YASKAWA CP-9200SH/CPU Programmable Controller

YASKAWA CP-9200SH/CPU Programmable Controller

Product Core Overview

As the core control unit of the CP-9200SH series, CP-9200SH/CPU adopts standardized modular design and can seamlessly integrate with various digital I/O modules (such as CP-317, DO-01), analog modules, and dedicated functional modules within the series, flexibly constructing a complete industrial control system. This controller integrates a high-speed computing core and rich communication interfaces, with powerful logical operations, timing control, and data processing capabilities. It can accurately execute control programs written in various programming languages such as ladder diagrams and SFC. Its core positioning is to serve as the "brain" of industrial control systems, receiving signals from various sensors and input modules, generating control instructions through logical operations, driving output modules and external actuators, and achieving collaborative linkage with other controllers and upper level machines through dedicated communication protocols, supporting the stable operation of medium and large-scale distributed control scenarios.

From the perspective of product series correlation, CP-9200SH/CPU is the core hub of CP-9200SH series, forming a complete "control execution interaction" system with I/O modules and communication modules within the series. It is also compatible with the communication logic of Yaskawa MP series products (such as MP920, MP2300), and relies on the extended Memobus protocol to achieve collaborative communication across series products. It not only has the ability to independently complete the control of small and medium-sized control systems, but also can be expanded through multi CPU networking to adapt to large-scale distributed control requirements. A single upper monitoring unit (such as GP series human-machine interface) can connect up to 31 CP-9200SH/CPUs, forming a multi node collaborative control network, greatly improving the system's scalability and redundancy backup level.

Typical application scenarios

CP-9200SH/CPU, with its efficient computing capability, flexible networking characteristics, and stable industrial grade performance, is widely used in various medium and large-scale industrial automation scenarios, becoming the core hub for implementing complex control logic and multi device collaboration. The following are several typical application cases:

1. Automotive manufacturing industry: Welding and stamping line control

In the automotive welding workshop, a multi CP-9200SH/CPU networking architecture is adopted, with each CPU responsible for controlling a welding station, and multi CPU collaboration is achieved by extending the Memobus protocol. The controller receives temperature and current signals from the welding sensor, and after logical operation, issues precise welding control instructions to drive the welding solenoid valve and clamping cylinder to operate; Simultaneously achieve centralized monitoring of multiple workstations through the upper computer, and synchronize the operating status of each workstation in real-time. This solution utilizes multi CPU distributed control to ensure synchronous actions of over 200 welding actuators, with a synchronization error of ≤ 5ms. The welding process qualification rate has increased from 99.2% to 99.8%, and the equipment failure rate has been reduced by 60%.

2. New energy industry: production of lithium battery separators

On the lithium battery separator production line, CP-9200SH/CPU serves as the core controller, connecting tension sensors, temperature sensors, and multiple expansion I/O modules. The controller collects key data such as diaphragm tension and production temperature in real time through an analog module, generates tension adjustment instructions after calculation, drives the magnetic powder brake and tension adjustment solenoid valve to operate, and achieves precise gradient control of taper tension; At the same time, the production data is uploaded to the upper monitoring system through the communication interface to achieve full traceability of the production process. After applying the controller, the fluctuation of diaphragm thickness decreased from ± 1.5 μ m to ± 0.3 μ m, the A-level product rate increased from 92% to 99.5%, and the annual income increased by over 20 million yuan.

3. Port logistics industry: remote monitoring of intelligent lifting equipment

In the intelligent scheduling system of automated port terminals, a distributed network of multiple CP-9200SH/CPUs is used, responsible for different tasks such as stacker crane control, lifting equipment control, and warehouse management. Each CPU achieves data exchange by extending the Memobus protocol, and cooperates with the upper central control system to complete the full process collaboration of cargo loading, unloading, transportation, and warehousing; The controller collects real-time signals such as the position of the stacker crane and the load of the lifting equipment, accurately drives the actions of the actuators such as lifting and translation, and simultaneously sends the equipment status back to the central control room in real time. After applying this solution, the efficiency of warehousing operations has been improved by 25%, the error rate of cargo handling has been reduced to below 0.01%, and the time for a single ship to be in port has been shortened by 4 hours.

4. Metal processing industry: Hot rolling and cold rolling control

In the steel rolling workshop (such as Baosteel's 1580mm hot rolling production line), CP-9200SH/CPU is responsible for the core tasks of controlling the speed of strip steel transportation and correcting deviation. The controller collects the speed signal of the strip steel conveyor through the high-speed counting module, receives the deviation sensor signal through the input module, and issues speed adjustment and deviation correction commands after logical operation, driving the roller conveyor motor contactor and deviation adjustment solenoid valve to act; Its industrial grade design that is resistant to high temperatures and electromagnetic interference ensures stable operation in environments with high temperatures of 70 ℃ and strong electromagnetic interference. Practical application shows that this solution can reduce the deviation of strip steel from ± 15mm to ± 3mm, directly reduce the scrap rate by 18%, and reduce annual economic losses by 15 million yuan.

Appearance structure and installation specifications

1. Appearance and interface layout

CP-9200SH/CPU adopts a rectangular modular structure, with a high-strength engineering plastic shell and clear status indicator and interface areas on the surface. The status indicator area includes power lights, operation lights, fault lights, and communication status lights, which can intuitively reflect the overall operation status, fault situation, and network communication status of the controller, making it easy for operation and maintenance personnel to quickly troubleshoot problems; The interface area clearly distinguishes between power interface, bus expansion interface (used to connect expansion modules), communication interface (RS-232C/RS-485), and debugging interface. The interface is designed with dust-proof protection to reduce dust damage to the interface; The bottom is equipped with a 35mm guide rail installation slot and fixing screw holes that comply with DIN46277 standard, suitable for two installation methods, making it easy to install and maintain intensively in industrial control cabinets.

2. Installation environment requirements

To ensure stable operation of the module, the installation environment must meet the following requirements:

-Environmental conditions: Installed in a dry, clean, and ventilated environment, avoiding dust, moisture, corrosive gases, and severe vibrations; The working temperature range is usually -10 ℃~60 ℃, and the relative humidity is ≤ 85% (no condensation); If the ambient temperature exceeds 50 ℃, a forced fan or cooling fan should be equipped, but avoid blowing cold air directly towards the module.

-Anti interference requirements: Keep away from high-voltage equipment, power equipment, and power cables, and the distance from power cables should be greater than 200mm to avoid electromagnetic interference affecting communication stability; If it is not possible to stay away, shielded cables should be used and grounding treatment should be done.

3. Installation and operation specifications

The module supports two standard installation methods, and the installation process must strictly follow the following specifications:

-Guide rail installation: It can be directly installed on a 35mm wide guide rail that complies with DIN46277 standard. During installation, align the card slot at the bottom of the module with the guide rail, press down and slide it to a fixed position to ensure that the module is tightly clamped without any looseness. This method is easy to install and facilitates the disassembly and maintenance of modules in the later stage.

-Screw fixation: Use M3 screws to fix the module to the installation panel through the fixing screw holes at the bottom of the module; If the module has 4 screw holes, it is recommended to use the two holes on the diagonal to secure it firmly and avoid module displacement due to vibration. The torque of screw tightening should be controlled at around 0.5N · m to avoid damaging the module due to over tightening or loosening, which may result in unstable fixation.

-Installation spacing: Sufficient heat dissipation space should be reserved between the module and surrounding equipment or cabinet walls, with a recommended spacing of no less than 20mm. If a dense installation method is used (such as multiple modules arranged continuously), ventilation and heat dissipation should be strengthened to avoid affecting the module life due to high temperature.

4. Wiring specifications

The quality of wiring directly affects the stability and safety of communication, and the following requirements must be followed when wiring:

-Preparation before wiring: All external power sources of the system must be cut off to avoid electric shock or module damage caused by live wiring; Confirm that the module model, interface type, and wiring equipment match, and select cables that meet specifications (such as shielded twisted pair cables recommended for RS-485 communication).

-Cable selection: The bus connection between the controller and the expansion module uses Yaskawa dedicated bus cables, with a transmission distance not exceeding 500 meters; Select the corresponding cable for communication with the upper computer and human-machine interface based on the interface type (RS-232C uses standard serial cable, length ≤ 15 meters); RS-485 uses shielded twisted pair cables with a length of ≤ 1200 meters; The power cable adopts multi strand copper core cable, and the cross-sectional area is selected according to the rated current to ensure stable power supply.

-Shielding treatment: The shielding layer of the shielded cable needs to be grounded at one end of the host side to avoid potential difference caused by grounding at both ends, which may lead to the introduction of interference signals; The analog output line and remote RS-485 communication line must use shielded twisted pair cables, and if necessary, a common mode coil can be connected at the front end of the signal receiving equipment to suppress line interference.

-Wiring operation: Use a straight screwdriver with a specification of 0.6 × 3.5mm and a length greater than 130mm for wiring operation, with a terminal spacing of 5.0mm. Peel off the insulation layer of the wire to an appropriate length to ensure that the conductor is fully inserted into the terminal, avoiding the exposed part of the wire from contacting adjacent terminals and causing a short circuit; After the wiring is completed, gently pull the wire to confirm that there is no looseness.

-Fuse setting: The module itself is not equipped with fuses. If additional protection is required, relay fuses can be set according to the specifications of rated voltage 250V and rated current 1A.

Precautions for safe operation and maintenance

To ensure the safety of personnel and stable operation of equipment, the following safety regulations must be strictly followed during operation and maintenance. Safety precautions are divided into two levels: "warning" and "caution". Failure to comply with the "warning" items may result in death or serious injury; If the "precautions" are not followed, it may result in minor injuries or equipment damage.

1. Core Warning Matters

-It is strictly prohibited to touch the power terminals and other high-voltage parts while the module is powered on to avoid the risk of electric shock.

-Before maintenance, inspection, or wiring operations, all external power sources of the system must be cut off, and the module must be completely powered off and cooled before proceeding to avoid electric shock or burns.

-Do not use this module in flammable or explosive gas environments to avoid causing fires or explosions.

-It is prohibited to dismantle, repair or modify modules, otherwise it may cause electric shock, fire or module failure.

-If a module failure may lead to a major system accident, appropriate protective circuits should be installed externally to prevent the accident from escalating.

-It is prohibited to mix control lines, communication cables with main circuit cables or power cables for laying. If unavoidable, the spacing should be greater than 100mm, otherwise it may cause module malfunction due to interference.

2. Key precautions

-Modules cannot be used in nuclear facilities or medical equipment related to human life to avoid serious consequences caused by equipment failure.

-When wiring, it is necessary to use wires that match the rated voltage and current, and strictly tighten the terminal screws according to the specified torque. If the screws are too loose, it may cause short circuits, fires, or malfunctions; Tightness may damage screws or modules, leading to module detachment or short circuit.

-Do not touch the module immediately after cutting off the power, as residual heat may cause burns.

-During installation, it is necessary to ensure sufficient heat dissipation space is reserved, otherwise the module life may be reduced due to temperature rise, and even fire may occur.

-Avoid foreign objects (such as dust, wire debris) from entering the interior of the module, as they may cause fires, malfunctions, or malfunctions.

-When disassembling the cable, it is necessary to hold the connector part to avoid pulling the cable directly, which may cause cable damage or poor contact.

-The module takes about 5 seconds from power input to normal output. If there is an interlocking action circuit signal, a time relay should be equipped to avoid signal triggering by mistake.

-When products are discarded, they should be disposed of according to industrial waste disposal standards to avoid environmental pollution.

3. Key points of daily maintenance

Regular inspections of modules are required for daily maintenance, with a focus on the following:

-Status indicator light: Regularly observe the status of the power light, communication light, and fault light. If the fault light is on, it is necessary to promptly check the communication link, wiring, and equipment status.

-Interface and wiring: Check if the interface is loose or oxidized, and if the wiring is secure. If oxidation occurs, clean or replace the interface in a timely manner; If the wiring is loose, it needs to be re tightened.

-Cleaning and maintenance: Regularly clean the dust on the surface and interface of the module to avoid dust accumulation affecting heat dissipation or causing poor interface contact; When cleaning, cut off the power and use a dry cloth to wipe, avoiding the use of corrosive cleaning agents.

-Fault record: If there is a communication interruption, data transmission error, or other fault, it is necessary to record the time of occurrence, working conditions, and indicator light status, in order to accurately locate the root cause of the problem.