Omron CS1W-MAD44 4-Input 4-Output Analog I/O Module for CS-Series PLCs

The Omron CS1W-MAD44 is a high-performance analog I/O module designed for the SYSMAC CS-series programmable logic controller systems. This module provides four analog input channels and four analog output channels in a single unit, offering a compact solution for applications requiring both analog measurement and analog control. The CS1W-MAD44 supports multiple input and output signal ranges including voltage and current signals, making it suitable for a wide range of process control applications in industries such as chemical processing, water treatment, HVAC, and manufacturing.

Key Specifications

• Model: CS1W-MAD44 Analog I/O Unit

• Product Series: SYSMAC CS-series Special I/O Unit

• Analog Inputs: 4 channels

• Analog Outputs: 4 channels

• Input Signal Ranges: 1-5V, 0-5V, 0-10V, -10-10V, 4-20mA

• Output Signal Ranges: 1-5V, 0-5V, 0-10V, -10-10V

• Resolution: 1/4000 (full scale)

• Conversion Speed (Input): 1 ms/point maximum

• Conversion Speed (Output): 1 ms/point

• Accuracy at 23°C: ±0.2% of full scale (voltage input), ±0.4% (current input)

• Accuracy at 0-55°C: ±0.4% of full scale (voltage input), ±0.6% (current input)

• Maximum Rated Input: ±15V for voltage, ±30mA for current

• Input Impedance: 1 MΩ min. for voltage, 250 Ω for current

• Output Impedance (Voltage): 0.5 Ω max.

• Maximum Output Current: 12 mA

• External Connection: 21-point detachable terminal block (M3 screws)

• Power Consumption: 200 mA max. at 5VDC, 200 mA max. at 26VDC

• Dimensions (W × H × D): 35 × 130 × 126 mm

• Weight: 450 g max.

Flexible Analog Input Configuration

The CS1W-MAD44 provides four analog input channels that can be individually configured for voltage or current input signals. Supported voltage ranges include 1-5V, 0-5V, 0-10V, and -10-10V, accommodating a wide variety of industrial sensors and transmitters. The current input range of 4-20mA provides compatibility with standard process control current loops, offering live zero detection for distinguishing between a zero reading and a broken wire condition. Each input channel includes a removable terminal block for convenient wiring connections, with M3 screws providing secure termination of field wiring.

Analog Output Capabilities

The module features four analog output channels that can be configured for voltage output signals. Supported output ranges include 1-5V, 0-5V, 0-10V, and -10-10V, providing compatibility with a wide range of field devices including variable frequency drives, I/P converters, proportional valves, and chart recorders. The output impedance is 0.5 Ω maximum for voltage outputs, with a maximum output current of 12 mA. The outputs are isolated between I/O and PLC signals using photocouplers, protecting the PLC from electrical noise and transients from field devices. The 1 ms/point conversion speed supports real-time control applications requiring rapid output updates.

High Resolution and Accuracy

The CS1W-MAD44 delivers 1/4000 resolution (full scale), providing precise measurement and control of analog signals. This high resolution is essential for applications requiring fine control of process variables, such as temperature regulation, pressure control, and flow management. The accuracy specifications ensure reliable operation across the operating temperature range, with ±0.2% of full scale accuracy at 23°C for voltage inputs and ±0.4% for current inputs. Over the full operating temperature range of 0°C to 55°C, accuracy remains within ±0.4% for voltage inputs and ±0.6% for current inputs, ensuring consistent performance in varying environmental conditions.

Advanced Input Functions

The CS1W-MAD44 includes advanced input processing functions to enhance measurement quality and simplify programming. The mean value processing function stores the last n data conversions in a buffer and outputs the mean value of the conversion results, with buffer sizes selectable as 2, 4, 8, 16, 32, or 64 conversions. This averaging reduces the effects of electrical noise and process variations on measurement accuracy. The peak value holding function stores the maximum conversion value while the Peak Value Hold Bit is ON, useful for capturing transient peaks in pressure, flow, or other process variables. Input disconnection detection detects when a sensor or transmitter has failed or become disconnected and turns ON the Disconnection Detection Flag for PLC monitoring.

Process Control Applications

The CS1W-MAD44 is widely used in process control applications requiring both analog input measurement and analog output control. In temperature control systems, the module reads thermocouple or RTD signals (via external signal conditioning) and outputs control signals to heating elements or cooling valves. In pressure control, it reads pressure transmitters and outputs to pump speed controls or pressure relief valves. In flow control, it reads flow meters and outputs to control valves or variable frequency drives. The combination of 4 inputs and 4 outputs in a single module provides a complete I/O solution for single-loop or multi-loop control applications.

PLC Integration and Data Exchange

The CS1W-MAD44 integrates with CS-series PLCs through the Special I/O Unit Area, exchanging 10 words of data per unit. The CPU writes configuration parameters and output values to the module and reads input values and status information. At power-up, the module receives 100 words of configuration data from the CPU's DM Area, including input signal conversion enable/disable settings, input signal range selection, output signal conversion enable/disable settings, output signal range selection, and mean value processing parameters. This configuration approach simplifies programming and allows the module to be configured without requiring complex setup procedures.

Isolation and Noise Immunity

The CS1W-MAD44 provides photocoupler isolation between I/O signals and the PLC, protecting the controller from electrical noise and voltage transients from field devices. This isolation is particularly important in industrial environments where motors, drives, and welding equipment generate significant electromagnetic interference. The module does not provide isolation between individual I/O signals, but the overall isolation design ensures reliable operation in typical industrial control systems. The removable terminal block with M3 screws provides secure connections that resist loosening due to vibration.

Industrial Applications

The Omron CS1W-MAD44 analog I/O module is deployed across a wide range of industrial process control applications. In HVAC systems, it monitors temperature and humidity sensors while controlling dampers and valves. In water treatment, it reads flow meters and level sensors while controlling pump speeds and chemical feed rates. In manufacturing, it measures force, pressure, and displacement while controlling hydraulic and pneumatic systems. In energy management, it monitors power consumption and controls equipment operation for demand reduction. The module's combination of 4 inputs and 4 outputs provides a compact I/O solution for applications requiring both measurement and control.

Conclusion

The Omron CS1W-MAD44 analog I/O module provides 4 analog inputs and 4 analog outputs with 1/4000 resolution, multiple signal ranges, and 1 ms/point conversion speed for CS-series PLCs. Its flexible configuration, advanced input functions, and high accuracy make it a versatile solution for industrial process control applications requiring both analog measurement and analog control.