
Execution time ms 0.4 0.4 0.4 0.4
Real−time clock Via Memory Module CQM1−M_
Number of I/O Units 11 11 11 11
15 with interface unit 15 with interface unit
Program memory kwords 3.2 3.2 7.2 15.2
Data words kwords 3 3 6 12
Auxiliary relay bits 3808 3808 3808 3808
(words) (238) (238) (238) (238)
Holding relay bits 1600 1600 1600 1600
(words) (100) (100) (100) (100)
Timer/Counter 512 512 512 512

CPU ports − Peripheral: − Peripheral: − Peripheral:

RS−232C switchable RS−232C switchable RS−232C switchable
with DIP switch 7, with DIP switch 7, with DIP switch 7,
RS−422 via adapter RS−422 via adapter RS−422 via adapter
− RS−232C − RS−232C
I/O refresh method Combination of cyclic scan with direct output and Combination of cyclic scan with direct output and
immediate refresh processing methods. immediate refresh processing methods.
Number of instructions 14 basic, 103 special instructions with edge triggered 14 basic, 123 special instructions with edge triggered
execution execution
Special instructions − Pulse output − Floating point arithmetic
− Scaling, SIN/COS − PID control
− I/O refresh − Pulse output
− Interpolation − Scaling
− Macro − ASCII/HEX,SIN/COS
− 7 segment decoder − Interpolation
− 10/16 key scan − Table compare instructions
− Subroutines − Arithmetic
− Indirect addressing − Macro
− 7 segment decoder
− 10/16 key scan
− Subroutine
− I/O refresh
− Indirect addressing
Trace memory − Yes
Data backup Battery Battery
Program backup Battery or Memory Module CQM1H−ME_ Battery or Memory Module CQM1−ME_
(5 years, at 25°C) (5 years, at 25°C)
Program protection Password Password
Pulse output 1 (1 kHz) 1 (1 kHz)
Pulse counter 1 (5 kHz) 1 (5 kHz)

Input interrupts 4 (pulse width 0.1 ms) 4 (pulse width 0.1 ms)
Counter interrupts 3 (1 kHz) 3 (1 kHz)
Time−controlled interrupts 3 (0.5 ms..5 min) 3 (0.5 ms..5 min)
Modular PLC Series CQM1H

General Data (CPU and Power Supply Units)

Programmable
Logic Contr .
Vibration resistance 10..57 Hz, 0.075 mm Amplitude, 57..100 Hz with an acceleration of 1 G in X, Y and Z directions each 10 sweeps of
8minutes
Shock resistance 15 G (12 G for contact outputs) in X, Y and Z directions, 3 times respectively
Temperature Operation 0 °C..55 °C
Storage −20 °C..75 °C (without battery)
Ambient humidity 10%..90% (without condensation)
Atmosphere Controller must not be exposed to the following conditions:
− Corrosive gases
− Severe temperature fluctuations
− Air with an extreme dust and salt content
− Metal filings or metallic dust
− Splash water
− Other chemicals
Degree of protection IEC IP30 (Control cabinet mounting)
Grounding According to EN60204
Insulation resistance 20 M& at 500 VDC, between AC terminal and GR terminal
Dielectric strength 2300 VAC; 50/60 Hz for 1 minute between AC terminal and housing, Leakage current: max. 10 mA
1000 VAC; 50/60 Hz for 1 minute between DC terminal and housing, Leakage current: max. 20 mA
Noise immunity 1500 Vss
Pulse duration 100 ns..1 ∝s
Rise time 1 ns

Memory Module (CPU Units)

The Memory Modules can be used to load the user program to the
PLC. This allows independence from the life of the buffer battery. It
does not represent a memory expansion.
When the PLC power supply is turned on, the content of the Memory
Module is copied to the RAM area.

Memory Module

Memory Modules Description Size Model code

Flash ROM 16 kwords CQM1H–ME16K
− With hardware clock CQM1H–ME16R
EPROM Module Memory Module without IC CQM1–MP08K
− With hardware clock CQM1–MP08R
− EPROM−IC 16 kwords, 150 ns, 27256 ROM–JD–B
32 kwords, 150 ns, 27512 ROM–KD–B
Modular PLC Series CQM1H

Power Supplies

In order to calculate the required output capacity, the power consumption of the Units must be added to the system configuration.

Power supply Model code CQM1–PA203

Input voltage 100..240 VAC, 50/60 Hz
Input voltage range 85..265 VAC, 50/60 Hz
Current Max. 3.6 A

Auxiliary voltage output −

Power supply Model code CQM1–PA216

Input voltage 100..240 VAC, 50/60 Hz
Input voltage range 85..265 VAC, 50/60 Hz
Current Max. 6 A

Auxiliary voltage output 24 VDC, 0.5 A

Power supply Model code CQM1–PD026

Input voltage 24 VDC
Input voltage range 20..28 VDC
Current Max. 6 A

Auxiliary voltage output −

Expansion Units

Interface unit Model code CQM1H–IC101

CPU U it 51/61
Max. 5 I/O Units 3.0 A

Interface unit Model code CQM1H–II101

E i bl k Max. 11 I/O Units 2.0 A

Bus cable Cable length: 0.3 m CS1W–CN313

Cable length: 0.7 m CS1W–CN713

RS–422 port adapter Cable length: 15 cm CQM1H–CIF12

− CQM1H adapter for connection to the
peripheral port
− DIN rail mounting
Modular PLC Series CQM1H

Programming, Accessories and Documentation

Programmable
Logic Contr .
Programming Description Cable length Model code
CX–Programmer. PLC programming software. − WS02–CXPC1–EV3.0
For WINDOWS 95/98/ME/2000/NT4.0−SP5/XP
− see page 434

Programming cable, 2m CS1W–CN226

peripheral port < > PC (RS 232C)
6m CS1W–CN626
DIP switch: no. 7 = ON

Programming consoles Programming console with cable 2m CQM1H–PRO01–E

Programming console without cable for − C200H–PRO27–E

installation in control cabinet door
Cable for PRO27 to CPU 2m CS1W–CN224
Cable for PRO27 to CPU 4m CS1W–CN624

Program copy device Writing of the user program, the PLC 20 cm CPM1–EMU01–V1
configuration, the expanded instruction
set and the data words from DM6144 to
DM6655 on EEPROM, as well as down
loading of EEPROM data in the PLC.
For PLC systems:
CPM and CQM1H
Supported EEPROMs:
Atmel AT28C256
NEC ∝PD28C256
(CS1W−CN114 adapter required)

Accessories, Description Model code

cables etc.
Adapter for miniature peripheral port to peripheral port CS1W–CN114
Connecting cable for relay modules G70A−ZOC16−3 for connection to G79–O_C–_
Output Unit CQM1−OD213
Terminal block for servo drives XW2B–20J6–3B
Spare battery for all CPU types CPM2A–BAT01
End plate with Bus terminal resistor CQM1–TER01
Clamp for DIN rail mounting PFP–M
Front connector, solder terminal, 40−pin C500–CE404
Front connector, crimp terminal, 40−pin C500–CE405
Front connector for ribbon cable, 40−pin C500–CE403

Technical English Product Title Model code

documentation d t ti
CQM1_ Dedicated I/O Units Operation Manual W238–E1
CQM1H−CLK21 Operation Manual W309–E1
Controller Link
CQM1H Operation Manual W363–E1
CQM1H Programming Manual W364–E1
CQM1H−SCB41 Communications W365–E1
CompoBus/S Operation Manual W266–E1
DeviceNet Operation Manual W267–E1
AS−Interface Operation Manual W357–E1
Modular PLC Series CQM1H

Dimensions (mm)

CPU Units
Front view Side view End plate with
Bus terminal
resistor
2

110 115.7

120 107
13.5

Power supply units

CQM1−PA203 CQM1−PA216 CQM1−PD026
W A B Model code
53.5 110 115.7 CQM1−PA203
85.5 110 115.7 CQM1−PA216
AB A B AB
85.5 110 115.7 CQM1−PD026

W W W

I/O Units
With terminal 2 With connector
block

110 115.7

107
32
approx. 140
Modular PLC Series CQM1H

Communication Examples

Programmable
Logic Contr .
CQM1H–CPU11/21 CQM1H–CPU51/61 Inner boards
CQM1H–SCB41
SYSMAC WAY (network) Yes Yes Yes
Active RS–232C Yes Yes Yes + Protocol macro function

1:1 CPU Link Yes Yes Yes

1:1 NT Link Yes Yes Yes

1:n NT Link − − Yes

SYSMAC WAY
SYSMAC WAY communicates via the RS−232C or
RS–232C port
RS−422 port and contains the open, OMRON−
specific ASCII protocol called Host Link.
By default, the CQM1H communication port runs in
Host Link slave mode and can therefore be easily
operated from a PC, a supervisory controller or CQM1H
Miniature peripheral PC
HMI. port
The CQM1H CPU11 does not have an RS−232C
port.
CS1W−CN226

Up to 32 Host Link slaves can be integrated into a

SYSMAC WAY network via RS−422 ports.
RS−422 cable

CQM1H +
CQM1H−SCB41 CS1 +
or CS1W−SCB41
CQM1H−CIF12

CJ1 +
CJ1W−SCU41

CPM1 +
CPM1−CIF11
Modular PLC Series CQM1H

Communication Examples (Continued)

Active RS–232C
The CQM1H’s ports can be switched to active RS−232C cable
RS−232C mode by the Host Link slave.
Transmit, Receive and Protocol macro instructions
can be used to send and receive ASCII character Modem
strings. Peripherals such as modems, printers or CQM1H
barcode readers can be integrated.

Printer

Barcode reader

Temperature control

1:1 CPU Link

Via the 1:1 CPU Link, up to 64 words can be RS−232C cable
continuously exchanged between two PLC CPU
Units without any programming effort, by means of
a peripheral or RS−232C port.
CQM1H CQM1H

CPM2C

CPM1A

1:1 NT Link
Various programmable terminals, from function RS−232C cable
keys to graphics−capable, touch−screen colour
terminals, are available to the user as a human/
machine interface.
Data is exchanged very efficiently between a CQM1H
programmable terminal and the PLC via the 1:1 NT OMRON
Link protocol. programmable terminal

1:n NT Link
Several NT series control terminals can be RS−422 cable
connected to the CQM1H series via an RS−422
network.

CQM1H +
CQM1H−SCB41 OMRON
programmable terminal
NT631_, NT31_ direct

OMRON
programmable terminal
NT20S, NT600S, NT620_
via NT−AL001
Modular PLC Series CQM1H

Application Examples

Programmable
Logic Contr .
2 Axes positioning
The two pulse outputs in the special I/O Module CQM1H−PLB21 can output pulses at up to 50 kHz.
This allows 2 axes positioning tasks to be triggered when used in conjunction with a servo or stepper motor.

CQM1H−CPU61 + XW2Z−_J−B5
CQM1H−PLB21

SmartStep SmartStep
Servomotor X

XW2Z_J−A3
X counter−
clockwise limit
X

XW2Z−_J−B5

Y
X origin point
XW2B−20J6−3B

X clockwise
Servomotor Y
limit

24 VDC
Emergency
stop
Y clockwise Y origin Y counter−
limit point clockwise limit

Absolute encoding
The optional inner board CQM1H−ABB21 has two Station 3 Station 2 Station 1
inputs for absolute value encoders, e.g. to
determine the absolute position of a rotary table.
When defined positions are reached, working
processes can be started.

Servo drive

CQM1H−CPU61 +
CQM1H−ABB21
Servomotor

Rotation angle
transmitter
Modular PLC Series CQM1H Inner Boards Overview

Overview of Optional Inner Boards (for CPU51, CPU61 only)

Communication CPU slot Description Model code Page

Analogue I/O Modules Only slot 2 4 analogue inputs: −10..10 VDC, 0..10 VDC, 0..20 mA CQM1H–MAB42 82
2 analogue outputs: −10..10 VDC, 0..20 mA
Slot 1 or Four built−in potentiometers: Range 0..200 BCD CQM1H–AVB41 82
Slot 2

Communication Only slot 1 One RS−232C and one RS−422/485 port CQM1H–SCB41 83
Protocol macro function

Pulse I/O Modules Slot 1 and Four high−speed counter inputs: max. 500 kHz CQM1H–CTB41 84
Slot 2
Only slot 2 Two high−speed counter inputs: max. 50 kHz CQM1H–PLB21–CE 84
Two pulse outputs: max. 50 kHz
Only slot 2 Two absolute encoder inputs CQM1H–ABB21 84
8, 10 and 12 bit Gray code

Analogue I/O Module Model code CQM1H–MAB42

− Plugs into slot 2 only Number of analogue inputs 4 inputs
Number of analogue outputs 2 inputs
Inputs
− Range per input 0..10 VDC, −10..10 VDC, 0..5 V
0..20 mA
− Resolution 1/4096 of full scale (12 bit)
− Conversion time Max. 6.8 ms for all inputs
− Precision ±0.5% at 23 °C
− Input impedance Voltage: 1 M&
Current: 250 &
Outputs
− Range per output −10..10 VDC
0..20 mA
− Resolution (voltage) 1/4096 of full scale (12 bit)
− Conversion time Max. 3.4 ms for all outputs
− Precision ±0.5% at 23 °C
− Load resistor Voltage: min. 2 k&
− Resolution (current) Current: max. 350 &
1/2047 of full scale (11 bit)
Internal power consumption 250 mA

Analogue setting module Model code CQM1H–AVB41

− Plugs into slot 1 or Number of potentiometers 4
slot 2
− One module possible Range for PLC address 0..200 BCD
Internal power consumption 10 mA
Modular PLC Series CQM1H Inner Boards

Inner Boards (Continued)

Programmable
Logic Contr .
Communication module Model code CQM1H–SCB41
− Plugs into slot 1 only Number of ports One RS−232C and
One RS−422A/485
RS−232C port
− Transmission method Half duplex, 1:1
− Transmission rate Max. 19.6 Kbps
− Media length Max. 15 m
RS−422A/485 port
− Transmission method Half duplex, 1:n
− Transmission rate Max. 19.6 Kbps
− Media length Max. 500 m
Protocols for each port Host Link, ASCII, 1:1 CPU Link
1:1 NT Link, 1:n NT Link (n = 1..8)

Protocol macro function Communications sequences can be de

fined using the CX−Protocol software.
− Number of protocols Max. 20
− Number of sequences Max. 1000
− Available protocols CompoWay/F Master, E5_K, E5ZE,
E5_J, 3Z4L, V600/620
F200, F300, F350, Hayes Modem
Internal power consumption 200 mA

Protocol Macro function In the CQM1H−SCB41 communication modules, the data is processed via the protocol
macro function, whereby the individual communication sequences are triggered by the
PLC using the PMCR instruction.

C200HE/HG/HX
PC

CX−Protocol Devices from other

software manufacturers

Communication module

Asynchronous communication (start/stop synchronisation)

Image processing Temperature Intelligent Barcode RFID systems Modems

systems control signal processors scanners

Programming (Communication Modules)

Programming Description Model code

CX–Protocol. Programming software for Protocol Macro. WS02–PSTC1–E
For WINDOWS 95/98/ME/2000/NT4.0/XP
− see page 438
Modular PLC Series CQM1H Inner Boards

Inner Boards (Continued)

High–speed counter module Model code CQM1H–CTB41

− Plugs into slot 1 or slot 2 Number of high−speed counters 4
− Two modules possible
Input frequency
− Pulse direction mode Max. 500 kHz
− Phase differential Max. 250 kHz
(for encoder phases A, B and Z)
Input signal 24 VDC or RS−422A line driver
Input range
− Linear counter mode −8,388,608..8,388,607 BCD
− Ring counter mode 0..64,999 BCD
Counter reset Hardware or software
Evaluation of actual counter value
− Target value interrupts 48 target values
− Range interrupts 8 ranges
Number of digital outputs 4
− Circuitry PNP or NPN
− Switching capacity 4.5 VDC/16 mA..26.5 VDC/80 mA
− Response time after target value or 1.5 ms
range interrupt triggering
Internal power consumption 400 mA

Pulse I/O Module Model code CQM1H–PLB21–CE

− Plugs into slot 2 only Number of high−speed counters 2
− 2 axes positioning
Number of pulse outputs 2

For terminal blocks, see page 465 Specification of high–speed counters

Input frequency
− Pulse direction mode Max. 50 kHz
− Phase differential mode Max. 25 kHz
(for encoder phases A, B and Z)
Input signal 12 VDC or 24 VDC
Input range
− Linear counter mode −8,388,608..8,388,607 BCD
− Ring counter mode 0..64,999 BCD
Counter reset Hardware or software
Evaluation of actual counter value
− Target value interrupts 48 target values
− Range interrupts 8 ranges
Specification of pulse outputs
Pulse output frequency Max. 50 kHz
− Signal direction Clockwise or counter−clockwise (CW/
CCW)
− Pulse width modulation 0..100% at output frequency
91.6 Hz, 1.5 kHz and 5.9 kHz
Circuitry NPN transistor
Switching capacity 5..24 VDC, 30 mA
Functions Pulse number and frequency
Frequency increase and reduction
Internal power consumption 160 mA

Absolute encoder module Model code CQM1H–ABB21

− Plugs into slot 2 only Number of absolute encoder inputs 2
Input frequency Max. 4 kHz

Input signal 24 VDC, binary Gray code, 8, 10, 12 bit

Input range BCD or 360° mode
Zero offset compensation Offset setting
Evaluation of actual encoder value
− Target value interrupts 48 target values
− Range interrupts 8 ranges
Internal power consumption 150 mA
Modular PLC Series CQM1H Unit Overview

Overview of Expansion Units

Programmable
Logic Contr .
I/O type Description Model code Page

Digital Input Units 8 DC inputs 12..24 VDC, 8 circuits, 1 input each CQM1–ID211 86
16 DC inputs 24 VDC, 1 circuit, 16 inputs CQM1–ID212 86
32 DC inputs 24 VDC, 1 circuit, 32 inputs in 4 groups CQM1–ID213 86
8 AC inputs 100..120 VAC, 1 circuit, 8 inputs CQM1–IA121 *1
8 AC inputs 200..240 VAC, 1 circuit, 8 inputs CQM1–IA221

Digital Output Units 8 relay 250 VAC, 2 A, 8 circuits, 1 output each CQM1–OC224 87
Total switching capacity: 2 A per circuit
16 relay 250 VAC, 2 A, 1 circuit, 16 outputs CQM1–OC222 87
Total switching capacity: 8 A per circuit
8 transistor, 24 VDC, 1 A, 1 circuit, 8 outputs CQM1–OD215 87
PNP Total switching capacity: 4A per circuit
16 transistor 24 VDC, 0.3 A, 1 circuit, 16 outputs CQM1–OD214 88
PNP Total switching capacity: 4.8 A per circuit
32, transistor, 24 VDC, 0.5 A, 1 circuit, 32 outp. in 4 groups CQM1–OD216 88
PNP, short circuit Total switching capacity: 5 A per circuit
protection
8 triac 100..240 VDC, 0.4 A, 2 circuits, 4 outputs each CQM1–OA221 *1
Total switching capacity: 1.2 A per circuit
8 transistor, 24 VDC, 2 A, 1 circuit, 8 outputs CQM1–OD211
NPN, short circuit Total switching capacity: 5 A per circuit
protection
16 transistor, 24 VDC, 0.3 A, 1 circuit, 16 outputs CQM1–OD212
NPN Total switching capacity: 4.8 A per circuit
32 transistor, 24 VDC, 0.1 A, 1 circuit, 32 outp. in 4 groups CQM1–OD213
NPN Total switching capacity: 3.2 A per circuit

Safety Units 1 or 2 channels Control class 4 to EN 954−1 CQM1–SF200 89

4 DC inputs 24 VDC, 1 circuit, 4 inputs (PLC)
2 NO contacts 250 VAC, 5 A safety contacts

Analogue Input Unit 4 or 2 inputs −10..+10 V, 0..10 V, 0..20 mA, CQM1–AD042 90

12 bit resolution

Analogue Output Unit 2 outputs −10..+10 V, 0..20 mA, CQM1–DA022 90

12 bit resolution for voltage output
11 bit resolution for current output

Temperature Controller 4 loops Thermocouple sensor, transistor output, PNP CQM1–TC202 90

Unit
4 loops Pt100 sensor, transistor output, PNP CQM1–TC302 90
2 loops Thermocouple sensor, transistor output, PNP, CQM1–TC204 90
heating current monitoring
2 loops Pt100 sensor, transistor output, PNP, CQM1–TC304 91
heating current monitoring
4 loops Thermocouple sensor, transistor output, NPN CQM1–TC201 *2
4 loops Pt100 sensor, transistor output, NPN CQM1–TC301
2 loops Thermocouple sensor, transistor output, NPN, CQM1–TC203
heating current monitoring
2 loops Pt100 sensor, transistor output, NPN, CQM1–TC303
heating current monitoring
Communication Units 32 nodes Controller Link (CLK), industrial network CQM1H–CLK21 91
Bus length max. 1 km
16 input bits I/O Link Unit CQM1–DRT21 92
16 output bits DeviceNet
64 inputs and Fieldbus master (CompoBus/S) CQM1–SRM21–V1 92
64 outputs Bus length 500 m
128 input bits I/O Link Unit CQM1–PRT21 92
128 output bits PROFIBUS−DP
31 Bus Modules AS−Interface master (open Fieldbus standard) CQM1–ARM21 92
Bus length 100 m
* Information on these Units can be found in the technical manuals:
1 = W363−E1−2
Modular PLC Series CQM1H Units

Digital Input Units

Digital Input Units Model code CQM1–ID211

− With 8 inputs Inputs 8 DC inputs
8 circuits, 1 input each
Connection method Screw terminal connectors
Status display LED
Internal power consumption 50 mA, 5 VDC

Specification for DC inputs Input voltage 12..24 VDC (10.2..26.4 VDC)

ON level Min. 10.2 V
OFF level Max. 3.0 V

Input impedance 2.4 k&

Input current 10 mA at 24 V
ON/OFF delay 8 ms (adjustable 1..128 ms)

Digital Input Unit Model code CQM1–ID212

− With 16 inputs Inputs 16 DC inputs
1 circuit, 16 inputs
Connection method Screw terminal connectors
Status display LED
Internal power consumption 85 mA, 5 VDC

Specification for DC inputs Input voltage 24 VDC (20.4..26.4 VDC)

ON level Min. 14.4 V
OFF level Max. 5.0 V

Input impedance 3.9 k&

Input current 6 mA at 24 V
ON/FF delay 8 ms (adjustable 1..128 ms)

Digital Input Unit Model code CQM1–ID213

− With 32 inputs Inputs 32 DC inputs
− Front connector is not included in 1 circuit, 32 inputs
the delivery package
− Prefabricated cable and terminal Connection method 1 piece, 40−pin connector
blocks, see page 465 Status display LED
Internal power consumption 170 mA, 5 VDC

Specification for DC inputs Input voltage 24 VDC (20.4..26.4 VDC)

ON level Min. 14.4 V
OFF level Max. 5.0 V

Input impedance 5.6 k&

Input current 4 mA at 24 V
ON/OFF delay 8 ms (adjustable 1..128 ms)
Modular PLC Series CQM1H Units

Digital Output Units

Programmable
Logic Contr .
Digital Relay Output Unit Model code CQM1–OC224
Outputs 8, relay
8 circuits, 1 output each
Total switching capacity 2 A per circuit
Connection method Screw terminal connectors
Status display LED
Internal power consumption 440 mA, 5 VDC

Model code CQM1–OC222

Outputs 16, relay
1 circuit, 16 outputs
Total switching capacity 8 A per circuit
Connection method Screw terminal connectors
Status display LED
Internal power consumption 850 mA, 5 VDC

Specification for relay outputs Switching capacity 250 VAC, 2 A (cos∏=1) R load
250 VAC, 2 A (cos∏=0.4) L load
maximum 24 VDC, 2 A
minimum 10 mA, 5 VDC
Relay life electrical 300,000 operations, R load
100,000 operations, L load
mechanical 50,000,000 operations
ON delay Max. 15 ms
OFF delay Max. 5 ms

Digital Transistor Output Unit Model code CQM1–OD215

− with 8 outputs Outputs 8, transistor, PNP
1 circuit, 8 outputs
Total switching capacity 4 A per circuit
Connection method Screw terminal connectors

Status display LED

Internal power consumption 110 mA, 5 VDC
External power supply Min. 26 mA (20.4..26.4 VDC)

Specification for transistor outputs Switching capacity 24 VDC, 1 A

Leakage current
0.1 mA max .
Residual voltage 0.2 V max.
ON delay Max. 0.2 ms
OFF delay Max. 0.8 ms
Short−circuit protection 1.6..2.0 A electronic, transistor PNP,
indicator output per 4 outputs
Reset 24 VDC input per 4 outputs
Modular PLC Series CQM1H Units

Digital Output Units (Continued)

Digital Transistor Output Unit Model code CQM1–OD214

− With 16 outputs Outputs 16, transistor, PNP
1 circuit, 16 outputs
Total switching capacity 4.8 A per circuit
Connection method Screw terminal connectors
Status display LED
Internal power consumption 170 mA, 5 VDC
External power supply Min. 60 mA, 20.4..26.4 VDC
Specification for transistor outputs Switching capacity 24 VDC, 0.3 A

Leakage current 0.1 mA max.

Residual voltage 0.8 V max.
ON delay Max. 0.1 ms
OFF delay Max. 0.4 ms
Short−circuit protection 3.5 A fuse per 8 outputs

Digital Transistor Output Unit Model code CQM1–OD216

− With 32 outputs Outputs 32, transistor, PNP
− Front connector is not included in 1 circuit, 32 inputs in 4 groups
the delivery package
− Prefabricated cable and terminal Total switching capacity 5 A per circuit
blocks, see page 465. Connection method 1 piece, 40−pin connector
Status display LED
Internal power consumption 240 mA, 5 VDC
External power supply Min. 160 mA, 20.4..26.4 VDC

Specification for transistor outputs Switching capacity 24 VDC, 0.5 A

Leakage current 0.1 mA max.

Residual voltage 0.8 V max.
ON delay Max. 0.1 ms

OFF delay Max. 0.3 ms

Short−circuit protection 7 A fuse per group
Modular PLC Series CQM1H Units

Safety Unit

Programmable
Logic Contr .
Safety Unit Model code CQM1–SF200
− Conforms to EN954−1 and Inputs (emergency stop) 1 or 2 channels
EN60204−1 up to control
gy Input current Max. 75 mA
category 4
Inputs (PLC) 4 DC inputs
1 circuit, 4 inputs
Connection method Screw terminal block connector
Status display LED
Internal power consumption 50 mA, 5 VDC
External power supply 70 mA, 10.2..26.4 VDC

Specification for DC inputs Input voltage 24 VDC (20.4..26.4 VDC)

ON level Min. 14.4 V
OFF level Max. 5 V

Input impedance 4 k&

Input current 6 mA at 24 V
ON/OFF delay 8 ms (adjustable 1..128 ms)
Specification for relay outputs Switching capacity maximum 250 VAC, 5 A (cos∏=1) R load
− Controlled by safety circuit minimum 1 mA, 5 VDC
Relay life electrical 100,000 operations, R load
mechanical 5,000,000 operations
ON delay Max. 300 ms
OFF delay Max. 10 ms

Application Example
CQM1H–SF200/CS1W–SF200
Emergency stop circuit
− 2 channel
− With cross fault detection S1
− With earth detection 11 21 K1 K2 K3
− Redundancy inputs A1
PLC
Input
− Manual start (release)/Stop 12 22
− 2 safety circuits A2
(category 4) Display
T11

K1 PWR
S1: Emergency stop switch T12
K3 K1

A22E
Redunda n t circ uit

S2: Start
Start
A22 S2 S2 Display
Output Unit

K2
KM1/KM2: J7K contactor B1 K1
CPU Unit

K3 K2
KM3: Soft starter T21
G3J
T22
EN 418
K1 Display
Y1
KM1 KM2 K3
K2
K1 K2
X1

K1 K2 K3
13
KM1
14
K1 K2 K3
23
KM2

24
Modular PLC Series CQM1H Units

Analogue I/O Units

Analogue Input Unit Model code CQM1–AD042

− With 4 or 2 inputs Number of analogue inputs 4 or 2
− Input range, can be set separately Number of reserved words 4 or 2 (64 or 32 I/O bits)
for each input
Range per input (separately adjustable)
− Removable terminal block
Voltage −10..+10 V; 0..10 V, 0..5 V
Current 0..20 mA
Input resistance
Voltage 1 M&
Current 250 &
Resolution 12 bits (1/4096)
Deviation ±0.5% (25°C); ±1% (0°..55 °C)
Max. input signal
Voltage ±15 V
Current ±30 mA
Conversion time 1.2 ms per input
Data refresh every 10 ms
Potential isolation Photocoupler
Internal power consumption 170 mA, 5 VDC

Analogue Output Unit Model code CQM1–DA022

− With 2 outputs Number of analogue inputs 2
− Output range, separately adjusta Number of reserved words 2 (32 I/O bits)
ble for each input
Range per output (separately adjustable)
− Removable terminal block
Voltage −10..+10 V
Current 0..20 mA
Load resistance limit values for
Voltage Min. 2 k&
Current Max. 350 &
Resolution 12 bits
Voltage 1/4096
Current 1/2048
Deviation ±1%
Conversion time 0.5 ms (both inputs)
Potential isolation Photocoupler
Internal power consumption 340 mA

Temperature Controller Unit

Temperature Controller Unit Model code CQM1–TC202

− LED status display Number of loops 4
− 1 input word
− 1 output word Measuring sensor Thermocouples
− Data transfer with IOTC instruction Output Transistor, PNP
(CQM1H only)
Connection method Screw terminal connectors

Model code CQM1–TC302

Number of loops 4
Measuring sensor Pt100
Output Transistor, PNP
Connection method Screw terminal connectors

Model code CQM1–TC204

Number of loops 2
Measuring sensor Thermocouples
Output Transistor, PNP
Connection method Screw terminal connectors
Type of monitoring Heater current
Modular PLC Series CQM1H Units

Temperature Controller Units (continued)

Programmable
Logic Contr .
Model code CQM1–TC304
Number of loops 2
Measuring sensor Pt100
Output Transistor, PNP
Connection method Screw terminal connectors

Type of monitoring Heater current

Thermocouple inputs Sensor types K, J, T, L, R, S, B

Precision 0.3% of set value or 1°C,
whichever is larger than a maximum of
+1 digit

Pt100 inputs Sensor types Pt, JPt

Precision 0.3% of set value or 0.8°C,
whichever is larger than a maximum of
+1 digit
Control loop Control type ON/OFF, PID and manual mode
Hysteresis (ON/OFF) 0.1..999.9 °C/°F
Proportional band 0.1..999.9 °C/°F
Integral time (reset time) 0..3999 s
Differential time (rate time) 0..3999 s
Output in manual mode 0..100.0%
Control cycle 1..99 s
Scanning period 500 ms
Output refresh 500 ms

Transistor outputs Circuitry PNP

External supply 24 VDC (20.4..26.4 VDC)
Switching capacity 24 VDC, 100 mA
Leakage current Max. 0.1 mA

Residual voltage Max. 0.8 V

Power demand Internal power consumption 5 V, 190 mA

Alarm function Heater current detection Max. 5 A, AC

Display accuracy 5% of minimum value x 1 place

Signal threshold 0.1..49.9 A

Min. detectable ON time 200 ms

Communication Units

Controller Link the industrial network for the manufacturing cell

Controller Link Unit Model code CQM1H–CLK21
− 2−wire connection
Connection method Screw terminals
Status display LED
Internal power consumption 290 mA, 5 VDC
Max. number of units per CPU 1
Suitable CPU types CQM1H−CPU51/61

For further information about “Controller Link” see page 221.

Modular PLC Series CQM1H Units

Communication Units (Continued)

DeviceNet open fieldbus

DeviceNet Unit Model code CQM1–DRT21
− I/O Link function Number of I/O points per unit 32
− Screw terminal block connector is maximum 96/160
not included in the delivery
package Status display LED
Connection method Screw terminal block connector
Internal power consumption 80 mA, 5 VDC
External power supply 40 mA, 11..25 VDC
Max. number of units per CPU 3 (CPU11/21), 5 (CPU51/61)

For further information about “DeviceNet” see page 231

CompoBus/S a high−speed fieldbus for 128 inputs and 128 outputs

CompoBus/S Master Unit Model code CQM1–SRM21–V1
− Supports high−speed mode and Number of inputs/outputs Adjustable via DIP switch:
Long−distance mode 128 (64 inputs and 64 outputs)
− No parameter settings required. 64 (32 inputs and 32 outputs)
Communication cycle time: 32 (16 inputs and 16 outputs)
1 ms in high−speed mode
Number of Bus Modules Max. 32
Number of units per CPU Max. 3 (CPU11/21), 5 (CPU51/61)

Current consumption 180 mA, 5 VDC

For further information about “CompoBus/S”, see page 256

PROFIBUS−DP open fieldbus standard

PROFIBUS–DP I/O Link Unit Model code CQM1–PRT21
Number of inputs/outputs (selectable) 32+32..128+128
Number of reserved I/O words 2+2..8+8
CQM1H all (8+8 with CPU51/61 only)
Current consumption 350 mA, 5 VDC
Bus and unit status display LED
Bus status message 24 VDC, 2 A, relay

Data exchange with CPU Max. 0.16 ms

Accessories GSD file on disk

For further information about “PROFIBUS–DP”, see page 264

AS−Interface − standard fieldbus direct for components

AS Interface Master Unit Model code CQM1–ARM21
− ASi, open fieldbus standard Number of reserved words Min. 6
− Installation using Max. 16 (adjustable)
cutter technique
Transmission medium Special ribbon cable
− Slave modules have IP67
− Bus length max. 100 m Number of Bus Modules Max. 31 (4 bits IN + 4 bits OUT each)

Number of units per CPU Max. 1 (CPU11/21), 2 (CPU51/61)

Communication cycle time 5 ms (with 31 Bus Modules)
Current consumption 300 mA

For further information about “AS–Interface” see page 267