Programmable Controller

TOYOPUC – Plus Safety Series

Base, Option, IF , Relay output conversion unit

User Guide
 1． SYSTEM OUTLINE 1

2． OUTLINE OF MODULE 2

3． INITIAL SETTING 3

4． INSTALLATION & WIRING 4

TOYOPUC-Plus Safety
Series 5． TRIAL OPERATION 5
Base, Option, IF, Safety communication,
Relay output conversion unit 6． ERROR CLASSIFICATION 6
User Guide
7． MAINTENANCE 7

8． GENERAL SPECIFICATIONS 8

9． SAFETY PROGRAMMING 9

10． APPLICATION EXAMPLES 10

11． ATTACHMENT

Information
Introduction
Thank you very much for your purchase of our programmable controller.
■ This is a user guide for TOYOPUC-PLUS SAFETY Series programmable logic controller consisting of
Base unit ,Option unit and IF unit.

■ For safe usage of this product, be sure to read the separate manual
"TOYOPUC-PLUS SAFETY Instruction Manual (T-385*)."Also, after
reading it through, keep it in a safe place that allows for easy access
during daily operation.
■ This manual shall be delivered to the end user who will actually perform operations.

 The specifications are subject to change for improvement without prior notice.

 In accordance with Foreign Exchange and Foreign Trade Control Law, the Japanese government's
export admission would be required in the case of exporting any product related to strategic items (or
services) from Japan.

 If this product becomes out of order due to our fault within the warranty period, we will repair or replace
it at our discretion. For other problems than the above, we will take any responsibility for damage
directly or indirectly caused by them.
For Safe Usage
Please read this instruction manual before installation, operation, maintenance and daily service.
Before using the product, fully understand the product information, safety precautions and other important
points described in this manual.
In this manual, the safety precautions are classified into "Warning" and "Caution."

This indicates an imminently hazardous situation which, if not handled

properly, may result in death or serious injury.

This indicates a potentially hazardous situation which, if not handled

properly, may result in injury or property damage.

 Do not disassemble any module or touch the inside when the power is

supplied. Otherwise, you will get an electric shock.

 Do not touch any terminal when the power is supplied.

Otherwise, you will get burned or an electric shock.

 Use the product under the general usage environment specified in this

manual.
 Do not attach or detach any module to or from the DIN rail when the power

is supplied.
 Do not directly touch the electric circuit in each module.

Otherwise the module will be broken due to static electricity.

This manual's revision history
The revision number is included in the manual's reference number in the cover page.

Instruction Manual
Number

T－××× ＊ N

N：Japanese
E: English
Series ID
Number Revision No

Revision
Revision date Contents of Revision
Code
1 February, 2015 First Edition

2 June, 2016 Addition of relay output conversion unit etc.

Reexamination of expression of Chapter 4.6
3 June, 2016 Correction of Chapter 9.2.7 (4)-9
Clear-izing of Fig10-2
4 January, 2019 Section 4.5.2. Note 4) Addition, 4.5.3. Chapter ⑤ Addition
Type of RY08-O, RY08-P, RY04-O, RY04-P is added.(Table 1-7)
5 April, 2019 RY00-O,RY00-P modules are added. (Table 1-7, Table 2-7)
Note on crimp tool is added. (4.5.1)
6 March, 2022 TOYODA brand logo removed

Related manuals
Instruction
Names General Description
Manual Number
Describes basic usage, functions, specifications and
TOYOPUC-Plus Safety
T-385*N
Instruction Manual
safety precautions for TOYOPUC-PLUS SAFETY
and PCwin-Safe-J.(Certification Manual)
Describes how to create and edit user's programs, how to
PCwin-Safe-Plus
T-A63*N use Function Block (FB), and how to set parameters for
Instruction Manual
TOYOPUC-PLUS SAFETY .
PCwin-Safe2 Instruction
Describes basic usage, functions, and specifications of
T-A62*N Manual (Integrated
PCwin-Safe2 in the integrated environment.
Environment)
-Introduction
-For Safe Use
-Instruction Manual Revision History
INDEX
1. System Outline .......................................................................................................... 1-1
1.1. Features ............................................................................................................................ 1-1
1.2. Basic Configuration .......................................................................................................... 1-2
1.2.1. Unit ............................................................................................................................................... 1-2
1.2.2. Module .......................................................................................................................................... 1-3
1.2.3. Connection of Module .................................................................................................................. 1-4
1.2.4. CPU Operation Mode and Configuration ................................................................................... 1-5
1.2.5. Example of System Configuration .............................................................................................. 1-6
1.3. External Appearance and Dimensions ............................................................................ 1-7
1.4. Unit Product List ............................................................................................................. 1-8
2. Outline of Module ...................................................................................................... 2-1
2.1. Specifications .................................................................................................................... 2-1
2.1.1. General Specification ................................................................................................................... 2-1
2.1.2. Semiconductor Output Current Specification (Restriction by Pair Address) .......................... 2-4
2.2. TOYOPUC-Plus Safety Unit ............................................................................................ 2-5
2.2.1. IF Unit .......................................................................................................................................... 2-7
2.2.2. Basic Unit ................................................................................................................................... 2-10
2.2.3. Option Unit ................................................................................................................................ 2-31
2.2.4. Relay Output Conversion Unit ................................................................................................. 2-48
2.2.5. Pin Assignment List of IO Terminal Blocks ............................................................................ 2-56
2.3. Module list ...................................................................................................................... 2-58
2.4. CPU Operation Mode ..................................................................................................... 2-59
2.4.1. Stand-alone Mode ...................................................................................................................... 2-59
2.4.2. Remote 1 Mode ........................................................................................................................... 2-60
2.4.3. Remote 2 Mode ........................................................................................................................... 2-60
2.5. Switch Operation ............................................................................................................ 2-61
2.5.1. RUN Mode .................................................................................................................................. 2-62
2.5.2. Maintenance Mode ..................................................................................................................... 2-66
3. Initial Setting ............................................................................................................ 3-1
3.1. Shipment Condition of Base Unit .................................................................................... 3-1
4. Installation and Wiring ............................................................................................. 4-1
4.1. Installation Environment................................................................................................. 4-1
4.2. Directions on Installation ................................................................................................ 4-1
4.2.1. Space ............................................................................................................................................. 4-1
4.2.2. Static Electricity Protection ........................................................................................................ 4-1
4.2.3. Internal IO Bus Short Circuit ..................................................................................................... 4-2
4.3. TOYOPUC-Plus Safety module installation manners .................................................... 4-3
4.3.1. Bracket installation type .......................................................................................................... 4-4
4.3.2. DIN rail bracket installation type .............................................................................................. 4-5
4.3.3. Direct mounting type ................................................................................................................ 4-8
4.3.4. Mounting of TOYOPUC-Plus ...................................................................................................... 4-9
4.4. TOYOPUC-Plus Safety Unit Assembling Manners ...................................................... 4-10
4.4.1. Unit Assemble ............................................................................................................................ 4-10
4.4.2. Example of Single-sided Installation using a bracket ............................................................. 4-15
 4.4.3. Example of Both-Sides Installation Using a Bracket .............................................................. 4-19
4.4.4. Example of Direct Installation Type ........................................................................................ 4-24
4.4.5. Cover, Bracket, Screw Selection ............................................................................................... 4-29
4.5. Wiring of TOYOPUC-Plus Safety .................................................................................. 4-30
4.5.1. Terminal Block ........................................................................................................................... 4-30
4.5.2. Power Supply Wiring ................................................................................................................. 4-33
4.5.3. Input/output Signal Wiring ....................................................................................................... 4-36
4.5.4. IO Bus Wiring ............................................................................................................................ 4-37
4.5.5. Connection with a Standard PLC ............................................................................................. 4-39
4.6. Connection with Programming Software ...................................................................... 4-41
4.6.1. Notes on USB connection between personal computer and TOYOPUC-Plus Safety ............ 4-43
4.6.2. Cause of USB port failure on PLC ............................................................................................ 4-43
4.6.3. Prior confirmation for USB connection .................................................................................... 4-44
4.6.4. Procedure for USB connection between PC and TOYOPUC-Plus Safety PLC ...................... 4-45
4.7. Unit Selection /Assemble Manners Selection ................................................................ 4-47
5. Trail Operation.......................................................................................................... 5-1
5.1. Points to Be Checked at Test Run ................................................................................... 5-1
5.2. Point to Be Checked before Power Supply connecting .................................................... 5-4
6. Error Classifications ................................................................................................. 6-1
6.1. Error Rank........................................................................................................................ 6-1
6.2. Error Code List ................................................................................................................. 6-2
6.3. Special Register for Error Information Storage .............................................................. 6-3
6.4. Error Code Contents ........................................................................................................ 6-4
6.5. Error Handling ................................................................................................................. 6-9
6.6. Special Relay for Error Information Output ................................................................. 6-12
7. Maintenance .............................................................................................................. 7-1
7.1. Maintenance Check .......................................................................................................... 7-1
7.2. Periodical Inspection of Spare Parts ................................................................................ 7-2
8. General Specifications............................................................................................... 8-1
8.1. General data (valid for all modules) ................................................................................ 8-1
8.2. CPU Functional Specification .......................................................................................... 8-2
8.3. Communication Function ................................................................................................. 8-3
8.3.1. SN-I/F communication ................................................................................................................. 8-3
8.3.2. MODBUS-RTU Communication (slave) ..................................................................................... 8-4
8.4. Real I / 0 Address Assignment ......................................................................................... 8-8
8.5. Special Flags(relay) ........................................................................................................ 8-11
8.6. Special registers ............................................................................................................. 8-13
9. Safety Programming ................................................................................................. 9-1
9.1. Instruction ........................................................................................................................ 9-1
9.1.1. Basic Instruction (16 Kinds) ....................................................................................................... 9-1
9.1.2. Timer Instruction (4 Kinds) ........................................................................................................ 9-2
9.1.3. Counter Instruction (3 Kinds) ..................................................................................................... 9-2
9.1.4. Application Instruction (Common to PS/PN) (5 Kinds)............................................................. 9-2
9.1.5. Application command (instruction) (PN) (40 kinds)............................................................. 9-5
 9.2. Basic rules on safety circuit ........................................................................................... 9-29
9.2.1. Definition of "S" (safety signal) mark ....................................................................................... 9-29
9.2.2. Definition of "U" (user confirmation signal) mark ................................................................... 9-29
9.2.3. Important points in rules .......................................................................................................... 9-29
9.2.4. Basic Rules ................................................................................................................................. 9-30
9.2.5. Conditions for "S" mark ............................................................................................................. 9-31
9.2.6. Coil mark depending on circuit ................................................................................................. 9-32
9.2.7. Self-maintaining circuit pattern ............................................................................................... 9-35
10. Application Examples ........................................................................................... 10-1
10.1. Example of operation ready circuit .............................................................................. 10-1
11. Attachment ............................................................................................................ 11-1
11.1. Connection with light curtain device ........................................................................... 11-1
11.2. Option Product ............................................................................................................. 11-2
11.2.1. Stud ........................................................................................................................................... 11-2
11.2.2. Screw......................................................................................................................................... 11-3
11.2.3. Bracket/ Cover.......................................................................................................................... 11-3
11.2.4. Cable ......................................................................................................................................... 11-6
11.3. Safety Integrity Level and Performance Level .......................................................... 11-13
11.4. Relay MTTFd (Mean Time to Dangerous Failure) .................................................... 11-14
11.5. Output Connectable Device List (Information) ......................................................... 11-15
11.6. Short Circuit Detection of Safety Input Circuit (Dry Contact Input) ....................... 11-18
11.7. Examples of Safety Input Circuit Incorrect Connection ........................................... 11-19
11.8. Unit Version Change History..................................................................................... 11-22
1. System Outline
1.1. Features
TOYOPUC-Plus Safety is a compact board safety PLC which inherited the structure of TOYOPUC-Plus.
By add-on of a unit/s according to a facility scale, the safety-PLC system can support from a compact
stand-alone facility to a large-sized line facility flexibly.
The safety control circuits can be programmed, therefore, comparing with the conventional relay control,
the more simple and easy-maintenance safety control system can be constructed.
TOYOPUC-Plus Safety acquires certification of PL(performance level) e of international safety standard
ISO13849-1, Cat.4, and SIL3 of IEC61508.

(1) Space-saving structure

Mounting to a DIN rail and direct mounting to a control panel are possible,
The add-on of TOYOPUC-Plus(standard-PLC) is also possible.

(2) The maximum safety I/O is 2048 points

Add-on of a unit/s according to a facility scale, the safety control up to maximum of 2048 points is
possible. From the compact stand-alone facility to the large-sized line facility can be supported flexibly.

(3) Operation mode

There are three operation modes (stand-alone, Remote 1, Remote 2) in TOYOPUC-Plus Safety.
It can be selected by parameter setting by a programming tool according to the facility scale or
necessary I/O point.

(4) High-speed response performance

The maximum response time of a TOYOPUC-Plus Safety system is 15.8ms (at the time of stand-alone
mode).
This is the value of considering f the maximum delay from input signal change to output signal change .
In addition, the system cycles of TOYOPUC-Plus Safety are 9ms / scan (at stand-alone mode).

(5) Function block (FB) function

The safety program of TOYOPUC-Plus Safety can implement a function block program (FB).
Standardization of a safety program can be performed by FBs, and can contribute to reliable safety
circuits design. Because the internal circuit of FB can display intelligibly, therefore it contribute easy
maintenance and adjustment of a facility .
And, there is a FB protection function in which the change of FB circuits by a user other than an
administrator can be prohibited, and support standardization powerfully.
FB for TOYOPUC-PCS-J can also be available.
※ Please refer to a PCwin-Safe-Plus instructions manual for the directions for use for a safety program
and FB.

(6) SN-I/F communication

By SN-I/F communication mounted on IF unit, data communication is easily made with PC10/PC3
JG/Plus series. Between TOYOPUC-Plus Safety and PC10/PC3JG /Plus series, the data communication
of fixed data (64 bytes / 64 bytes) can be performed without parameter setting.
Also, the layer command communication from a upper-level host is supported.

(7) USB memory function

Even if there is no peripheral device, the writing from a USB memory, backup, etc. are available.

(8) Battery-less
The maintenance of a battery is unnecessary because of battery-less.

(9) Input standardization

Dry contact input/ light curtain input/ semiconductor input can be selected with the parameter from a
programming tool.

1-1
1.2. Basic Configuration
1.2.1. Unit

TOYOPUC-Plus Safety consists of roughly three kinds of units.

Please select the unit suitable for a application.
Unit Classification Name Contents
IF unit Full option I/F
IF0000 Function selection SW, USB I/F, USB
It is a unit memory, SN-I/F, Remote IO x2
with various
I/F.
Dedicated Remote slave station I/F
It is used IF00RS USB I/F, Remote IO x2
combining a
basic unit.
Dedicated CPU(stand-alone) I/F
IF00SA Function selection SW, USB I/F, USB
memory, SN-I/F

Dedicated CPU(stand-alone) I/F

IF00SJ Function selection SW, USB I/F, SN-I/F

Basic unit Safety basic 0(none) input, 16 outputs

unit BS0016
It is basic IO
unit. 8 inputs, 8 outputs *1
BS0808

12 inputs, 4 outputs *1
BS1204

16 inputs, 0(none) output *1

BS1600

Standard Input/output point: 16 points *2

basic unit BN16-P
Option unit Safety option 0(none) input, 16 outputs
unit OS0016
It is an IO 8 inputs, 8 outputs *1
expansion OS0808
unit .
It is used 12 inputs, 4 outputs *1
combining a
OS1600
basic unit. 16 inputs, 0(none) output *1
OS1200
Standard Input/output point: 16 points *2
option unit
ON16-P

※1 Dry contact input or semiconductor input ( with a test pulse/no-test pulse) can be set per each 2 inputs
with a programming tool.
※2 The ratio of Input and output can be set with a programming tool per two points.
Table 1-1 Unit list

For details, please refer " Chapter 2.1 Specification" and the "Chapter 2.2 TOYOPUC-Plus Safety Unit."

1-2
1.2.2. Module

A basic unit can be changed as CPU module, Remote slave station module or internal extension IO module.
Changing is carried out by setting of a station number.
A CPU module and a Remote slave station module, an IF unit and an option unit can mounted
respectively.
An internal extension IO module, One option unit can be mounted.
Station number Module name View
/ unit
configuration

option

CPU
module

00 ([IF****] + )※1
[BS****]
(+[OS/ON****])

option
Remote slave
station
module
01
[IF****]※2 +
～ [BS/BN****]
(+[OS/ON****])

1F
※2: IF0000 or
IF00RS
Indispensable
option

Internal
21 extension IO
module

～
[BS/BN****]
(+[OS/ON****])
23

Table 1-2 Unit list

For details, please refer "Chapter 2.3 module list."

1-3
1.2.3. Connection of Module

① CPUmodule and internal extension IO module

Maximum of 3 sets of the internal extensions IO module are connectable with CPU module.

Internal extension IO module CPU

St. No：23 St. No：22 St. No：21 module

Figure 1-1 Connection of CPU module and internal extension IO module

 Internal IO bus: (please use the specified cable. Refer to Chapter 4.5.4.)
 Setting of a termination switch is required for a termination module .In the above example of
connection, Termination switch setting is required for the internal extension IO module of
CPUmodule and the station number 23. (Refer to Chapter 2.2.2 (2))
 The same station number cannot be used for an internal extension IO module.
 When setting of a station number is changed, the failures of station number is caused after
power supply reconnecting, the reset operation is required.
(see the operation manner of Chapter 2.5.1.4)

② Remote slave station module and Internal extension IO module

Internal extension IO module Remote slave station

St. No：23 St. No：22 St. No：21 module

Figure 1-2 Connection of Remote slave station module and internal extension IO module
 Internal IO bus：

 Setting of a termination switch is required for termination modules. In the above-mentioned

connection exampl, Termination switch setting is required for the Remote slave station module
and the internal extension IO module of station number 23. (Refer to Chapter 2.2.2 (2))
 The same station number cannot be used as an internal extension IO module.
 When setting of a station number is changed, the station number error is caused after power
supply reconnecting. Therefore, the reset operation is required. (see the operation manners of
Chapter 2.5.1.4)

1-4
 ③ CPU module and Remote slave station module

Remote slave station module CPU

St. No：1F ・・・ St. No：10 ・・・ St. No：01 module

・・・ ・・・

Max. of 31 sets
Figure 1-3 CPU module and Remote slave station module

 Remote IO bus : (Please use the specified cable. Refer to Chapter 4.5.4.
 The same station number is cannot used for Remote slave station module.
 When setting of a station number is changed, the station number error is caused after power
supply reconnecting. Therefore, the reset operation is required. (see the operation manners of
Chapter 2.5.1.4)

1.2.4. CPU Operation Mode and Configuration

Please select CPU operation mode according to required input/output points and functions.
Mode of Maximum IO Remote Scan time Response
operation point station Speed
number
Stand-alone 128 points - 9.0ms 15.8ms
Remote 1 256 points 3 or less 10.5ms 18.8ms
Remote 2 2048 points 31 or less 17.5ms 32.8ms
Table 1-3 CPU operation mode

For details, please refer to "Chapter 2.4 CPU operation mode."

1-5
 1.2.5. Example of System Configuration

Note)
I/O BUS (Remote IO) connectors of CPU
Only one port is available for connection.

Mode select switch A CPU only can locate at terminal location

* reset / start of communication line(Remote IO BUS).
①Base unit
*USB memory R/W
* Maximum connection : 1 set
of option I/O is possible.
Internal IO bus
Option unit I/F unit USB I/F for engineering tool
( PCwin-Safe-Plus)
Option unit
Internal
内部ＩＯバス IO bus

SN-I/F:Communi Remote IO bus

リモートＩＯバス
Extension
増設 IO module
IO module (bases (+ option)) cation connector
* Maximum connection : 1-set of
（基本(＋オプション）） with a standard Extension IO module (bases (+
option unit is available.
※ｵﾌﾟｼｮﾝﾕﾆｯﾄを最大１台接続可能 PLC option))
USB memory * Maximum connection : 1-set of
* Program storage option unit is available.

⑥Remote I/O slave station (base

⑤CPU (Base unit +IF unit) +I/F)
* Maximum I/O point : 2048 points *Maximum connection :1-set of
* Maximum connection : one-set of option I/O option I/O
* Maximum connection :3-set of a base module . * Maximum connection :3-set
* Maximum connection: 31-set of remote I/O slave station

Figure 1-4 Configuration example

1-6
1.3. External Appearance and Dimensions
Outside dimension 140mm x 90mm, Maximum 5 units. (DIN rail adapter +IF unit +BS unit + option unit)
100mm of width.:
Between BS-IF:
基本とI/Fの間
8mm
8ｍｍ 固定fixed

4 64 16 16 16
mm mm mm
4

Board thickness:
140

132

基板厚み：１．６ｍｍ
1.6mm

Between BS-OS:16mm 16
82 基本とｵﾌﾟｼｮﾝの間 16ｍｍ fixed
固定 mm
90 21

Stack configuration is up to 5 sheets.

(RY unit counts as 3 sheets/unit)
When 2 brackets used for both ends, 11
Figure 1-5 Dimensions and appearance sheets/unit is possible

1-7
1.4. Unit Product List
(1) Unit Product List
Safety I/O unit product list
Unit line-up Name Type Safety input Safety output
number number
Safety I/O Base unit BS0016 TNC-6886 0 16
BS0808 TNC-6887 8 8
BS1204 TNC-6888 12 4
BS1600 TNC-6889 16 0
Option unit OS0016 TNK-6890 0 16
OS0808 TNK-6891 8 8
OS1600 TNK-6892 16 0
OS1200 TNK-6893 12 0
Unit name explanation

B S 08 08
Output points
Input points
S: Safety I/O
B:Base unit
O:Option unit

Table 1-4 Safety I/O Unit Product List

Standard I/O unit product list
Unit line-up Name Type I/O function
Standard Base unit PNP I/O 16pt.：Setup of the input and output in every
I/O BN16-P TNC-6894
two points with eng. tool (PCwin-Safe-Plus)
Option unit PNP I/O 16pt.：Setup of the input and output in every
ON16-P TNK-6896
two points with eng. tool (PCwin-Safe-Plus)
Unit name explanation

B N 16 -P
-P:PNP I/O
I/O points.
N: Standard I/O
B:Base unit
O:Option unit

Table 1-5 Standard I/O unit product list

1-8
Interface unit product list
Unit line-up Name Type Function
Interface Interface Function USB Remote
unit IF0000 TNF-6898 USB I/F SN-I/F
select SW Memory I/O
Remote
IF00RS TNF-6899 USB I/F I/O
Function USB
IF00SA TNF-6934 USB I/F SN-I/F
select SW Memory
Function
IF00SJ TNF-6935 USB I/F SN-I/F
select SW
Naming

I F 00 00
Refer to upper table.

IF:IF unit

Table 1-6 Interface unit product list

Safety relay output conversion unit

Unit line-up Name Type output Function
4 channels Socket and relay（G7SA-3A1B）: OMRON
RY08-O TNK-6972
(4X3=12) 8 sets
Socket and relay （ SFS3-L-DC24V ） :
4 channels
RY08-P TNK-6973 Panasonic
(4X3=12)
8 sets
2 channels Socket and relay（G7SA-3A1B）: OMRON
RY04-O TNK-6970
(2x3=6) 4 sets
Safety relay Socket and relay （ SFS3-L-DC24V ） :
2 channels
output RY04-P TNK-6971 Panasonic
(2x3=6)
conversion unit 4 sets
Socket : OMRON 8 pieces
4 channels *Relays are not attached.Please be prepared
RY00-O TNK-6950
by customer. (For suitable relay type, refer to
(4X3=12)
chapter 2.2.4.4)
Socket : Panasonic 8 pieces
4 channels *Relays are not attached.Please be prepared
RY00-P TNK-6957
by customer. (For suitable relay type, refer to
(4X3=12)
chapter 2.2.4.4)
Naming

RY08 -O

- O: OMRON
- P: Panasonic
Refer to the above table
RY: Relay output conversion unit

Table 1-7 Safety relay output conversion unit

1-9
(2) Peripheral equipment list

Unit line-up Name Type Speficication

Programming software for
TOYOPUC-PCS/TOYOPUC-PCS-J/TOYOPUC-Plus Safety
PCwin-Safe2 TJA-2701
(PCwin-Safe, PCwin-Safe-J, PCwin-Safe-Plus integrated
(Japanese) ※2
environmental software)
Programming
[CD-ROM Japanese version]
software
Programming software for
※1
TJA-2703 TOYOPUC-PCS/TOYOPUC-PCS-J/TOYOPUC-Plus Safety
PCwin-Safe2
(PCwin-Safe, PCwin-Safe-J, PCwin-Safe-Plus integrated
(English) ※2
environmental software)
[CD-ROM English version]

※1 Please refer to the instructions manual for programming software.

※2 PCwin-Safe2 is the same type code as PCwin-Safe.
The user, who are using the PCwin-Safe, can upgrade to PCwin-Safe2 by free.
Table 1-8 Peripheral equipment list

1-10
2. Outline of Module
2.1. Specifications
2.1.1. General Specification
(1) General Specification
№ Item Specification
1 Shape Board type
Size ( ex. 5unit ) 90(D)×140(H) ×100(W)mm
2 Power supply 24 V DC +20% / - 15 %
Ripple (peak-to-peak) +- 5 % of
nominal Voltage
The Power Supply must fulfil the
requirements of IEC/EN 60950-1, EN
50178 (UL Class 2, SELV)
3 Ambient temperature 0 - 55 °C
4 Relative humidity 10～95％RH(no dew condensation)
5 Atmosphere No corrosive gas allowed
6 Programming language LD(+FBD)
7 Extensio Internal IO bus For extension I/O
n bus RS-485 3Mbps (1:N communication
total length max 50m)
Extension IO module MAX. 4 units
Remote I/O bus Supporting Remote I/O system.
RS-485 3Mbps
( 1:1 communication between each
board ,max 50m )
Remote IO module MAX 32 units
8 Safety I/O DC24V Total of I/O: 16pts.per unit
Input 5mA/per point
Output 0.5A/per point ( 0.7A according to
the condition) Refer to Table 2-5
The example of output current
combination
9 Standard DC24V, 16 points / unit
I/O I/O is selected every two points with
parameters
BN16-P/ON16-P: PNP I/O
Input 5mA per point
Output 0.5A per point ( 0.7A according to the
condition) Refer to Table 2-5 The
example of output current
combination
10 Peripheral device I/F USB Full Speed (12 Mbps)
(connection with PCwin Safe
Plus)
11 Program reading/writing by USB Flash memory (12 Mbps)
an external memory
12 Standard communication SN-I/F (TOYOPUC-safety PLC
communication 1:1 communication)
MODBUS-RTU ( 1:N communication )
13 Display - Status display
- Function selection display
- Module display
With three-primary-colors LED
14 Battery RTC 15 days by a super capacitor.
-less (Clock data) *1
Data backup Backup of standard register, error
history, and operation log by FRAM

*1 After 15 days or more ,the clock data disappears , therefore the alarm AF is caused and coil V0F5
turns on. (A Safety PLC maintains RUN status.) Please refer to table 6-11 for handling.

Table 2-1 General Specification

2-1
(2) Function Specifications
No Item Specification
Safety category ISO13849-1 PL e
1
IEC61508 SIL3
2 Power supply DC24V
3 Program system Stored program system
4 Program control system Cyclic computing type
5 I/O control system Image register system
6 Programming language LD(+FBD)
Stand-alone (the number of 9.0ms （ point ＜ ＝ 128
remote I/O slave stations = 0 points）
station)
Scan Remote 1 (remote I/O slave 10.5ms （ point ＜ ＝ 256
7
time station <=3 stations) points）
Remote 2 (remote I/O slave 17.5ms （ point ＜ ＝
station <=31 stations) 2048 points）
Stand-alone 15.8ms （ point ＜ ＝ 128
Response time (when points）
using a relay output Remote 1 18.8ms （ point ＜ ＝ 256
8-1 conversion unit,
points）
+20ms of each
response time) Remote 2 32.8ms（point＜＝2048
points）
Stand-alone Please refer to Chapter
Response time using エラー! 参照元が見つか
8-2 safety-communication Remote 1 りません。
(FL network (safety) „Safety-communication
Remote 2
Response Time“
Program capacity Safety 128KB (Safety +
9 (object size) Standard standard)
USB memory
10 External memory
(program storage, etc.)
Safety 128 points (standalone)
Standard 2048 points (safety +
11 I/O point
standard) ( using
remote I/O)
Dry contact DC24V Photo-coupler
input input (- common)
* Input : 5mA/point
Light curtain * Dry contact input or
input light curtain input
Safety input
selection with a
12 Input specification parameter
* Pulse check invalidity
or validity selection with
a parameter
DC24V Photo-coupler
Standard
input
input
* Input : 5mA/point
Table 2-2 General Specification 1/2

2-2
 No Item Specification
Safety output DC24V FET output (+ common)
* Output current : 0.5A / point
0.7A is available by conditions.
Refer to Table 2-5 The
example of output current
combination
* Pulse check validity/invalidity
selection by a parameter
Output * With a fuse-less short circuit
13
specification protection function
Standard DC24V FET output
output DC24V FET output * Output current : 0.5A / point
* Output current : 0.5A 0.7A is available by conditions.
/ point Refer to Table 2-5 The
* With a fuse-less example of output current
short circuit protection combination
function * With a fuse-less short circuit
protection function
(1) SN-I/F : (TOYOPUC-safety
PLC communication 1:1
communication)
14 Standard communication (2) MODBUS-RTU conformity
(support [ 1:N communication ]
Alternative selection with a
parameter
Safety-communication Industrial Ethernet safety
15 communication
- FL network (safety)
USB I/F(eng. tool, PCwin-Safe
16 Peripheral device Plus):type B port
USB flash memory: type A port
Table 2-3 General Specification 2/2
(3) Unit power supply specification

Item Specification
Supply voltage 24 volt DC +20% / - 15 %
Current
0.3A max.( IF**** + BS/BN**** + OS/ON****)
Watt 7.2W max.
Fuse Unit power supply part : Internal poly fuse 0.75A
I/O : 2.0A (heating shutdown circuit , built-in FET)
Table 2-4 Unit power supply specification

Note）The electric power unit must satisfy one of the following requirements. :
・ Safety mains transformer to IEC 61558/VDE 0570 Part 2-6: “Special requirements on safety
transformers for general applications (IEC 61558-2-6:1997)“.
・ Switch mode power supply to IEC60950-1 :"Information technology equipment - Safety -
Part 1" and to IEC50178 : ""Electronic Equipment for Use in Power Installations".
Furthermore the power supply unit must be suitable for supplying its SELV circuits in
accordance with IEC60950-1. (OMRON S8VS and S8AS power supply are conforming
SELV)
Because a Plus Safety does not conform to protection level IP2X, 0V line must be
grounding as protective earth. (By grounding the output (0V) of a SELV power supply, the
circuits become PELV circuits according to IEC60204-1 " Safety of Machinery - Electrical
equipment of machines - Part 1: General requirements " ) (Refer to 4.5.2.)

2-3
2.1.2. Semiconductor Output Current Specification (Restriction by Pair Address)

Output currents are limited by a pair address.

Example: In the case of the pair of address 0 and 2.
There is a relation: I002+I022 =< 0.5.
In the case of I00=0.7A, I02 will be = 0.1A.
The typical currents combination of a pair addresses are shown below.
Pair
Output
Output Output current combination [A]
current
Address
0 I00 0.70A 0.60A 0.50A 0.40A 0.30A 0.20A 0.10A
2 I02 0.10A 0.37A 0.50A 0.58A 0.64A 0.68A 0.70A
1 I01 0.70A 0.60A 0.50A 0.40A 0.30A 0.20A 0.10A
3 I03 0.10A 0.37A 0.50A 0.58A 0.64A 0.68A 0.70A
4 I04 0.70A 0.60A 0.50A 0.40A 0.30A 0.20A 0.10A
6 I06 0.10A 0.37A 0.50A 0.58A 0.64A 0.68A 0.70A
5 I05 0.70A 0.60A 0.50A 0.40A 0.30A 0.20A 0.10A
7 I07 0.10A 0.37A 0.50A 0.58A 0.64A 0.68A 0.70A
8 I08 0.70A 0.60A 0.50A 0.40A 0.30A 0.20A 0.10A
A I0A 0.10A 0.37A 0.50A 0.58A 0.64A 0.68A 0.70A
9 I09 0.70A 0.60A 0.50A 0.40A 0.30A 0.20A 0.10A
B I0B 0.10A 0.37A 0.50A 0.58A 0.64A 0.68A 0.70A
C I0C 0.70A 0.60A 0.50A 0.40A 0.30A 0.20A 0.10A
E I0E 0.10A 0.37A 0.50A 0.58A 0.64A 0.68A 0.70A
D I0D 0.70A 0.60A 0.50A 0.40A 0.30A 0.20A 0.10A
F I0F 0.10A 0.37A 0.50A 0.58A 0.64A 0.68A 0.70A

Table 2-5 The example of output current combination

2-4
2.2. TOYOPUC-Plus Safety Unit
Unit Classification Name Description
Interface A unit which mounts the following
unit IF0000 functions.
(Mounting functions differ depending
on the model.)
- Selection of function SW
IF00RS - USB A port (for USB memories)
- USB B port
(for PC (PCwin-Safe-Plus))
- Remote IO port
IF00SA - SN-I/F or MODBUS
It is combined with a basic unit
(connect by the connector between
boards),
IF00SJ It functions as a CPU module or a
Remote slave station module.
Base unit A unit which mounts the following
BS0016 functions.
- Microprocessor
- Power supply circuit
BS0808 - Safety input/output circuit
Safety - Internal IO bus I/F
basic unit By combination (or stand alone) with
BS1204 other units and setting of a station
number, it functions as CPU
module/Internal extension IO module/
BS1600 Remote slave station module.

A unit which mounts the following

functions.
- Microprocessor
- Power supply circuit
- Standard input/output circuit
Standard
basic unit
BN16-P - Internal IO bus I/F
By combination (or stand alone) with
other units and setting of a station
number, it functions as CPU
module/Internal extension IO module/
Remote slave station module.
Option unit An expansion unit of safety IO.
OS0016 Safety IO is extendable by combined
with a basic unit (connect by the
OS0808 connector between boards).
Safety option
unit
OS1600

OS1200
An expansion unit of standard IO.
Standard Standard IO is extendable combined
option unit
ON16-P with a basic unit (connect by the
connector between boards).
Table 2-6 Units 1/2

2-5
 Unit Classification Name Description
Relay output A safety output (semiconductor output)
RY08-O
conversion is converted into a relay contact output.
unit When a category 4 is realized,
RY04-O
Please make a two-channel
RY00-O configuration and create the read back
check sequential circuit of external
RY08-P equipment.
2.2.4.6 Refer to examplses of wiring
RY04-P 2.2.4.7 Refer to external device back
check sequential circuits (category 4)
RY00-P example

Table 2-7 Units 2/2

2-6
2.2.1. IF Unit

(1) Please select from the following four products by a purpose.

Purpose
Name Outside view CPU module
Function CPU module Remote slave
(Remote 1,
(stand-alone) station module
Remote 2)
IF0000 Function
Selection ○
SW
USB I/F ○
USB
memory
○ ○ ○ ○
SN-I/F ○
Remote
IO ○

IF00RS Function
Selection ×
SW
USB I/F ○
USB
memory
× × × ○
SN-I/F ×
Remote
IO ○

IF00SA Function
Selection ○
SW
USB I/F ○
USB
memory
○ ○ × ×
SN-I/F ○
Remote
IO ×

IF00SJ Function
Selection ○
SW
USB I/F ○
USB
memory
× ○ × ×
SN-I/F ○
Remote
IO ×

Table 2-8 IF Unit

2-7
(2)Specification
Item Specification
Name IF0000 IF00RS IF00SA IF00SJ
Type TNF-6898 TNF-6899 TNF-6934 TNF-6935
Rated voltage / 224 V DC +20% / - 15 % / 13mA (from a basic unit
Consumption current supply) At using a USB memory maximum+110mA
Dimensions / Weight 140H×90W×18D mm / 70g

Table 2-9 Specification

(3) Name and function of each part
Right-hand side Front

⑨
④

⑤
⑥
⑦

① Function selection switch

⑧ ② USB I/F
③ USB memory I/F
④ SN-I/F (MODBUS) Termination
switch
⑤ SN-I/F (MODBUS)
Left-hand side ⑥ SN-I/F Communication
(MODBUS) condition LED
⑦ FG terminal (for SN-I/F cables)
⑧ Remote IO bus I/F
⑨ connector for basic unit connection

Figure 2-1 I/F unit Name and function of

each part

2-8
①Function selection switch (Mounted only IF0000, IF00SA, and IF00 SJ)
Perform selection of function and decision operation.
Select a function by sliding a switch to right and left, and function is decided by pushing a
switch.
The selective state of a function can be judged by the color of LED for a function selection
display of a basic unit.

Execution
operation

Function
selection

Figure 2-2 Function selection switch

②USB I/F
At the time of the user program download to TOYOPUOC-Plus Safety or at monitoring, a USB (B
type) connector for connecting a programming tool (PCwin-Safe-Plus).

③USB memory I/F (mounted only IF0000 and IF00 SA)

A USB (A type) connector for connecting a USB memory. User program writing from a USB
memory, and user program reading to a USB memory can be performed.

④SN-I/F (MODBUS) Termination switch （Mounted only IF0000, IF00SA, and IF00 SJ.）
1 Unused (always OFF)
Please do not change by any means.
1
2 SN-I/F, Modbus termination switch 2
A terminator becomes available by ON.
OFF⇔ON

Figure 2-3 SN-I/F (MODBUS) Termination switch

⑤SN-I/F (MODBUS) （Mounted only IF0000, IF00SA, and IF00 SJ.）

The change of SN-I/F communication or MODBUS-RTU communication by parameter setting
is available.

・At SN-I/F selection

The connector for communication with a Operationall PLC. TOYOPUOC-Plus Safety is
connectable with TOYOPUC-PC10, Plus, etc., the PLCs which mounts SN-I/F
communication.
And, connect with a Gateway module and can connect open networks like Devicenet or
Profibus .
Please refer to "Chapter 4 Installation and Wiring" for the connection method.

・At MODBUS-RTU selection

It can connect with the control devices ,a display, PLC, PC, etc which mounts MODBUS-RTU
communication (master).

2-9
 MODBUS-RTU Communication specification
No. Item Specification
1 Communication Half duplex method
method
2 Communication speed 300, 600, 900, 1200, 2400, 4800, 9600, 19200,
38400, 57600, 115200bps (Selection with a
parameter) *1
3 Using device SCI6+DMA0
4 Receiving timeout None
5 Reply wait time up to the communication speed
(1/communication-speed bps * 11bits * 3.5
character).
6 The maximum delay Max. 200ms
time from receiving
completion to
transmitting start
7 Station number 01～255 (Selection with a parameter)
8 Transmission format
Data length 8-bit fixing
Parity None, odd, even (selection with a parameter)
Stop bit 1 or 2 bits (selection with a parameter)
9 Supporting command 01: ON/OFF status reading of a series of
internal relays.
02: Read the present input state.
03: Read the present value of a series of data
registers.
Table 2-10 MODBUS-RTU Communication specification

⑥SN-I/F Communication (MODBUS) condition LED（mounted on IF0000、IF00SA、IF00SJ）

lighting in orange during communication.

⑦FG terminal (for SN-I/F cable)（mounted on IF0000、IF00SA、IF00SJ）

Connect FG line at the time of using [ double shielded cable ] (when cable length is longer than
3m).
Please refer to " Chapter 4 Installation and Wiring " for the connection method.

⑧Remote IO bus I/F（mounted on IF0000、IF00RS）

A connector for Remote IO bus connections.
Connect a CPU module, a Remote slave station module, and Remote slave station modules.
Please refer to "Chapter 4 Installation and Wiring" for the connection method.

⑨A connector for basic unit connection

For connection with a basic unit.

2.2.2. Basic Unit

2-10
(1) IO point
Name Safety inputs Safety output Standard
number number input/output
number
BS0016 0 point 16 points
BS0808 8 points ※1 8 points
BS1204 12 points ※1 4 points
BS1600 16 points ※1 0 point
BN16-P 16 points ※2
※1 Input setting: dry contact, semiconductor (test pulses /no test pulse) can be set by per two
points using a programming tool
※2 The point of input/output can be set each 2 points by a programming tool.
Table 2-11 Basic Unit I/O point
(2)Name and each part functions
Left-hand side
① ② Front

④
⑤
③
⑥
⑦

① Station number switch

② Termination switch for internal IO
bus
③ Internal IO bus I/F
④ Unit identification LED
⑪ ⑩ ⑤ Module identification LED
Right-hand Side
⑥ Status display LED
⑦ Function selection display LED
⑧ Terminal block TB2
⑨ Terminal block TB1
⑩ Unit power supply LED
⑪ Connector for option unit
connection
⑫ Connector for IF unit connection

Figure 2-4 Basic unit Name and each

part functions

2-11
 ① Station number switch
Carry out module setting and station number setting of Remote IO bus communication and
internal IO bus communication. Example
Upper-digit Lower-digit
Station number switch Module operation
setting range
0x00 Working as a CPU module.
0x01 – 0x1F Working as an Remote IO 1 0
module.
0x21 – 0x23 Working as an Extension IO Station number：0x10
⇒It becomes a
module.
Remote slave station
Table 2-12 Station number switch Figure 2-5 Station number switch
When a number other than the above setting, It becomes error.
Note) When a station number is changed, the errors in a station number (error 92) may
cause at the time of a power supply ON.
In this case, error reset operation of station number is required.
(About the operation manner, Please refer to clause2.5.1.4 Station Number Error Reset /
Data Error Unconfirmed Reset.）

② Termination switch for internal IO bus

SW Contents If incorrect settings
1,2,3 A terminator becomes Error B1 (IO bus communication
available by ON. At error) may cause by the using ON 1 2 3 4

⇔
using terminators, conditions
please be sure to turn OFF
on all three.
4 For our company When setting of a CPU module
maintenance purpose is mistaken, safety PLC does not Figure 2-6 Termination switch
(Always OFF) start ( not RUN). When settings
Please do not change of a Remote slave station and a
by any means. expansion IO module are
mistaken, it becomes error B1
(IO bus communication error).

③ Internal IO bus I/F

Connector for internal IO bus connections.
Connect a CPU module and an internal extension IO module, internal extension IO
modules. Please refer to "Chapter4 Installation and Wiring" for the connection manner.

④ Unit identification LED

LED indicates follows according to a unit kind.
Unit kind
■(green) Safety unit
■(Blue) Standard unit

⑤ Module identification LED

LED indicates as follows according to the module
kind set by station number switches.
Module kind
■(Off）--- (power supply OFF condition)
■(Blue) CPU module Station number: 00
USB
I/F

■(green) Remote slave station module Station number: 0x01-1F

■(water) Extension IO module Station number: 0x21
■(purple) Extension IO module Station number: 0x22
□(White) Extension IO module Station number: 0x23

Figure 2-7 Basic unit LED explanation

2-12
⑥ Status display LED
Indicate the condition of CPU with a status display LED .

Status
■(Off） Under stop
■(green) RUN
■(Red) Under a major error occurrence
■(purple) Under a minor error occurrence
■(Yellow) Under warning
■(Blue) Under maintenance mode

USB
I/F
Figure 2-8 Basic unit LED explanation

⑦ Function selection display LED

Indicate the function selected with function selection switches.
When a selection of function is not implemented for 5 seconds, LED turns out
The LED color meanings differ at maintenance mode and RUN mode.
Operation selection
RUN mode
■(Off) Waiting for selection
■(Green) Reset/RUN
■(Yellow) Stop
■(Blue) Maintenance mode
■(Purple) Station number error/ data check reset

Maintenance mode
■(Off) Waiting for selection

USB
■(Green) RUN

I/F
■(Blue) Write (USB memory).
□(White) Read (USB memory).
■(Water) :USB memory security registration
■(Purple) USB memory security registration reset
■(Yellow) Under USB memory certification

Figure 2-9 Basic unit LED explanation

2-13
⑧ Terminal block TB2
A terminal block for input/output (addresses 0-7) and the power supply connection for IO.
Please refer to clause 2.2.2.1 to2.2.2.5 for details.
TB2 Terminal
Address No.
block No.
L0 R0 0
L1 R1 1
L2 R2 2
L3 R3 3
L4 R4 4
L5 R5 5
L6 R6 6
L7 R7 7
P1 N1 I/O power supply for 0-7
TB2
P2 N2 I/O power supply for 0-7

Table 2-13 Basic unit Terminal block TB2

⑨ Terminal block TB1

Terminal block for power supply connection for a unit
and input/output (address 8-F)
Please refer to clause 2.2.2.1 to2.2.2.5 for details.
TB2 Terminal TB1
Address No.
block No.
L8 R8 8
L9 R9 9
LA RA A
LB RB B
LC RC C
Figure 2-10 Basic unit
LD RD D termainal block
LE RE E
LF RF F
P3 N3 I/O power supply for 8-F
P4 N4 I/O power supply for 8-F
P5 N5 Power for unit
P6 N6 Power for unit
Table 2-7 Basic unit Terminal block TB1

⑩ LED for unit power supply

Display the condition of a unit power supply.

Color Specification
Off Power supply OFF status
Red The failures in a power supply (24V failures
(Over/under voltage detected by 1st detection
circuit))
Yellow The failures in a power supply (24V failures
(Over/under voltage detected by 2nd detection
circuit ) or WD error detection or Internal logic
power failure)
White Power supply normal

Table 2-14 LED for unit power supply

2-14
 ⑪ Connector for option unit connection
Use it for connection with an option unit.

⑫ Connector for IF unit connection

Use it for connection with an IF unit.

2.2.2.1. BS0016
Safety 16 point output unit.

(1) Specification
Item Description
Name BS0016
Type TNC-6886
Rated voltage /
24VDC+20%,-15% / 93mA
Consumption current
IO power supply DC20.4V～28.8V
Number of outputs Total 16 points
2 points x 8=16 points (PNP, PNP) : (Double
output: 8 sets) *1
Output current Output current : 0.5A / point
( 0.7A according to the condition, Refer to Table 2-5
The example of output current combination)
Maximum voltage descent Less than 1.5V
at ON.
Leak current at OFF. 0.1mA or less
Output method FET output
Response OFF→ON Less than１msec
time ON →OFF Less than１msec
Overcurrent protection 2.0A (FET built-inheating shutdown circuit)
Dimensions /weight 140Hx90Wx18D mm / 120g
Accessories Terminal block
*1：Default condition, all setting of double/single output is double.
However, change of single <=> double can be performed in I/O parameter change by
PCwin-Safe-Plus.
Table 2-15 BS0016 Specification

2-15
(2) Terminal Block Arrangement
TB2 Terminal Block
Terminal Terminal
Name Name
No. No.
L0 OUT00 (Ad.:Q000) R0 O_COM00
L1 OUT01 (Ad.:Q001) R1 O_COM01
L2 OUT02 (Ad.:Q002) R2 O_COM02
L3 OUT03 (Ad.:Q003) R3 O_COM03
L4 OUT04 (Ad.:Q004) R4 O_COM04
L5 OUT05 (Ad.:Q005) R5 O_COM05
L6 OUT06 (Ad.:Q006) R6 O_COM06
L7 OUT07 (Ad.:Q007) R7 O_COM07
P1 IO_PWR0+ (0～7 I/O Power) N1 IO_PWR0- (0～7 I/O Power)
P2 IO_PWR0+ (0～7 I/O Power) N2 IO_PWR0- (0～7 I/O Power)
Table 2-16 BS0016 TB2 Terminal Block
TB1 Terminal Block
Terminal Terminal
Name Name
No. No.
L8 OUT08 (Ad.:Q008) R8 O_COM08
L9 OUT09 (Ad.:Q009) R9 O_COM09
LA OUT0A (Ad.:Q00A) RA O_COM0A
LB OUT0B (Ad.:Q00B) RB O_COM0B
LC OUT0C (Ad.:Q00C) RC O_COM0C
LD OUT0D (Ad.:Q00D) RD O_COM0D
LE OUT0E (Ad.:Q00E) RE O_COM0E
LF OUT0F (Ad.:Q00F) RF O_COM0F
P3 IO_PWR1+ (8～F I/O Power) N3 IO_PWR1- (8～F I/O Power )
P4 IO_PWR1+ (8～F I/O Power ) N4 IO_PWR1- (8～F I/O Power )
P5 DC24V (Unit Power) N5 0V (Unit Power)
P6 DC24V (Unit Power) N6 0V (Unit Power)
Table 2-17 BS0016 TB1 Terminal Block

2-16
 (3) IO connection block diagram
Max.0.5A
TB2 Q**0 R0 O_COM00
L0 OUT00 MS1
Q**1 L1 OUT01
R1 O_COM01 MS2
The maximum output of one
Q**2 R2 O_COM02
channel is 0.5A. ( 0.7A
L2 OUT02 MS3
according to the condition,
Refer to Table 2-5 The Q**3 L3 OUT03
example of output current R3 O_COM03 MS4
combination Q**4 R4 O_COM04
There is a built-in heating L4 OUT04 MS5
shutdown circuit (2.0A) with Q**5 L5 OUT05
FET in each output. R5 O_COM05 MS6
Q**6 R6 O_COM06
L6 OUT06 MS7
Q**7 L7 OUT07
R7 O_COM07 MS8
P2
P1 IO_PWR0+
DC24V
N1 IO_PWR0-

N2
0V

TB1 Q**8 R8 O_COM08

L8 OUT08 MS9
Q**9 L9 OUT09
R9 O_COM09 MS10
Q**A RA O_COM0A
LA OUT0A MS11
Q**B LB OUT0B
RB O_COM0B MS12
Q**C RC O_COM0C
LC OUT0C MS13
Q**D LD OUT0D
RD O_COM0D MS14
Q**E RE O_COM0E
LE OUT0E MS15
Q**F LF OUT0F
RF O_COM0F MS16
P4
P3 IO_PWR1+
DC24V
N3 IO_PWR1-
N4 0V

Figure 2-11 IO connection block diagram

2-17
2.2.2.2. BS0808
Safety 8 inputs and safety 8 outputs unit.

(1) Specification
Item Description
Name BS0808
Type TNC-6887
Rated voltage /
4VDC+20%,-15% / 107mA
Consumption current
IO power supply DC20.4V～28.8V
8 inputs, 8 outputs total of 16 points
Input:2 x 4=8points (PNP, PNP). : (double input: 4
Input/output point sets) *1
Output: 2 x 4=8 points (PNP, PNP). : (double output:
4 sets) *2
Input resistor About 4.7KΩ
Input 5mA / Point
ON voltage / ON current Less than 16.8V / less than 5mA
OFF Voltage/OFF More than 7.2V / more than 2mA
Current
Input

Input kind Dry contact input, light curtain input, semiconductor

input *3
Input digital filter Selection from 0.7, 1.0, and 1.3 ms *4
- CPU can be selected by 16-point together.
- Internal extension I/O and Remote I/O can be
selected individually. *5
Output current Maximum 0.5A/point
( 0.7A according to the condition, Refer to Table 2-5
The example of output current combination)
Maximum voltage Less than 1.5V
descent at ON.
Output

Leak current at OFF. 0.1mA or less

Output method FET output
Response OFF→ON Less than１msec
time ON →OFF Less than１msec
Overcurrent protection 2.0A (FET built-inheating shutdown circuit)
Dimensions /weight 140Hx90Wx18D mm / 120g
Accessories Terminal block
*1: In default condition, all setting of double / single input is double setting.
However, change of single <=> double can be performed in I/O parameter change by
PCwin-Safe-Plus.
*2: In default condition, all setting of double / single output is double setting.
However, change of single <=> double can be performed in I/O parameter change by
PCwin-Safe-Plus.
*3: In default condition, dry contact input.
Change to a light curtain input or a semiconductor input can be changed the I/O parameter
of PCwin-Safe-Plus
*4: In default condition, 0.7ms.
Change to 1.0ms or 1.3ms can be changed by I/O parameter of PCwin-Safe-Plus.
*5: A single input can be selected by single and a double input can be selected every two points
for every point.

Table 2-18 BS0808 speficication

2-18
(2)Terminal Block Arrangement

TB2 Terminal Block

Terminal Terminal
Name Name
No. No.
L0 OUT00 (Ad.:Q000) R0 O_COM00
L1 OUT01 (Ad.:Q001) R1 O_COM01
L2 OUT02 (Ad.:Q002) R2 O_COM02
L3 OUT03 (Ad.:Q003) R3 O_COM03
L4 OUT04 (Ad.:Q004) R4 O_COM04
L5 OUT05 (Ad.:Q005) R5 O_COM05
L6 OUT06 (Ad.:Q006) R6 O_COM06
L7 OUT07 (Ad.:Q007) R7 O_COM07
P1 IO_PWR0+ (0～7 I/O Power) N1 IO_PWR0- (0～7 I/O Power)
P2 IO_PWR0+ (0～7 I/O Power) N2 IO_PWR0- (0～7 I/O Power)
Table 2-19 BS0808 TB2 Terminal Block
TB1 Terminal Block
Terminal Terminal
Block Name Block Name
No. No.
L8 I_COM08 R8 IN08 (Ad.:I008)
L9 I_COM09 R9 IN09 (Ad.:I009)
LA I_COM0A RA IN0A (Ad.:I00A)
LB I_COM0B RB IN0B (Ad.:I00B)
LC I_COM0C RC IN0C (Ad.:I00C)
LD I_COM0D RD IN0D (Ad.:I00D)
LE I_COM0E RE IN0E (Ad.:I00E)
LF I_COM0F RF IN0F (Ad.:I00F)
P3 IO_PWR1+ (8～F I/O Power) N3 IO_PWR1- (8～F I/O Power )
P4 IO_PWR1+ (8～F I/O Power ) N4 IO_PWR1- (8～F I/O Power )
P5 DC24V (Unit Power) N5 0V (Unit Power)
P6 DC24V (Unit Power) N6 0V (Unit Power)
Table 2-20 BS0808 TB1 Terminal Block

2-19
 (3)IO connection block diagram

Max.0.5A
TB2 Q**0 R0 O_COM00
L0 OUT00 MS1
Q**1 L1 OUT01
R1 O_COM01 MS2
Q**2 R2 O_COM02
The maximum output of one L2 OUT02 MS3
channel is 0.5A. ( 0.7A Q**3 L3 OUT03
according to the condition, R3 O_COM03 MS4
Refer toTable 2-5 The
Q**4 R4 O_COM04
example of output current MS5
L4 OUT04
combination)
There is a built-in heating Q**5 L5 OUT05
R5 O_COM05 MS6
shutdown circuit (2.0A) with
FET in each output. Q**6 R6 O_COM06
L6 OUT06 MS7
Q**7 L7 OUT07
R7 O_COM07 MS8
P2
P1 IO_PWR0+
DC24V
N1 IO_PWR0-

N2
0V

TB1
0V DC24V P4
IO_PWR1+ P3
IO_PWR1- N3
N4
Light curtain_1
I_COM08 L8
IN08 R8 I**8
IN09 R9 I**9
I_COM09 L9
Light curtain_2
I_COM0A LA
IN0A RA I**A
The kind of input can be
IN0B RB I**B set by I/O parameter of
I_COM0B LB PCwin-Safe-Plus .
E-stop_1 Please make setting
I_COM0C LC
IN0C RC I**C according to a
IN0D RD I**D connection device.
I_COM0D LD
E-stop _2
I_COM0E LE
IN0E RE I**E
IN0F RF I**F
I_COM0F LF

Figure 2-12 IO connection block diagram

2-20
2.2.2.3. BS1204
Safety 12 inputs and safety 4 outputs unit.

(1)Specification
Item Description
Name BS1204
Type TNC-6888
Rated voltage /
24VDC+20%,-15% / 116mA
Consumption current
IO power supply DC20.4V～28.8V
12 inputs, 4 outputs total of 16 points
Input:2 x 6=12points (PNP, PNP). : (double input:
Input/output point 6sets) *1
Output: 2 x 2=4 points (PNP, PNP). : (double output:
2 sets) *2
Input resistor About 4.7KΩ
Input

Input 5mA / Point

ON voltage / ON current Less than 16.8V / less than 5mA
OFF Voltage/OFF More than 7.2V / more than 2mA
Current
Input kind Dry contact input, light curtain input, semiconductor
input *3
Input digital filter Selection from 0.7, 1.0, and 1.3 ms *4
- CPU can be selected by 16-point together.
- Internal extension I/O and Remote I/O can be
selected individually. *5
Output current Maximum 0.5A/point
Output

( 0.7A according to the condition, Refer to Table 2-5

The example of output current combination)
Maximum voltage Less than 1.5V
descent at ON.
Leak current at OFF. 0.1mA or less
Output method FET output
Response OFF→ON Less than１msec
time ON →OFF Less than１msec
Overcurrent protection 2.0A (FET built-inheating shutdown circuit)
Dimensions /weight 140Hx90Wx18D mm / 120g
Accessories Terminal block
*1: In default condition, all setting of double / single input is double setting.
However, change of single <=> double can be performed in I/O parameter change by
PCwin-Safe-Plus.
*2: In default condition, all setting of double / single output is double setting.
However, change of single <=> double can be performed in I/O parameter change by
PCwin-Safe-Plus.
*3: In default condition, dry contact input.
Change to a light curtain input or a semiconductor input can be changed the I/O parameter
of PCwin-Safe-Plus
*4: In default condition, 0.7ms.
Change to 1.0ms or 1.3ms can be changed by I/O parameter of PCwin-Safe-Plus.
*5: A single input can be selected by single and a double input can be selected every two points
for every point.
Table 2-21 BS1204 Specification

2-21
(2)Terminal Block Arrangement

TB2 Terminal Block

Terminal Terminal
Block Name Block Name
No. No.
L0 OUT00 (Ad.:Q000) R0 O_COM00
L1 OUT01 (Ad.:Q001) R1 O_COM01
L2 OUT02 (Ad.:Q002) R2 O_COM02
L3 OUT03 (Ad.:Q003) R3 O_COM03
L4 I_COM04 R4 IN04 (Ad.:I004)
L5 I_COM05 R5 IN05 (Ad.:I005)
L6 I_COM06 R6 IN06 (Ad.:I006)
L7 I_COM07 R7 IN07 (Ad.:I007)
P1 IO_PWR0+ (0～7 I/O Power) N1 IO_PWR0- (0～7 I/O Power)
P2 IO_PWR0+ (0～7 I/O Power) N2 IO_PWR0- (0～7 I/O Power)
Table 2-22 BS1204 TB2 Terminal Block

TB1 Terminal Block

Terminal Terminal
Block Name Block Name
No. No.
L8 I_COM08 R8 IN08 (Ad.:I008)
L9 I_COM09 R9 IN09 (Ad.:I009)
LA I_COM0A RA IN0A (Ad.:I00A)
LB I_COM0B RB IN0B (Ad.:I00B)
LC I_COM0C RC IN0C (Ad.:I00C)
LD I_COM0D RD IN0D (Ad.:I00D)
LE I_COM0E RE IN0E (Ad.:I00E)
LF I_COM0F RF IN0F (Ad.:I00F)
P3 IO_PWR1+ (8～F I/O Power) N3 IO_PWR1- (8～F I/O Power )
P4 IO_PWR1+ (8～F I/O Power ) N4 IO_PWR1- (8～F I/O Power )
P5 DC24V (Unit Power) N5 0V (Unit Power)
P6 DC24V (Unit Power) N6 0V (Unit Power)
Table 2-23 BS1204 TB1 Terminal Block

2-22
 (3)IO connection block diagram

Max.0.5A
TB2 R0 O_COM00
The maximum output of one Q**0 L0 OUT00 MS1
channel is 0.5A. ( 0.7A Q**1 L1 OUT01
according to the condition, R1 O_COM01 MS2
Refer to Table 2-5 The
example of output current R2 O_COM02
combination) Q**2 L2 OUT02 MS3
There is a built-in heating Q**3 L3 OUT03
shutdown circuit (2.0A) with R3 O_COM03 MS4
FET in each output.

0V DC24V P2
IO_PWR0+ P1
IO_PWR0- N1
N2
Light curtain_1
I_COM04 L4
IN04 R4 I**4
IN05 R5 I**5
I_COM05 L5
E-stop_1
I_COM06 L6
IN06 R6 I**6
IN07 R7 I**7
I_COM07 L7 The kind of input can be
set by I/O parameter of
PCwin-Safe-Plus .
TB1
0V DC24V P4 Please make setting
IO_PWR1+ P3 according to a
connection device.
IO_PWR1- N3
Light curtain_2 N4
I_COM08 L8
IN08 R8 I**8
IN09 R9 I**9
I_COM09 L9
Light curtain_3
I_COM0A LA
IN0A RA I**A
IN0B RB I**B
I_COM0B LB
E-stop_2
I_COM0C LC
IN0C RC I**C
IN0D RD I**D
I_COM0D LD
E-stop_3
I_COM0E LE
IN0E RE I**E
IN0F RF I**F
I_COM0F LF

Figure 2-13 IO connection block diagram

2-23
2.2.2.4. BS1600
Safety 16 inputs unit.

(1)Specification
Item Description
Name BS1600
Type TNC-6889
Rated voltage /
24VDC+20%,-15% / 125mA
Consumption current
IO power supply DC20.4V～28.8V
Total 16 points
Input point
2 x 8=16 points (PNP, PNP). : (double input: 8 sets) *1
Input resistor About 4.7KΩ
Input 5mA / Point
ON voltage / ON current Less than 16.8V / less than 5mA
OFF Voltage/OFF More than 7.2V / more than 2mA
Current
Input kind Dry contact input, light curtain input, semiconductor input
*3
Input digital filter Selection from 0.7, 1.0, and 1.3 ms *4
- CPU can be selected by 16-point together.
- Internal extension I/O and Remote I/O can be selected
individually. *5
Dimensions /weight 140Hx90Wx18D mm / 120g
Accessories Terminal block
*1: In default condition, all setting of double / single input is double setting.
However, change of single <=> double can be performed in I/O parameter change by
PCwin-Safe-Plus.
*2: In default condition, dry contact input.
Change to a light curtain input or a semiconductor input can be changed the I/O parameter
of PCwin-Safe-Plus
*3: In default condition, 0.7ms.
Change to 1.0ms or 1.3ms can be changed by I/O parameter of PCwin-Safe-Plus.
*4: A single input can be selected by single and a double input can be selected every two points
for every point.
Table 2-24 BS1600 Specification

2-24
(2)Terminal Block Arrangement

TB2 Terminal Block

Terminal Terminal
Block Name Block Name
No. No.
L0 I_COM00 R0 IN00 (Ad.:I000)
L1 I_COM01 R1 IN01 (Ad.:I001)
L2 I_COM02 R2 IN02 (Ad.:I002)
L3 I_COM03 R3 IN03 (Ad.:I003)
L4 I_COM04 R4 IN04 (Ad.:I004)
L5 I_COM05 R5 IN05 (Ad.:I005)
L6 I_COM06 R6 IN06 (Ad.:I006)
L7 I_COM07 R7 IN07 (Ad.:I007)
P1 IO_PWR0+ (0～7 I/O Power) N1 IO_PWR0- (0～7 I/O Power)
P2 IO_PWR0+ (0～7 I/O Power) N2 IO_PWR0- (0～7 I/O Power)
Table 2-25 BS1600 TB2 Terminal Block
TB1 Terminal Block
Terminal Terminal
Block Name Block Name
No. No.
L8 I_COM08 R8 IN08 (Ad.:I008)
L9 I_COM09 R9 IN09 (Ad.:I009)
LA I_COM0A RA IN0A (Ad.:I00A)
LB I_COM0B RB IN0B (Ad.:I00B)
LC I_COM0C RC IN0C (Ad.:I00C)
LD I_COM0D RD IN0D (Ad.:I00D)
LE I_COM0E RE IN0E (Ad.:I00E)
LF I_COM0F RF IN0F (Ad.:I00F)
P3 IO_PWR1+ (8～F I/O Power) N3 IO_PWR1- (8～F I/O Power )
P4 IO_PWR1+ (8～F I/O Power ) N4 IO_PWR1- (8～F I/O Power )
P5 DC24V (Unit Power) N5 0V (Unit Power)
P6 DC24V (Unit Power) N6 0V (Unit Power)
Table 2-26 BS1600 TB1 Terminal Block

2-25
(3)IO connection block diagram

TB2
0V DC24V P2
IO_PWR0+ P1
IO_PWR0- N1
Light curtain_1 N2
I_COM00 L0 The kind of input can be
IN00 R0 I**0 set by I/O parameter of
PCwin-Safe-Plus .
IN01 R1 I**1
I_COM01 L1 Please make setting
Light curtain _2 according to a
I_COM02 L2 connection device.
IN02 R2 I**2
IN03 R3 I**3
I_COM03 L3
E-stop1
I_COM04 L4
IN04 R4 I**4
IN05 R5 I**5
I_COM05 L5
E-stop _2
I_COM06 L6
IN06 R6 I**6
IN07 R7 I**7
I_COM07 L7

TB1
0V DC24V P4
IO_PWR1+ P3
IO_PWR1- N3
N4
Light curtain _3
I_COM08 L8
IN08 R8 I**8
IN09 R9 I**9
I_COM09 L9
Light curtain _4
I_COM0A LA
IN0A RA I**A
IN0B RB I**B
I_COM0B LB
E-stop _3
I_COM0C LC
IN0C RC I**C
IN0D RD I**D
I_COM0D LD
E-stop _4
I_COM0E LE
IN0E RE I**E
IN0F RF I**F
I_COM0F LF

Figure 2-14 IO connection block diagram

2-26
2.2.2.5. BN16-P
Standard 16 points input/outputs unit. 。
In the case of using safety devices, please select a BS unit
Input/output can be set with a programming tool (PCwin-Safe-Plus) for every two points
(1)Specification
Item Description
Type TNC-6894
Name BN16-P
Rated voltage /
24VDC+20%,-15% / 93mA
Consumption current
IO power supply DC20.4V～28.8V
Total of 16 points (selection of an input/output can
Input/output point be performed every two points with a parameter.)
Polarity :PNP
Input resistor About 4.7KΩ
Input

Input 5mA / Point

ON voltage / ON current Less than 16.8V / less than 5mA
OFF Voltage/OFF More than 7.2V / more than 2mA
Current
Input digital filter Selection from 0.7, 1.0, and 1.3 ms *1
- CPU can be selected 16 points together.
- Internal extension I/O and Remote I/O can be
selected the individually.
Common method 2 points/ common
Output current Maximum 0.5A/point
Output

( 0.7A according to the condition, Refer to Table 2-5

The example of output current combination)
Maximum voltage Less than 1.5V
descent at ON.
Leak current at OFF. 0.1mA or less
Output method FET output
Response OFF→ON Less than１msec
time ON →OFF Less than１msec
Overcurrent protection 2.0A (FET built-inheating shutdown circuit)
Common method 8 points/ common
Dimensions /weight 140Hx90Wx18D mm / 120g
Accessories Terminal block
*1：In default condition, 0.7ms.
Change to 1.0ms or 1.3ms can be changed by I/O parameter of PCwin-Safe-Plus.

Table 2-27 BN16-P Specification

2-27
(2)Terminal Block Arrangement

TB2 Terminal Block (Input/output can be set a parameter )

Terminal Name Terminal Name
Block Block Input Output
No. Input Output No.
L0 IN00 OUT00
R0 I_COM00/01 N.C.
(Ad.:X000) (Ad.:Y000)
L1 IN01 OUT01 R1
I_COM00/01 N.C.
(Ad.:X001) (Ad.:Y001)
L2 IN02 OUT02 R2
I_COM02/03 N.C.
(Ad.:X002) (Ad.:Y002)
L3 IN03 OUT03 R3
I_COM02/03 N.C.
(Ad.:X003) (Ad.:Y003)
L4 IN04 OUT04 R4
I_COM04/05 N.C.
(Ad.:X004) (Ad.:Y004)
L5 IN05 OUT05 R5
I_COM04/05 N.C.
(Ad.:X005) (Ad.:Y005)
L6 IN06 OUT06 R6
I_COM06/07 N.C.
(Ad.:X006) (Ad.:Y006)
L7 IN07 OUT07 R7
I_COM06/07 N.C.
(Ad.:X007) (Ad.:Y007)
P1 IO_PWR0+ (0～7 I/O Power) N1 IO_PWR0- (0～7 I/O Power)
P2 IO_PWR0+ (0～7 I/O Power) N2 IO_PWR0- (0～7 I/O Power)
Table 2-28 BN16-P TB2 Terminal Block
TB1 Terminal Block (Input/output can be set a parameter )
Terminal Name Terminal Name
Block Block
Input Output Input Output
No. No.
L8 IN08 OUT08
R8 I_COM08/09 N.C.
(Ad.:X008) (Ad.:Y008)
L9 IN09 OUT09 R9
I_COM08/09 N.C.
(Ad.:X009) (Ad.:Y009)
LA IN0A OUT0A RA
I_COM0A/0B N.C.
(Ad.:X00A) (Ad.:Y00A)
LB IN0B OUT0B RB
I_COM0A/0B N.C.
(Ad.:X00B) (Ad.:Y00B)
LC IN0C OUT0C RC
I_COM0C/0D N.C.
(Ad.:X00C) (Ad.:Y00C)
LD IN0D OUT0D RD
I_COM0C/0D N.C.
(Ad.:X00D) (Ad.:Y00D)
LE IN0E OUT0E RE
I_COM0E/0F N.C.
(Ad.:X00E) (Ad.:Y00E)
LF IN0F OUT0F RF
I_COM0E/0F N.C.
(Ad.:X00F) (Ad.:Y00F)
P3 IO_PWR1+ (8～F I/O Power) N3 IO_PWR1- (8～F I/O Power )
P4 IO_PWR1+ (8～F I/O Power ) N4 IO_PWR1- (8～F I/O Power )
P5 DC24V (Unit Power) N5 0V (Unit Power)
P6 DC24V (Unit Power) N6 0V (Unit Power)

Table 2-29 BN16-P TB1 Terminal Block

2-28
 (3)IO connection block diagram
Input/output can be set
with a programming tool
(PCwin-Safe-Plus) for
every two points

When setting as input When setting as output

(2 points/common) (8 points/common)

TB2 L0
SW _1 IN00 L0 X**0 Y**0 OUT00
I_COM00/01 R0
MS1
SW_2 IN01 L1 X**1 Y**1 L1 OUT01
I_COM00/01 R1
MS2

SW _3 IN02 L2 X**2 Y**2 L2 OUT02

I_COM02/03 R2
MS3
SW _4 IN03 L3 X**3 Y**3 L3 OUT03
I_COM02/03 R3 MS4

IN04 L4 X**4 Y**4 L4 OUT04

SW _5 MS5
I_COM04/05 R4
SW _6 IN05 L5 X**5 Y**5 L5 OUT05
I_COM04/05 R5
MS6

IN06 L6 X**6 Y**6 L6 OUT06

SW _7 MS7
I_COM06/07 R6
SW _8 IN07 L7 X**7 Y**7 L7 OUT07
I_COM06/07 R7 MS8

0V DC24V P2
IO_PWR0+ P1
IO_PWR0- A2
A1

TB1
SW _9 IN08 L8 X**8 Y**8 L8 OUT08
I_COM08/09 R8
MS9
SW _10 IN09 L9 X**9 Y**9 L9 OUT09
I_COM08/09 R9
MS10

SW _11 IN0A LA X**A Y**A LA OUT0A

I_COM0A/0B RA
MS11

SW _12 IN0B LB X**B Y**B LB OUT0B

I_COM0A/0B RB MS12

SW _13 IN0C LC X**C Y**C LC OUT0C

I_COM0C/0D RC
MS13
SW _14 IN0D LD X**D Y**D LD OUT0D
I_COM0C/0D RD MS14

SW _15 IN0E LE X**E Y**E LE OUT0E MS15

I_COM0E/0F RE
SW _16 IN0F LF X**F Y**F LF OUT0F
I_COM0E/0F RF MS16

0V DC24V P4
IO_PWR1+ P3
IO_PWR1- N3
N4

Figure 2-15 IO connection block diagram

2-29
2.2.2.6. LED Display List

Figure 2-16 LED Display List

2-30
2.2.3. Option Unit

(1) IO point
Name Safety input Safety output Standard
number number input/output
OS0016 0 point 16 points
OS0808 8 points ※１ 8 points
OS1600 16 points ※１ 0 point
OS1200 12 points ※１ 0 point
ON16-P 16 points※2
※1 Input setting: dry contact, semiconductor (test pulses /no test pulse) can be set by per two
points using a programming tool
※2 Input/output point can be set per every 2 points with a programming tool .
Table 2-30 Option Unit IO point
(2) Name and function of each part
Left-hand side Front

Right-hand side
① Terminal block TB2
② Terminal block TB1
③ Connector for basic unit connection

Figure 2-17 Option Unit

2-31
① Terminal block TB2
Terminal block for input/output (addresses 0-7) and
power supply connection for IO.
Please refer to clause 2.2.3 to 2.2.3.5 for details.
TB2 Terminal
Address No.
block No.
L0 R0 0
L1 R1 1
L2 R2 2
L3 R3 3
L4 R4 4
L5 R5 5 TB2
L6 R6 6
L7 R7 7
I/O power supply
N1 N1
for 0-7
N2 N2 I/O power supply
for 0-7
Table 2-31 Option Unit terminal block TB2
TB1
② Terminal block TB1
Terminal Block for input/output (address 8-F) and
power supply connection for IO.
Please refer to clause 2.2.3 to 2.2.3.5 for details.

TB1 Terminal Address No.

L8 R8 8 Figure 2-18 Option Unit
L9 R9 9
LA RA A
LB RB B
LC RC C
LD RD D
LE RE E
LF RF F
I/O power
P3 N3
supply for 8-F
I/O power
P4 N4
supply for 8-F
Table 2-32 Option Unit terminal block TB1

③Connector for basic unit connection

Use it for connection with a basic unit.

2-32
2.2.3.1. OS0016
Safety 16 outputs unit for extension.

(1)Specification
Item Description
Name OS0016
Type TNK-6890
Rated voltage / 24VDC+20%,-15% / 16mA (supplied from a basic
Consumption current unit )
IO power supply DC20.4V～28.8V
Number of outputs Total 16 points
2 points x 8=16 points (PNP, PNP) : (Double
output: 8 sets) *1
Output current Maximum 0.5A/point
( 0.7A according to the condition, Refer to Table 2-5
The example of output current combination)
Maximum voltage descent Less than 1.5V
at ON.
Leak current at OFF. 0.1mA or less
Output method FET output
Response OFF→ON Less than１msec
time ON →OFF Less than１msec
Overcurrent protection 2.0A (with FET built-in heating shutdown circuit )
Dimensions /weight 140Hx90Wx18D mm / 90g
Accessories Terminal block
*1：Default condition, all setting of double/single output is double.
However, change of single <=> double can be performed in I/O parameter change by
PCwin-Safe-Plus.
Table 2-33 OS0016 Specification

2-33
(2)Terminal Block Arrangement
TB2 Terminal Block
Terminal Terminal
Block Name Block Name
No. No.
L0 OUT00 (Ad.:Q000) R0 O_COM00
L1 OUT01 (Ad.:Q001) R1 O_COM01
L2 OUT02 (Ad.:Q002) R2 O_COM02
L3 OUT03 (Ad.:Q003) R3 O_COM03
L4 OUT04 (Ad.:Q004) R4 O_COM04
L5 OUT05 (Ad.:Q005) R5 O_COM05
L6 OUT06 (Ad.:Q006) R6 O_COM06
L7 OUT07 (Ad.:Q007) R7 O_COM07
N1 IO_PWR0+ (0～7 I/O Power) N1 IO_PWR0- (0～7 I/O Power)
N2 IO_PWR0+ (0～7 I/O Power) N2 IO_PWR0- (0～7 I/O Power)
Table 2-34 OS0016 TB2 Terminal Block
TB1 Terminal Block
Terminal Terminal
Block Name Block Name
No. No.
L8 OUT08 (Ad.:Q008) R8 O_COM08
L9 OUT09 (Ad.:Q009) R9 O_COM09
LA OUT0A (Ad.:Q00A) RA O_COM0A
LB OUT0B (Ad.:Q00B) RB O_COM0B
LC OUT0C (Ad.:Q00C) RC O_COM0C
LD OUT0D (Ad.:Q00D) RD O_COM0D
LE OUT0E (Ad.:Q00E) RE O_COM0E
LF OUT0F (Ad.:Q00F) RF O_COM0F
P3 IO_PWR1+ (8～F I/O Power) N3 IO_PWR1- (8～F I/O Power )
P4 IO_PWR1+ (8～F I/O Power ) N4 IO_PWR1- (8～F I/O Power )
Table 2-35 OS0016 TB1 Terminal Block

2-34
(3) IO connection block diagram
Max.0.5A
TB2 Q**0 R0 O_COM00
L0 OUT00 MS1
Q**1 L1 OUT01
R1 O_COM01 MS2
The maximum output of one
Q**2 R2 O_COM02
channel is 0.5A. ( 0.7A MS3
according to the condition, L2 OUT02
Refer to Table 2-5 The Q**3 L3 OUT03
example of output current R3 O_COM03 MS4
combination) Q**4 R4 O_COM04
There is a built-in heating L4 OUT04 MS5
shutdown circuit (2.0A) with Q**5 L5 OUT05
FET in each output. R5 O_COM05 MS6
Q**6 R6 O_COM06
L6 OUT06 MS7
Q**7 L7 OUT07
R7 O_COM07 MS8
P2
P1 IO_PWR0+
DC24V
N1 IO_PWR0-

N2
0V

TB1 Q**8 R8 O_COM08

L8 OUT08 MS9
Q**9 L9 OUT09
R9 O_COM09 MS10
Q**A RA O_COM0A
LA OUT0A MS11
Q**B LB OUT0B
RB O_COM0B MS12
Q**C RC O_COM0C
LC OUT0C MS13
Q**D LD OUT0D
RD O_COM0D MS14
Q**E RE O_COM0E
LE OUT0E MS15
Q**F LF OUT0F
RF O_COM0F MS16
P4
P3 IO_PWR1+
DC24V
N3 IO_PWR1-
N4 0V

Figure 2-19 IO connection block diagram

2-35
2.2.3.2. OS0808
Safety 8 inputs and safety 8 outputs unit for extension.

(1)Specification
Item Description
Name OS0808
Type TNK-6891
Rated voltage /
24 V DC +20% / - 15 % / 12mA
Consumption current
IO power supply DC20.4V～28.8V
8 inputs, 8 outputs total of 16 points
Input:2 x 4=8points (PNP, PNP). : (double input: 4
nput/output point sets) *1
Output: 2 x 4=8 points (PNP, PNP). : (double output:
4 sets) *2
Input resistor About 4.7KΩ
Input 5mA / Point
ON voltage / ON current Less than 16.8V / less than 5mA
OFF Voltage/OFF More than 7.2V / more than 2mA
Current
Input

Input kind Dry contact input, light curtain input, semiconductor

input *3
Input digital filter Selection from 0.7, 1.0, and 1.3 ms *4
- CPU can be selected by 16-point together.
- Internal extension I/O and Remote I/O can be
selected individually. *5
Output current Maximum 0.5A/point
( 0.7A according to the condition, Refer to Table 2-5
The example of output current combination)
Maximum voltage Less than 1.5V
descent at ON.
Output

Leak current at OFF. 0.1mA or less

Output method FET output
Response OFF→ON Less than１msec
time ON →OFF Less than１msec
Overcurrent protection 2.0A (FET built-inheating shutdown circuit)
Dimensions /weight 140H×90W×18D mm / 90g
Accessories Terminal Block
*1: In default condition, all setting of double / single input is double setting.
However, change of single <=> double can be performed in I/O parameter change by
PCwin-Safe-Plus.
*2: In default condition, all setting of double / single output is double setting.
However, change of single <=> double can be performed in I/O parameter change by
PCwin-Safe-Plus.
*3: In default condition, dry contact input.
Change to a light curtain input or a semiconductor input can be changed the I/O parameter
of PCwin-Safe-Plus
*4: In default condition, 0.7ms.
Change to 1.0ms or 1.3ms can be changed by I/O parameter of PCwin-Safe-Plus.
*5: A single input can be selected by single and a double input can be selected every two points
for every point.
Table 2-36 OS0808 Specification

2-36
(2)Terminal Block Arrangement

TB2 Terminal Block

Terminal Terminal
Block Name Block Name
No. No.
L0 OUT00 (Ad.:Q000) R0 O_COM00
L1 OUT01 (Ad.:Q001) R1 O_COM01
L2 OUT02 (Ad.:Q002) R2 O_COM02
L3 OUT03 (Ad.:Q003) R3 O_COM03
L4 OUT04 (Ad.:Q004) R4 O_COM04
L5 OUT05 (Ad.:Q005) R5 O_COM05
L6 OUT06 (Ad.:Q006) R6 O_COM06
L7 OUT07 (Ad.:Q007) R7 O_COM07
N1 IO_PWR0+ (0～7 I/O Power) N1 IO_PWR0- (0～7 I/O Power)
N2 IO_PWR0+ (0～7 I/O Power) N2 IO_PWR0- (0～7 I/O Power)
Table 2-37 OS0808 TB2 Terminal Block
TB1 Terminal Block
Terminal Terminal
Block Name Block Name
No. No.
L8 I_COM08 R8 IN08 (Ad.:I008)
L9 I_COM09 R9 IN09 (Ad.:I009)
LA I_COM0A RA IN0A (Ad.:I00A)
LB I_COM0B RB IN0B (Ad.:I00B)
LC I_COM0C RC IN0C (Ad.:I00C)
LD I_COM0D RD IN0D (Ad.:I00D)
LE I_COM0E RE IN0E (Ad.:I00E)
LF I_COM0F RF IN0F (Ad.:I00F)
P3 IO_PWR1+ (8～F I/O Power) N3 IO_PWR1- (8～F I/O Power )
P4 IO_PWR1+ (8～F I/O Power) N4 IO_PWR1- (8～F I/O Power )
Table 2-38 OS0808 TB1 Terminal Block

2-37
 (3)IO connection block diagram
TB2 Q**0 R0 O_COM00
L0 OUT00 MS1
Q**1 L1 OUT01
R1 O_COM01 MS2
Q**2 R2 O_COM02
The maximum output of one L2 OUT02 MS3
channel is 0.5A. ( 0.7A Q**3 L3 OUT03
according to the condition, R3 O_COM03 MS4
Refer to Table 2-5 The
Q**4 R4 O_COM04
example of output current MS5
L4 OUT04
combination)
There is a built-in heating Q**5 L5 OUT05
R5 O_COM05 MS6
shutdown circuit (2.0A) with
FET in each output. Q**6 R6 O_COM06
L6 OUT06 MS7
Q**7 L7 OUT07
R7 O_COM07 MS8
P2
P1 IO_PWR0+
DC24V
N1 IO_PWR0-

N2
0V

TB1
0V DC24V P4
IO_PWR1+ P3
IO_PWR1- N3
Light curtain _1 N4
I_COM08 L8
IN08 R8 I**8
IN09 R9 I**9
I_COM09 L9
Light curtain_2
I_COM0A LA
IN0A RA I**A
The kind of input can be
IN0B RB I**B set by I/O parameter of
I_COM0B LB PCwin-Safe-Plus .
E-stop _1 Please make setting
I_COM0C LC
IN0C RC I**C according to a
IN0D RD I**D connection device
I_COM0D LD
E-stop _2
I_COM0E LE
IN0E RE I**E
IN0F RF I**F
I_COM0F LF

Figure 2-20 IO connection block diagram

2-38
2.2.3.3. OS1600
Safety 16 inputs unit.

(1)Specification
Item Description
Name OS1600
Type TNK-6892
Rated voltage / 24VDC +20% / -15 %
Consumption current / 8mA
IO power supply DC20.4V～28.8V
Total 16 points
Input point
2 x 8=16 points (PNP, PNP). : (double input: 8 sets) *1
Input resistor About 4.7KΩ
Input 5mA / Point
ON voltage / ON current Less than 16.8V / less than 5mA
OFF Voltage/OFF Current More than 7.2V / more than 2mA
Input kind Dry contact input, light curtain input, semiconductor input
*3
Input digital filter Selection from 0.7, 1.0, and 1.3 ms *4
- CPU can be selected by 16-point together.
- Internal extension I/O and Remote I/O can be selected
individually. *5
Dimensions /weight 140H×90W×18D mm / 120g
Accessories Terminal Block

*1: In default condition, all setting of double / single input is double setting.
However, change of single <=> double can be performed in I/O parameter change by
PCwin-Safe-Plus.
*2: In default condition, dry contact input.
Change to a light curtain input or a semiconductor input can be changed the I/O parameter
of PCwin-Safe-Plus
*3: In default condition, 0.7ms.
Change to 1.0ms or 1.3ms can be changed by I/O parameter of PCwin-Safe-Plus.
*4: A single input can be selected by single and a double input can be selected every two points
for every point.
Table 2-39 OS1600 Specification

2-39
(2)Terminal Block Arrangement

TB2 Terminal Block

Terminal Terminal
Block Name Block Name
No. No.
L0 I_COM00 R0 IN00 (Ad.:I000)
L1 I_COM01 R1 IN01 (Ad.:I001)
L2 I_COM02 R2 IN02 (Ad.:I002)
L3 I_COM03 R3 IN03 (Ad.:I003)
L4 I_COM04 R4 IN04 (Ad.:I004)
L5 I_COM05 R5 IN05 (Ad.:I005)
L6 I_COM06 R6 IN06 (Ad.:I006)
L7 I_COM07 R7 IN07 (Ad.:I007)
N1 IO_PWR0+ (0～7 I/O Power) N1 IO_PWR0- (0～7 I/O Power)
N2 IO_PWR0+ (0～7 I/O Power) N2 IO_PWR0- (0～7 I/O Power)
Table 2-40 OS1600 TB2 Terminal Block

TB1 Terminal Block

Terminal Terminal
Block Name Block Name
No. No.
L8 I_COM08 R8 IN08 (Ad.:I008)
L9 I_COM09 R9 IN09 (Ad.:I009)
LA I_COM0A RA IN0A (Ad.:I00A)
LB I_COM0B RB IN0B (Ad.:I00B)
LC I_COM0C RC IN0C (Ad.:I00C)
LD I_COM0D RD IN0D (Ad.:I00D)
LE I_COM0E RE IN0E (Ad.:I00E)
LF I_COM0F RF IN0F (Ad.:I00F)
P3 IO_PWR1+ (8～F I/O Power) N3 IO_PWR1- (8～F I/O Power )
P4 IO_PWR1+ (8～F I/O Power ) N4 IO_PWR1- (8～F I/O Power )
Table 2-41 OS1600 TB1 Terminal Block

2-40
(3) IO connection block diagram

0V DC24V P2
IO_PWR0+ P1
IO_PWR0- N1
Light curtain_1 N2
I_COM00 L0 The kind of input can be
IN00 R0 I**0 set by I/O parameter of
PCwin-Safe-Plus .
IN01 R1 I**1
I_COM01 L1 Please make setting
Light curtain_2 according to a
I_COM02 L2 connection device
IN02 R2 I**2
IN03 R3 I**3
I_COM03 L3
E-stop_1
I_COM04 L4
IN04 R4 I**4
IN05 R5 I**5
I_COM05 L5
E-stop _2
I_COM06 L6
IN06 R6 I**6
IN07 R7 I**7
I_COM07 L7

TB1
0V DC24V P4
IO_PWR1+ P3
IO_PWR1- N3
N4
Light curtain _3
I_COM08 L8
IN08 R8 I**8
IN09 R9 I**9
I_COM09 L9
Light curtain _4
I_COM0A LA
IN0A RA I**A
IN0B RB I**B
I_COM0B LB
E-stop_3
I_COM0C LC
IN0C RC I**C
IN0D RD I**D
I_COM0D LD
E-stop _4
I_COM0E LE
IN0E RE I**E
IN0F RF I**F
I_COM0F LF

Figure 2-21 IO connection block diagram

2-41
2.2.3.4. OS1200
Safety 16 inputs unit.

(1)Specification
Item Description
Name OS1200
Type TNK-6893
Rated voltage /
24VDC +20% / -15 % / 8mA
Consumption current
IO power supply DC20.4V～28.8V
Total 12 points
Input point
2 x 6=12 points (PNP, PNP). : (double input: 6sets) *1
Input resistor About 4.7KΩ
Input 5mA / Point
ON voltage / ON current Less than 16.8V / less than 5mA
OFF Voltage/OFF Current More than 7.2V / more than 2mA
Input kind Dry contact input, light curtain input, semiconductor input
*3
Input digital filter Selection from 0.7, 1.0, and 1.3 ms *4
- CPU can be selected by 16-point together.
- Internal extension I/O and Remote I/O can be selected
individually. *5
Dimensions /weight 140H×90W×18D mm / 120g
Accessories Terminal Block

*1: In default condition, all setting of double / single input is double setting.
However, change of single <=> double can be performed in I/O parameter change by
PCwin-Safe-Plus.
*2: In default condition, dry contact input.
Change to a light curtain input or a semiconductor input can be changed the I/O parameter
of PCwin-Safe-Plus
*3: In default condition, 0.7ms.
Change to 1.0ms or 1.3ms can be changed by I/O parameter of PCwin-Safe-Plus.
*4: A single input can be selected by single and a double input can be selected every two points
for every point.
Table 2-42 OS1200 Specification

2-42
(2)Terminal Block Arrangement

TB2 Terminal Block

Terminal Terminal
Block Name Block Name
No. No.
L0 Unused R0 Unused
L1 Unused R1 Unused
L2 Unused R2 Unused
L3 Unused R3 Unused
L4 I_COM04 R4 IN04 (Ad.:I004)
L5 I_COM05 R5 IN05 (Ad.:I005)
L6 I_COM06 R6 IN06 (Ad.:I006)
L7 I_COM07 R7 IN07 (Ad.:I007)
N1 IO_PWR0+ (0～7 I/O Power) N1 IO_PWR0- (0～7 I/O Power)
N2 IO_PWR0+ (0～7 I/O Power) N2 IO_PWR0- (0～7 I/O Power)

Table 2-43 OS1200 TB2 Terminal Block

TB1 Terminal Block
Terminal Terminal
Block Name Block Name
No. No.
L8 I_COM08 R8 IN08 (Ad.:I008)
L9 I_COM09 R9 IN09 (Ad.:I009)
LA I_COM0A RA IN0A (Ad.:I00A)
LB I_COM0B RB IN0B (Ad.:I00B)
LC I_COM0C RC IN0C (Ad.:I00C)
LD I_COM0D RD IN0D (Ad.:I00D)
LE I_COM0E RE IN0E (Ad.:I00E)
LF I_COM0F RF IN0F (Ad.:I00F)
P3 IO_PWR1+ (8～F I/O Power) N3 IO_PWR1- (8～F I/O Power )
P4 IO_PWR1+ (8～F I/O Power ) N4 IO_PWR1- (8～F I/O Power )
Table 2-44 OS1200 TB1 Terminal Block

2-43
(3) IO connection block diagram

TB2

L0-L3 and R0-R3 are

not used.

0V DC24V P2
IO_PWR0+ P1
IO_PWR0- N1
N2
Light curtain_1
I_COM04 L4
IN04 R4 I**4
IN05 R5 I**5
I_COM05 L5 The kind of input can be
E-stop_1
I_COM06 L6 set by I/O parameter of
IN06 R6 I**6 PCwin-Safe-Plus .
IN07 R7 I**7 Please make setting
I_COM07 L7 according to a
connection device
TB1
0V DC24V P4
IO_PWR1+ P3
IO_PWR1- N3
N4
Light curtain_2
I_COM08 L8
IN08 R8 I**8
IN09 R9 I**9
I_COM09 L9
Light curtain_3
I_COM0A LA
IN0A RA I**A
IN0B RB I**B
I_COM0B LB
E-stop_2
I_COM0C LC
IN0C RC I**C
IN0D RD I**D
I_COM0D LD
E-stop_3
I_COM0E LE
IN0E RE I**E
IN0F RF I**F
I_COM0F LF

Figure 2-22 IO connection block diagram

2-44
2.2.3.5. ON16-P
Standard 16 points input/outputs unit. If the customer are using safety devices, please
select a OS unit. Input/output can be set with a programming tool (PCwin-Safe-Plus) for
every two points

(1)Specification
Item Description
IO power supply ON16-P
Name TNK-6896
Rated voltage /
24VDC +20% / -15 % / 8mA
Consumption current
Type DC20.4V～28.8V
Total of 16 points (selection of an input/output can
Input/output point be performed every two points with a parameter.)
Polarity :PNP
Input resistor About 4.7KΩ
Input 5mA / Point

ON voltage / ON current Less than 16.8V / less than 5mA

OFF Voltage/OFF More than 7.2V / more than 2mA
Input

Current
Input digital filter Selection from 0.7, 1.0, and 1.3 ms *1
- CPU can be selected 16 points together.
- Internal extension I/O and Remote I/O can be
selected individually.
Common method 2 points/ common
Output current: 0.5A / point
Output current 0.7A is available by conditions. Refer toTable 2-5
The example of output current combination.
Maximum voltage Less than 1.5V
descent at ON.
Leak current at OFF. 0.1mA or less
Output

Output method FET output

Maximum voltage Less than 1.5V
descent at ON.
Response OFF→ON Less than１msec
time ON →OFF Less than１msec
Overcurrent protection 2.0A (FET built-inheating shutdown circuit)
Common method 8 points/ common
Dimensions /weight 140H×90W×18D mm / 120g
Accessories Terminal Block
*1：In default condition, 0.7ms.
Change to 1.0ms or 1.3ms can be changed by I/O parameter of PCwin-Safe-Plus.
Table 2-45 ON16-P Specification

2-45
(2)Terminal Block Arrangement

TB2 Terminal Block (Input/output can be set a parameter )

Terminal Name Terminal Name
Block Block
No. Input Output No. Input Output
IN00 OUT00
L0 (Ad.:X000) (Ad.:Y000)
R0 I_COM00/01 N.C.
L1 IN01 OUT01 R1
I_COM00/01 N.C.
(Ad.:X001) (Ad.:Y001)
L2 IN02 OUT02 R2
I_COM02/03 N.C.
(Ad.:X002) (Ad.:Y002)
L3 IN03 OUT03 R3
I_COM02/03 N.C.
(Ad.:X003) (Ad.:Y003)
L4 IN04 OUT04 R4
I_COM04/05 N.C.
(Ad.:X004) (Ad.:Y004)
L5 IN05 OUT05 R5
I_COM04/05 N.C.
(Ad.:X005) (Ad.:Y005)
L6 IN06 OUT06 R6
I_COM06/07 N.C.
(Ad.:X006) (Ad.:Y006)
L7 IN07 OUT07 R7
I_COM06/07 N.C.
(Ad.:X007) (Ad.:Y007)
N1 IO_PWR0+ (0～7 I/O Power) N1 IO_PWR0- (0～7 I/O Power)
N2 IO_PWR0+ (0～7 I/O Power) N2 IO_PWR0- (0～7 I/O Power)
Table 2-46 ON16-P TB2 Terminal Block
TB1 Terminal Block (Input/output can be set a parameter )
Terminal Name Terminal Name
Block Block
No. Input Output No. Input Output
L8 IN08 OUT08
(Ad.:X008) (Ad.:Y008)
R8 I_COM08/09 N.C.
L9 IN09 OUT09 R9 I_COM08/09 N.C.
(Ad.:X009) (Ad.:Y009)
LA IN0A OUT0A RA I_COM0A/0B N.C.
(Ad.:X00A) (Ad.:Y00A)
LB IN0B OUT0B RB I_COM0A/0B N.C.
(Ad.:X00B) (Ad.:Y00B)
LC IN0C OUT0C RC I_COM0C/0D N.C.
(Ad.:X00C) (Ad.:Y00C)
LD IN0D OUT0D RD I_COM0C/0D N.C.
(Ad.:X00D) (Ad.:Y00D)
LE IN0E OUT0E RE I_COM0E/0F N.C.
(Ad.:X00E) (Ad.:Y00E)
LF IN0F OUT0F
(Ad.:X00F) (Ad.:Y00F)
RF I_COM0E/0F N.C.
P3 IO_PWR1+ (8～F I/O Power) N3 IO_PWR1- (8～F I/O Power )
P4 IO_PWR1+ (8～F I/O Power ) N4 IO_PWR1- (8～F I/O Power )

Table 2-47 ON16-P TB2 Terminal Block

2-46
 (3) IO connection block diagram

Input/output can be set

with a programming tool
(PCwin-Safe-Plus) for
every two points
When setting as input When setting as output
(2 points/common) (8 points/common)

TB2 L0
SW_1 IN00 L0 X**0 Y**0 OUT00
I_COM00/01 R0
MS1
SW_2 IN01 R1 X**1 Y**1 L1 OUT01
I_COM00/01 L1
MS2

SW _3 IN02 L2 X**2 Y**2 L2 OUT02

I_COM02/03 R2
MS3
SW _4 IN03 R3 X**3 Y**3 L3 OUT03
I_COM02/03 L3 MS4

IN04 L4 X**4 Y**4 L4 OUT04

SW _5 MS5
I_COM04/05 R4
SW _6 IN05 R5 X**5 Y**5 L5 OUT05
I_COM04/05 L5
MS6

IN06 L6 X**6 Y**6 L6 OUT06

SW _7 MS7
I_COM06/07 R6
SW _8 IN07 R7 X**7 Y**7 L7 OUT07
I_COM06/07 L7 MS8

0V DC24V P2
IO_PWR0+ P1
IO_PWR0- N1
N2

TB1 L8
SW_9 IN08 L8 X**8 Y**8 OUT08
I_COM08/09 R8
MS9
SW _10 IN09 R9 X**9 Y**9 L9 OUT09
I_COM08/09 L9
MS10

SW _11 IN0A LA X**A Y**A LA OUT0A

I_COM0A/0B RA
MS11
SW _12 IN0B RB X**B Y**B LB OUT0B
I_COM0A/0B LB MS12

SW _13 IN0C LC X**C Y**C LC OUT0C

I_COM0C/0D RC
MS13
SW _14 IN0D RD X**D Y**D LD OUT0D
I_COM0C/0D LD MS14

SW _15 IN0E LE X**E Y**E LE OUT0E MS15

I_COM0E/0F RE
SW _16 IN0F RF X**F Y**F LF OUT0F
I_COM0E/0F LF MS16

0V DC24V P4
IO_PWR1+ P3
IO_PWR1- N3
N4

Figure 2-23 IO connection block diagram

2-47
2.2.4. Relay Output Conversion Unit

Inputs of relay unit are outputs of safety semiconductor outputs, and a unit aiming
at the using as a contact output. It cannot output directly from a safety PLC.
Shape is the same dimensions as other safety units, and can be installed by the
same method as other units.
And when using it as a category 4, it must be a two-channel structure, and must
implement failure diagnosis of an external device (Example: contactor) by the back
check of an external device in the sequential circuit in a safety PLC.
When failure of an external device is detected, implement shutdown of related
outputs
2.2.4.1. Specification

№ Item Specification
1 Shape Board type
size 90(D)×140(H) ×51(W)mm
2 Ambient air temperature - 10 - 55 °C
3 Relative humidity 10-95%RH ( no dew condensation)
4 Atmosphere There is no corrosive gas.
5 Safety relay output  8 relay mounting module (RY08)
3 X4 = 12 Output (4 Channels)
 4 relay mounting module (RY04)
3 X2 = 6 Output (2 Channels)
 At using a 3a1b relay
: a-contact 3 outputs/ Relay
 At using a 2a2b relay：
a-contact 2, b-contact 1 output / Relay

Reference ,Table 2-53 Relay circuit

* However, b-contact output can not be
used for the safety purpose ん

Contact specification: DC24V 4A/point

6 Read back output 8 points (at 8 relay units mounting )
DC24V
* it is only for the read back and please
do not use it as a relay output
7 Relay coil control input 8 points (8 relays mounting )
DC24V 15mA/point

Table 2-48 Relay output conversion unit specification

2-48
2.2.4.2. Appearance

Top

Relay socket
(RY04-* is non-mounting)

Relay output
(OUT0/1 - OUT6/7)

Relay coil control

(IN0-IN7)

Read back output

(RB0-RB7)

Relay socket
Bottom

Figure 2-24 Relay output conversion unit appearance

2-49
2.2.4.3. I/O Terminal Block Arrangement

TB2

TB1

Figure 2-25 Relay output conversion unit terminal block

2-50
Table 2-49 TB2

Table 2-50 TB1

2-51
2.2.4.4. Usable Safety Relay Types
The usable safety relay types for each unit as follows.
Unit Contact Type Relay Type Name

3A1B G7SA-3A1B (Omron)

RY**-O
2A2B G7SA-2A2B (Omron)

SFS3-L-DC24V (Panasonic)
3A1B
SFS3-DC24V (Panasonic)
RY**-P
SFS2-L-DC24V (Panasonic)
2A2B
SFS2-DC24V (Panasonic)

Table 2-51 Usable Safety Relay Types

2.2.4.5. Relay Unit Circuit Block Diagram

Figure 2-26 Relay Unit Circuit Block Diagram

Relay Relay Read
address No. control back Relay output
IN0+ RB0-1
OUT0 RY1 OUT0/1-1 OUT0/1-3 OUT0/1-5
IN0- RB0-2
IN1+ RB1-1
OUT1 RY2 OUT0/1-2 OUT0/1-4 OUT0/1-6
IN1- RB1-2
IN2+ RB2-1
OUT2 RY3 OUT2/3-1 OUT2/3-3 OUT2/3-5
IN2- RB2-2
IN3+ RB3-1
OUT3 RY4 OUT2/3-2 OUT2/3-4 OUT2/3-6
IN3- RB3-2
IN4+ RB4-1
OUT4 RY5 OUT4/5-1 OUT4/5-3 OUT4/5-5
IN4- RB4-2
IN5+ RB5-1
OUT5 RY6 OUT4/5-2 OUT4/5-4 OUT4/5-6
IN5- RB5-2
IN6+ RB6-1
OUT6 RY7 OUT6/7-1 OUT6/7-3 OUT6/7-5
IN6- RB6-2
IN7+ RB7-1
OUT7 RY8 OUT6/7-2 OUT6/7-4 OUT6/7-6
IN7- RB7-2
Table 2-52 Relay circuit

2-52
Actual Example of Wiring
Category 4: 2 channels
Semiconductor safety output -> relay unit -> external device -> semiconductor
safety input

Cable length Max.3m:

The wiring length between a relay output conversion unit, and a basic unit/option
Relay unit can be unit should be 3m or less.
used with PCS and
PCS-J.

（BS0808→Relay）

(Relay→BS0808)

Figure 2-27 Actual Example of Wiring

Warnings about response time:

When this relay unit is used, the maximum response time becomes + 20ms of the
each maximum response time

2-53
2.2.4.6. Example of External Device Back Check Sequential Circuit (Category 4)

Starting
conditions

Read back check time

Reset
condition

Figure 2-28 Example of External Device Back Check Sequential Circuit

About the frequency of a back check for category 4, Make a relay working
(diagnostic) at least one time for 1 hour in application . (Refer to Chapter 8.2 of IEC
14119: 2013))

2-54
2.2.4.7. Relay unit installation method
A
Cover
cover(CV00DN)
or a bracket
is is
located
attachedontothe
theright
rightof
a
side
RYofunit.
a relay unit.
The studs of RY unit
right-hand side
push(contact) a cover
or a bracket.
(Because for
prevention of a board
bending at inserting a
relay in a socket.)

Figure 2-29 Relay unit installation method

2-55
2.2.5. Pin Assignment List of IO Terminal Blocks

(1) Safety unit

BS0016 / OS0016 BS0808 / OS0808 BS1600 / OS1600 BS1204 OS1200

L0 R0 OUT**0 COM**0 OUT**0 COM**0 COM**0 IN**0 OUT**0 COM**0
OS L1 R1 OUT**1 COM**1 OUT**1 COM**1 COM**1 IN**1 OUT**1 COM**1

L2 R2 OUT**2 COM**2 OUT**2 COM**2 COM**2 IN**2 OUT**2 COM**2

L3 R3 OUT**3 COM**3 OUT**3 COM**3 COM**3 IN**3 OUT**3 COM**3

L4 R4 OUT**4 COM**4 OUT**4 COM**4 COM**4 IN**4 COM**4 IN**4 COM**4 IN**4

L5 R5 OUT**5 COM**5 OUT**5 COM**5 COM**5 IN**5 COM**5 IN**5 COM**5 IN**5
L6 R6 OUT**6 COM**6 OUT**6 COM**6 COM**6 IN**6 COM**6 IN**6 COM**6 IN**6

L7 R7 OUT**7 COM**7 OUT**7 COM**7 COM**7 IN**7 COM**7 IN**7 COM**7 IN**7

P1 N1 IO_PWR0 + IO_PWR0 - IO_PWR0 + IO_PWR0 - IO_PWR0 + IO_PWR0 - IO_PWR0 + IO_PWR0 - IO_PWR0 + IO_PWR0 -
TB2 P2 N2 IO_PWR0 + IO_PWR0 - IO_PWR0 + IO_PWR0 - IO_PWR0 + IO_PWR0 - IO_PWR0 + IO_PWR0 - IO_PWR0 + IO_PWR0 -

BS0016 / OS0016 BS0808 / OS0808 BS1600 / OS1600 BS1204 OS1200

L8 R8 OUT**8 COM**8 COM**8 IN**8 COM**8 IN**8 COM**8 IN**8 COM**8 IN**8

L9 R9 OUT**9 COM**9 COM**9 IN**9 COM**9 IN**9 COM**9 IN**9 COM**9 IN**9

TB1 LA RA OUT**A COM**A COM**A IN**A COM**A IN**A COM**A IN**A COM**A IN**A

LB RB OUT**B COM**B COM**B IN**B COM**B IN**B COM**B IN**B COM**B IN**B

LC RC OUT**C COM**C COM**C IN**C COM**C IN**C COM**C IN**C COM**C IN**C
LD RD OUT**D COM**D COM**D IN**D COM**D IN**D COM**D IN**D COM**D IN**D

LE RE OUT**E COM**E COM**E IN**E COM**E IN**E COM**E IN**E COM**E IN**E

LF RF OUT**F COM**F COM**F IN**F COM**F IN**F COM**F IN**F COM**F IN**F

P3 N3 IO_PWR1 + IO_PWR1 - IO_PWR1 + IO_PWR1 - IO_PWR1 + IO_PWR1 - IO_PWR1 + IO_PWR1 - IO_PWR1 + IO_PWR1 -

P4 N4 IO_PWR1 + IO_PWR1 - IO_PWR1 + IO_PWR1 - IO_PWR1 + IO_PWR1 - IO_PWR1 + IO_PWR1 - IO_PWR1 + IO_PWR1 -
BS P5 N5 U_PWR + U_PWR - U_PWR + U_PWR - U_PWR + U_PWR - U_PWR + U_PWR - U_PWR + U_PWR -
or
BN P6 N6 U_PWR + U_PWR - U_PWR + U_PWR - U_PWR + U_PWR - U_PWR + U_PWR - U_PWR + U_PWR -

Figure 2-30 Pin assignment of IO terminal blocks

2-56
(1) Standard unit

The points of input/output

can be setable by each
2-points using a programing
tool.
Input: 2 points/common

Example

B N 16-P / O N 16-P B N 16-P / O N 16-P

B N 16-P / O N 16-P
(at O utput setting) (at Input setting)

R0 O U T **0 IN **0 C O M **0/**1 O U T **0

R1 O U T **1 IN **1 C O M **0/**1 O U T **1

R2 O U T **2 IN **2 C O M **2/**3 IN **2 C O M **2/**3

R3 O U T **3 IN **3 C O M **2/**3 IN **3 C O M **2/**3

BS OS
R4 O U T **4 IN **4 C O M **4/**5 O U T **4

R5 O U T **5 IN **5 C O M **4/**5 O U T **5

R6 O U T **6 IN **6 C O M **6//**7 IN **6 C O M **6//**7

R7 O U T **7 IN **7 C O M **6//**7 IN **7 C O M **6//**7

N1 IO _P W R 0 + IO _P W R 0 - IO _P W R 0 + IO _P W R 0 - IO _P W R 0 + IO _P W R 0 -
TB2
N2 IO _P W R 0 + IO _P W R 0 - IO _P W R 0 + IO _P W R 0 - IO _P W R 0 + IO _P W R 0 -

B N 16-P / O N 16-P B N 16-P / O N 16-P B N 16-P / O N 16-P

L8 R8 O U T **8 IN **8 C O M **8/**9 IN **8 C O M **8/**9

TB1
L9 R9 O U T **9 IN **9 C O M **8/**9 IN **9 C O M **8/**9

LA RA O U T **A IN **A C O M **A /**B O U T **A

LB RB O U T **B IN **B C O M **A /**B O U T **B

LC RC O U T **C IN **C C O M **C /**D IN **C C O M **C /**D

LD RD O U T **D IN **D C O M **C /**D IN **D C O M **C /**D

LE RE O U T **E IN **E C O M **E /**F O U T **E

LF RF O U T **F IN **F C O M **E /**F O U T **F

P3 N3 IO _P W R 1 + IO _P W R 1 - IO _P W R 1 + IO _P W R 1 - IO _P W R 1 + IO _P W R 1 -

P4 N4 IO _P W R 1 + IO _P W R 1 - IO _P W R 1 + IO _P W R 1 - IO _P W R 1 + IO _P W R 1 -

BS P5 N5 U _P W R + U _P W R - U _P W R + U _P W R - U _P W R + U _P W R -
or
BN P6 N6 U _P W R + U _P W R - U _P W R + U _P W R - U _P W R + U _P W R -

Figure 2-31 Pin assignment of IO terminal blocks

2-57
2.3. Module list
The modules are constructed by the combination of an interface unit, a base unit or an option unit and by
station number setting.
Station
Module name Unit configuration Functions
number
Process a user program and control
option input/output modules.

CPU CPU becomes a master station of internal IO

Module bus and Remote IO bus.

CPU Connects with a PC (PCwin-Safe-Plus)

via USBI/F.
00 ([IF****] + )※1
Data transfer with a USB memory can be
[BS****]
performed via USB memory I/F.
(+[OS/ON****])
Communication with TOYOPUC-PLC
(PC10G, Plus, etc.) via SN-I/F.

One set of an option unit can be added to one

set of a basic unit.

01～1F Remote IO bus function (slave station) and

option can communicate with a CPU module.

Remote salve satation becomes a master

station of an internal IO bus.
Remote slave
Module A maximum of 31 Remote slave station
modules are connectable.
[IF****] + One set of an option unit can be added to one
[BS/BN****] set of a basic unit.
(+[OS/ON****])

option Internal IO bus function (slave station) and

can communicate with a CPU module.

Maximum of 3 sets of internal extension IO

modules can be added to CPU module or
Extension IO Remote slave station module..
module
One set of an option unit can be added to one
21～23 set of a basic unit.
[BS/BN****]
(+[OS/ON****])

Table 2-53 Module list

2-58
 ※１ Connecting with an interface unit at off-line, and a program is downloaded via PC or a USB memory.
After downloading a program, remove an interface unit. Then install a PLC in a machine. (A fixed program,
and built-in type which does not implement change of circuits, monitoring, etc. during operation)
2.4. CPU Operation Mode
The following CPU operation mode can be set with a programming tool (PCwin-Safe-Plus)
Depending on CPU operation mode, usable IO point, scan time, etc. are different.

Operation Maximum IO Number of Scan time Response

Mode point Remote time
stations
Stand-alone 128 points - 9.0ms 15.8ms
Remote 1 256 points 3 or less 10.5ms 18.8ms
Remote 2 2048 points 31 or less 17.5ms 32.8ms
Table 2-54 CPU operation mode

2.4.1. Stand-alone Mode

Max. 128 points (basic unit x4+ option unit x4+IF unit)
Max. internal extension IO modules is 3 units, and connect them by internal IO bus cables.
The total extended cables is up to 50m.

Total IO bus cable

Maximum 50m

Internal IO
bus cable

Internal CPU
extension
IO module module

Figure 2-32 Stand-alone Mode

2-59
2.4.2. Remote 1 Mode

Max. 256 points

Max. number of Remote slave station modules is 3 stations (station number 01-03), and connect
them by Remote IO bus cables.
Max. cable length between each node is 50m .
For a Remote slave station module, max. connectable internal extension IO modules is 3 units , and
connect them by internal IO bus cables.
The total extended cables is up to 50m for internal extension IO modules.

Remote
IO bus
cable

CPU Remote slave Remote slave Remote slave

module station module station module station module

Figure 2-33 Remote 1 Mode

2.4.3. Remote 2 Mode

Max. 2048 points

Max. number of Remote slave station modules is 31 stations (station number 01-1F), and connect them
by Remote IO bus cables.
Max. cable length between each node is 50m .
For a Remote slave station module, max. connectable internal extension IO modules is 3 units , and
connect them by internal IO bus cables.
The total extended cables is up to 50m for internal extension IO modules.

CPU Remote
Remote
module salve station
salve station

Max 32 stations

Figure 2-34 Remote 2 Mode

2-60
2.5. Switch Operation
With the function selection switch in a CPU module, selection of function and execution operation can
be performed.
Operations differs at maintenance mode and RUN mode.
Execution
operation

Figure 2-35 Switch Operation

Function
selection

Mode Function Contents Operation

Transfer to Change to maintenance mode. Refere to 2.5.1.1

maintenance mode
Program stop Stop user program operation Refere to 2.5.1.2
Reset / RUN operation Contents are different up to status. Refere to 2.5.1.3
・ RUN : A user program is interrupted and
operation is started from a head.
・ During error occurrence: Reset
errors ,and start the user program
At RUN
operation. (Please remove a error factor
mode
before operation.)
・ During stop : tart the user program
operation
Station number error Station number error (error 92) reset, and data Refere to エラー!
reset error unconfirmed (error AE) reset . 参照元が見つかり
/Data unconfirmed ・ Please be sure to implement ません。
error reset above-mentioned reset/RUN operation
after reset operation.
Transfer to RUN mode Change to RUN mode. Refere to エラー!
参照元が見つかり
ません。
USB memory A user program is read from TOYOPUC-Plus Refere to エラー!
operation Safety to a USB memory. 参照元が見つかり
User program Data read by PCwin-Safe-Plus is convertible ません。 (1)
reading USB for the data for PCwin-Safe-Plus.

USB memory A user program is written in TOYOPUC-Plus Refere to エラー!

At operation Safety from a USB memory. 参照元が見つかり
maintenance User program writing It is necessary to make data conversion of user ません。 (2)
mode USB program used by PCwin-Safe-Plus and to write
in a USB memory.
USB memory Security registration can be performed using Refere to エラー!
operation the security data file. 参照元が見つかり
Security registration A security data file is made by ません。 (3)
PCwin-Safe-Plus.
USB memory Reset of security registration can be performed Refere to エラー!
operation using the security data file. 参照元が見つかり
Security registration For reset of registration, the USB memory used ません。 (4)
reset at security registration and a security data file
are required.

Table 2-55 Switch operation list

2-61
2.5.1. RUN Mode

The following functions can be implemented during RUN mode.

- Transfer to maintenance mode
- The stop of a program
- Reset operation
- A station number error reset
/data error unconfirmed reset

2.5.1.1. Transfer to maintenance mode

Maintenance mode has the following functions.
- User program writing from a programming tool (PCwin-Safe-Plus)
- Operation of USB memory (please refer to the clause 2.5.2.2 USB Memory
Operation)

RUN mode
USB
I/F

①Move a
selection switch
up/ down
②Function
selection LED lights
USB
I/F

blue
(maintenance).

③Push this
switch

④ Confirm that LED

for a status display
becomes blue
( maintenance
USB
I/F

mode).

Figure 2-36 Transfer to maintenance mode

2-62
2.5.1.2. Program Stop
Stop user program Operation

Run

USB
I/F
①Move a
selection switch
up and down

②
Function
USB
I/F

selection
LED lights
yellow
(Stop).
③Push this
switch

④Status LED lights

off (stop).
USB
I/F

Figure 2-37 Program Stop

2-63
 2.5.1.3. Reset/RUN Operation

Operation during RUN

: The user program is interrupted and start operation from a head.
Operation during Error
: Reset Error and start an user program.
(Please remove a error cause before operation.)
Operation during Stop
: Start the user program.

Error
occurre
Stop
Run nce

USB
USB
USB

I/F
I/F
I/F

①Move a
function
selection switch
②Confirm a up and down.
function selection
display LED
becomes green
USB

USB
USB

(Reset/RUN).
I/F

I/F
I/F

③Push a function
selection switch.

④Confirm a status
display LED
becomes green
USB
I/F

(RUN).

Figure 2-38 Reset/RUN Operation

2-64
2.5.1.4. Station Number Error Reset / Data Error Unconfirmed Reset
Reset the station number error (error 92) and data error unconfirmed (error AE)

Error
occurrence

USB
I/F
①Move a
function
selection switch
②Confirm function up and down.
selection display
LED becomes
purple ( station
USB
I/F

number error/ data

error confirmation
reset).

③Push a
function
selection
switch.
USB
I/F

Note:
Please implement Reset / RUN operation
(clause 2.5.1.3 ) after reset operation.

Figure 2-39 Station Number Error Reset / Data Error Unconfirmed Reset

2-65
2.5.2. Maintenance Mode

The following functions can be implemented during maintenance mode.

- Transfer to RUN mode
- USB memory operation

2.5.2.1. Transfer to RUN mode

Maintenance
Mode

USB
I/F ①Move a
function
selection switch
②Confirm a up and down.
function selection
display LED
becomes green
USB
I/F

(Reset/RUN).

③Push a
function
selection
switch.
④Confirm a status
display LED
becomes green
USB
I/F

(RUN).

Figure 2-40 Maintenance Mode

2-66
 2.5.2.2. USB Memory Operation

User program writing from a USB memory, and user program read to a USB memory can be
performed. And security setting can be implemented using a USB memory.
Once setting USB security, the user program can be read to a USB memory or writing from a USB
memory only after reset of security by a security set USB memory . (When the USB memory which
made security setting is lost , reset of security becomes impossible.)

(1) Reading the user program

Read an user program from TOYOPUC-Plus Safety to a USB memory.
The read data can be converted for the data for PCwin-Safe-Plus by PCwin-Safe-Plus.
Operation will change according to security registration or not.

・Incase of no security registration

Maintenance
mode
USB
I/F

①Connect a USB memory to IF unit. ⑥At read

completion, a
function selection
display LED

USB
turns off.

I/F
②Move a
③Confirm a function selection
function selection switch up and
display LED down.
becomes white After reading, USERPRG folder is created in
(read to a USB the USB memory.
memory).
USB
I/F

Conversion to the file for

PCwin-Safe-Plus is possible
for the data in USERPRG by
④Push a PCwin-Safe-Plus
function selection
⑤In the reading, switch.
Confirm that a
function selection
display LED
blinks in white.
USB
I/F

Figure 2-41 USB Memory Operation

2-67
 ・In case of with security registration

Note:
The USB memory and security
information file PASSCODE.txt
Maintenance which were used for security
mode registration are always
necessary.

USB
Other USB memories can not

I/F
read.

①Connect a USB memory to IF unit.

②Move a
function
selection
switch up and ⑧At read
down. completion, a
③Confirm a function selection
function selection display LED

USB
display LED turns off.

I/F
becomes white
USB
I/F

(read to a USB
memory).
After read, a USERPRG folder is created in
the USB memory.
④Push a Conversion to the file for
function selection PCwin-Safe-Plus is possible
⑤During security switch. for the data in USERPRG by
certification, PCwin-Safe-Plus
Confirm a
function selection
display LED
USB

lights up in
I/F

yellow.

⑥Push a
function selection
switch.

⑦During read,
confirm a function
selection display
USB
I/F

LED blinks white.

Figure 2-42 In case of with security registration

2-68
(2) User program writing
Write an user program in TOYOPUC-Plus Safety from a USB memory.
It is necessary to make data conversion of the user program to be used, and to write in a
USB memory by PCwin-Safe-Plus.
Operation will change according to security registration or not.

・Without security registration

Maintenance
mode

USB
I/F
①Connect a USB memory to IF unit.
A USERPRG folder is
necessary for the writing an
user program.
Create this file by
PCwin-Safe-Plus.

②Move a
function
selection switch
③Confirm a up and down.
function
selection display
LED becomes
blue (writing
USB
I/F

from a USB
memory).

④Push a
function
⑤Confirm
during writing, a
function
selection
display LED
USB

blinks green.
I/F

⑥A function
selection
display LED
turns off at
writing
completion
USB
I/F

Figure 2-43 Without security registration

2-69
・In case of with security registration

Maintenance
mode

USB
I/F
Note:
The USB memory and security
①Connect a USB memory to IF unit.
information file PASSCODE.txt
A USERPRG folder is which were used for security
necessary for writing of an
registration are always
user program.
Create this file by
necessary.
PCwin-Safe-Plus. Other USB memories can not
read.

②Move a
③Confirm a function
function
selection selection
display LED switch up and
becomes blue down.
(writing from a
USB
I/F

USB memory).

④Push a
function
⑤Confirm for a selection
function
selection switch.
display LED
lights up in
yellow during
USB
I/F

security

⑥Push a
function
⑦During selection
writing, switch.
confirm a
function
selection
USB

display LED
I/F

blinks green.

⑧A function
selection
display LED
turns off a
USB

twriting
I/F

completion.

Figure 2-44 In case of with security registration

2-70
(3) Security registration
Security registration can be performed using a security information file.
Create a security information file by PCwin-Safe-Plus.

Maintenance
mode

USB
I/F
①Connect a USB memory to IF unit.
Security information file
PASSCODE.txt is
necessary for setting of
security.
Create this file by
PCwin-Safe-Plus.

②Move a
③Confirm a function
function selection
selection switch up and
display LED
becomes a down.
light blue
USB
I/F

(security
registration).

④Push a
function
⑤Confirm a selection
function switch.
selection
display LED
blinks
USB
I/F

light-blue
during security
registration.

⑥A function
selection
display LED
turns off at
completion of
USB
I/F

security

Figure 2-45 Security registration

2-71
(4) Security registration reset
Reset of security registration can be performed using a security information file.
For reset of registration, the USB memory used at the time of security registration and a
security information file are required.

Maintenance
mode

USB
I/F
Note:
The USB memory and security
information file PASSCODE.txt
①Connect a USB memory to IF unit. which were used for security
registration are always
Security information file necessary.
PASSCODE.txt is The other USB memories can
necessary for reset of not work!
security.

②Move a
function
selection
switch up and
③Confirm a
function down.
selection
display LED
becomes
USB
I/F

purple
(security
registration
reset).

④Push a
function
⑤ During a selection
security switch.
registration
reset,
Confirm a
USB
I/F

function
selection
display LED
blinks purple.

⑥A function
selection
display LED
turns off at the
completion of
USB
I/F

a security
reset

Figure 2-46 Security registration reset

2-72
3. Initial Setting
3.1. Shipment Condition of Base Unit
The shipment condition of a base unit is as follows.
(1) PIN code * initial value is "0000."
(2) There is no user program.
(3) There is no parameter setting.
(4) There is no security setting.

※ The PIN code is a code of four digits which a user set and is memorized by the TOYOPUC-Plus Safety .
It is a function for neither operation mode nor a program to be changed illegally.
When the PIN code is inputted, please set xxxx (half-width numbers) other than "0000" .

※ Once, the CPU module which downloaded the user program can also be returned to the
above-mentioned shipment condition by the "initialization of PIN code" function of programming soft
PCwin-Safe-Plus.
Refer to the PCwin-Safe-Plus instructions manual for the details about initialization of the PIN code and
the PIN code.

3-1
4. Installation and Wiring
Explain the manners and directions of installation and wiring.

4.1. Installation Environment

Please avoid the following environment

(1) The location where ambient temperature exceeds the range of -10-55 degree C
(2) The location where ambient humidity exceeds the range of 10 - 95 %RH
(3) The location where dew condensation by rapid temperature change
(4) The location with corrosive gas and inflammable gas
(5) The location where organic solvent, powder of conductivity, oil mist and salt, are existing.
(6) The location where a strong electric field or strong magnetic field existing
(7) The location where direct rays hit
(8) The location where direct vibration or impact are transmitted

4.2. Directions on Installation

4.2.1. Space
In order to secure exact assembly/decomposition and sufficient ventilation of each module, keep space of at
least 50mm or more vertically and horizontally, and install products horizontally.
And, please do not locate high voltage wires in less than 50mm of fronts of a module.

min.50mm min.100mm
(including 50mm
drawing wires )
min.50mm min.50mm min.50mm min.50mm

min.50mm min.50mm

Figure 4-1 Directions on Installation

4.2.2. Static Electricity Protection
Because each unit does not hae a protectve housing, in order to protect a unit from the infulence of static
elecrricity at the time of handling, please be sure to wear a wrist band.

Figure 4-2 Wrist band

4-1
4.2.3. Internal IO Bus Short Circuit
The internal IO bus looks cascade cable wirings, but it connected by just one cable actually. Therefore,
when IO bus internal wires are short-circuited, the short-part cannot be judged easily by error data.
It is necessary to determine a short-part by removing one by one cable.
The internal IO bus can be installed at even outside of a cabinet. Determination of the short-part takes a lot of
time and effort.

Actual wiring

Internal IO bus

Cable B Cable C
Cable A

Station Station Station CPU module

number: 21 number: 23 number: 22

Figure 4-3 Determination of internal IO bus short-part

【Determination of short-part】
Remove a cable which is most distant from a CPU module (Fig. 4-2, Cable-A.)
Each time, Power supply is reconnected, and determine the short-place from the error data.

(1) When Cable-A has short-circuited

Remove cable A and reconnect power supply.
The next error data is caused.
・Error B1-43 (IO bus communication error- connection station discrepancy) is caused at station 21.

The above fact shows that short-circuit happened at cable-A.

(2) When Cable-B has short-circuited

Remove cable A and reconnect power supply.
The next error data is caused.
・Error B1-43 (IO bus communication error- connection station discrepancy) is caused at station 21
・Error B1-43 (IO bus communication error- connection station discrepancy) is caused at station 22
・Error B1-43 (IO bus communication error- connection station discrepancy) is caused at station 23
Then, remove Cable B and reconnect a power supply.
The next error data is caused
・Error B1-43 (IO bus communication error- connection station discrepancy) is caused at station 21
・Error B1-43 (IO bus communication error- connection station discrepancy) is caused at station 22

The above fact shows that short-circuit happened at cable-B

4-2
 (3) When Cable-C has short-circuited
Remove cable A and reconnect power supply.
The next error data is caused.
・Error B1-43 (IO bus communication error- connection station discrepancy) is caused at station 21
・Error B1-43 (IO bus communication error- connection station discrepancy) is caused at station 22
・Error B1-43 (IO bus communication error- connection station discrepancy) is caused at station 23
Then, remove Cable B and reconnect a power supply.
The next error data is caused.
・Error B1-43 (IO bus communication error- connection station discrepancy) is caused at station 21
・Error B1-43 (IO bus communication error- connection station discrepancy) is caused at station 22
・Error B1-43 (IO bus communication error- connection station discrepancy) is caused at station 23
Then, remove Cable C and reconnect a power supply.
The next error data is caused.。
・Error B1-43 (IO bus communication error- connection station discrepancy) is caused at station 21
・Error B1-43 (IO bus communication error- connection station discrepancy) is caused at station 22
・Error B1-43 (IO bus communication error- connection station discrepancy) is caused at station 23

The above fact shows that short-circuit happened at cable-C

4.3. TOYOPUC-Plus Safety module installation manners

TOYOPUC-Plus Safety, the following three kinds of installation are available.
(1) Bracket installation type
(2) DIN rail bracket installation type
(3) Direct mounting type

(1) (2) (3)

OK OK OK
OKwall surface
OK

Top

Ground

NG wall surface

Horizontal installation, or Under

installation (terminal block is NG
facing down), ventilation of Top
modules become worse and
never install modules.

Ground
Figure 4-4 Installation manners

4-3
4.3.1. Bracket installation type
Control panel

Cover Bracket
(JTEKT product) (JTEKT product )
type: CV0000 type: BK0000
Note)
If operator‘s fingers can not
reach or touch boards, a
upper protective cover is not
necessary. Judgement of
M4 screw, washer using a cover or not ,
please implement the risk
Upper assessment and decide on
the customer risk
assessment results

Front

Bottom M4 screw, washer

One side Maximum 5 sets

Both sides total Maximum 5 sets
Figure 4-5 Bracket installation (5-units configuration)

Top

Bottom

※One RY unit must be ※It is necessary to locate a cover or a bracket

counted three units for unit When using 2 brackets on the right side of RY unit for avoiding the
installation number at both ends, 11 units board bending when inserting a relay in a
culculation. can be installed relay socket.
Figure 4-6 Bracket installation type(11-set configuration)

4-4
 4.3.2. DIN rail bracket installation type

1(One) bracket

Control panel

Bracket
Cover (JTEKT product )
(JTEKT product) type: CV00DN
type: CV0000DN
Two covers are
required when
mounting at both
sides.

Upper side
Bracket
(JTEKT product )
type: BK00DN

Uppper

Front DIN Rail

End fixing unit

Bottom

One side Maximum 5 sets

Both sides total Maximum 5 sets

Figure 4-7 DIN rail bracket installation type（5-units configuration）

4-5
Note) Fixing-bracket mounting
When fixing a product on a DIN rail, fixing brackets are required.

When a fixing
bracket is fixed at
both ends, two
covers are required.

One side is also

fixable with a DIN
rail bracket.

Please use 15mm or

less.。

A cover is If operator‘s fingers can not reach A cover is

required. or touch boards, a protective required.
cover is not necessary.
Judgement of using a cover or
not , please implement the risk
assessment and decide on the
customer risk assessment results

Figure 4-8 DIN rail bracket installation type (5-units configuration)

4-6
 When using 2 brackets
at both ends, 11 units
can be installed

※One RY unit must be ※It is necessary to locate a cover or a bracket

counted as three units . on the right side of RY unit to avoid the board
bending when inserting a relay in a relay socket.

Figure 4-9 DIN rail bracket installation type (11-units configuration）

4-7
4.3.3. Direct mounting type Control panel
(fixing face)
Terminal block: Upward installation Terminal block: Sideways installation

Maximum
5 Units

2mm or more of
board thickness
Upper surface Upper surface of a control
Upper panel
Upper (attachment
plate)
necessary.

Bottom Front
Bottom Front

Mounting hole
Mounting hole dimensions
dimensions 4 64
4

21

4-M3 Tap hole

4-M3 Tap hole
14 13
64 90 0 2

4 4 132
140

82
Figure 4-10 Direct mounting type 90 21
4-8
4.3.4. Mounting of TOYOPUC-Plus

TOYOPUC-Plus Safety can be mounted on the same bracket of TOYOPUC-Plus.

The following example is bracket installation type .

Difference of stud positions are absorbed by

cover hole positions.

Plus-PLC Plus-Safety

One side Maximum 5 sets Cover for TOYOPUC-Plus Safety

Both sides total Maximum 5 sets (type: CV0000)

Figure 4-11 Mounting of TOYOPUC-Plus

Please refer to "TOYOPUC-Plus Instructions Manual" for installation of TOYOPUC-Plus.

4-9
4.4. TOYOPUC-Plus Safety Unit Assembling Manners
4.4.1. Unit Assemble
(1)BS/BN Unit
Units assembled at left-hand side Units assembled at right-hand side
①BS/BN Unit ①IF Unit
Please use M3 and stud of L= BS/BN Unit Using connectors connection
16mm or more. between IF-BS/BN. Please be sure
to use M3 and L= 8mm stud.
16mm or 8mm fix
more

Recommendation stud：STD16X4 Recommendation stud：ST8X4MF

②OS/ON Unit ②BS/BN Unit、OS/ON Unit
Using connectors connection Please use M3 and stud of L=
between BS/BN-OS/ON. 16mm or more.
Please be sure to use M3 and L=
16mm fix 16mm or 16mm or
16mm stud.
more more

Recommendation stud：STD16X4 Recommendation stud：STD16X4

③Bracket/cover ③Bracket/cover
Please use M3 and stud of L= Please use stud of M3 and L=
16mm or more. 8mm or more *1.
16mm or 16mm or 8mm or
more. more. 8mm or more.
more. 1
※
※1

※ 1 When using female studs at

both-sides L= 16mm or more
Recommendation stud Recommendation stud
:STD16X4,ST16X4MM, ：ST8X4MF ,ST16X4FF
ST16X4FF
Figure 4-12 BS/BN Unit

4-10
 The unit assembleed at left-hand The unit assembleed at right-hand
side side
④RY unit + cover※2 ④ RY unit
Please use M3, L= 16mm stud. BS/BN unit Please use M3 L= 48mm stud.
8mm
16mm 48mm

※2
ｶﾊﾞｰ

Recommended stud：STD16X4 Recommended stud：ST48X4MF

Figure 4-13 BS/BN unit Assemble (2/2)

※2
It is necessary to locate a cover or a bracket on
the right side of RY unit to avoid the board
bending when inserting a relay in a relay socket.
Between a RY unit - a cover/bracket, An 8mm
stud is required.

4-11
(2)OS/ON Unit
Units assembled at left-hand side Units assembled at right-hand side
①BS/BN Unit ① BS/BN Unit
Please use stud of M3 and L= OS/ON Unit Using connectors connection
16mm or more. between BS/BN-OS/ON. Please
16mmor be sure to use M3 and L=16mm
more stud
16mm

Recommendation stud：STD16X4 Recommendation stud：STD16X4

②Bracket/cover
Please use M3 and a stud of L=
16mm or more.
16mm or 16mm or
more more

Recommendation stud
：STD16X4、ST16X4MM
ST16X4FF
④ RY unit ＋cover ※2
Please use stud of M3 and L=
16mm or more.
8mm
16mm

※2 It is necessary to locate a cover or a bracket

on the right side of RY unit to avoid the board
bending when inserting a relay in a relay socket.
Between a RY unit - a cover/bracket, An 8mm
stud is required.

※2
Cover

Recommendation stud
：STD16X4 (16mm),
ST8X4MF (8mm)
Cover：CV0000
Figure 4-14 OS/ON Unit

4-12
(3)IF Unit
Units assembled at left-hand side Units assembled at right-hand side
①BS/BN Unit ①Bracket/cover
Using connectors connection IF Unt Please use M3 and a stud of L=
between IF-BS/BN. Please be 16mm or more.
sure to use M3 and L=8mm stud 16mmor
8mm Fix 16mmor
more more

Recommendation stud：ST8X4MF Recommendation stud

：STD16X4,ST16XFF
Figure 4-15 IF Unit

4-13
(4)RYunit
Units assembled at left-hand side Units assembled at right-hand side
② BS/BN unit ① BS/BNunit 、OS/ON unit
Please use stud of M3 and L= RY unit Please use M3, L=8mm L =
48mm or more.48mm 16mm stud and a cover.
8mm 16mm 8mm 16mm

※2
ｶﾊﾞｰ

Recommended stud：ST48X4MF Recommended stud：ST8X4MF

②RY unit ＋Cover ※2 ② bracket/cover
Please use stud of M3 and L= Please use stud of M3 and L=
48mm or more. 8mm or more.
8mm 8mm
8mm 48mm

※2
ｶﾊﾞｰ
Recommended stud：ST48X4MF Recommended stud：ST8X4FF
③ bracket/cover
Please use stud of M3 and L=
48mm or more.
48mm 48mm

※2 For prevention of a board bending at

inserting a relay in a socket, a cover or a
bracket must be located on the right of a RY
unit.
8mm stud are required between a RY unit
and a cover/bracket.

Recommended stud：ST48X4MF,
ST48X4FF, ST48X4MM

Figure 4-16 Assemble of RY unit

4-14
4.4.2. Example of Single-sided Installation using a bracket
Assemble in order of the right.

Cover OS/ON Unit OS/ON Unit IF Unit

(CV0000 or CV00DN) Bracket
BS/BN Unit BS/BN Unit (BK0000 or BK00DN)

Screw M3X6mm Screw M3X6mm

4 places 4 places (SCR6X4)
(SCR6X4)

Note:
1) Recommendation bolting
torque is 0.5 N-m.
2) Screws and studs should
be metal .
3) Brackets, covers, screws
and studs are not attached
to a unit. Please prepare
separately.
4) Please use a grounding
Cover wrist band properly for
Stud between OS/ON electrostatic discharge
L= 16mm (16mm or more) damage prevention .
female-female type
4 places (ST16X4FF)

Stud between IF-bracket

Stud between BS/BN-OS/ON Stud between Stud between L = 16mm (16mm or more)
L = 16mm (16mm or more) BS/BN-OS/ON BS/BN-IF Male- female type
Male- female type L = 16mm L=8mm 4 places (STD16X4)
4 places (STD16X4) Male- female type Male-female type
4 places (STD16X4) 4 places (ST8X4MF)

Figure 4-17 Example of Single-sided Installationusing a bracket

① Studs L= 16mm , Male- female type (STD16X4) are fixed on a bracket (BK0000 or BK00DN) using
screws (SCR6X4) (4 places of ○ parts)

※If mount a BS (or BN) unit at first without using a IF unit. The studs to be used L= 8mm and Male-
female type (ST8X4MF).
Figure 4-18. Example of Single-sided Installation using a bracket

4-15
 ② Insert an IF-Unit, fixed by L= 8mm of studs, and Male- female type (ST8X4MF).

IF unit Note:
1) Studs should use L=
8mm .
If other length studs are
used, assembling of a
BS/BN unit cannot be
carried out properly.
2) Be careful of direction of IF
unit.

Figure 4-19 Example of Single-sided Installation using a bracket

③ Insert a BS/BN Unit, and fix using studs L= 16mm , Male- female type (STD16X4).
Note:
1) BS/BN unit and IF unit are
connected using connectors
BS/BN Unit (2 places).
Please insert them securely.
If not, may cause
malfunction or failure.
2) When an OS/ON unit is
mounted, studs should be
used L= 16mm .
If other length is used, a
assembling OS/ON unit
cannot be carried out
properly.
3) Be careful of direction of an
OS/ON unit.

Figure 4-20 Example of Single-sided Installation using a bracket

④ Insert an OS/ON Unit and fix by studs L= 16mm Male- female type (STD16X4).

Note:
OS/ON Unit 1) BS/BN unit and an OS/ON
unit are connected using
connectors (1 place).
Please insert them securely.
If not, may cause malfunction
or failure.

2) Be careful of direction of an
OS/ON unit.

Figure 4-21 Example of Single-sided Installation using a bracket

4-16
 ⑤ Insert a BS/BN unit, fix by studs L= 16mm Male- female type (STD16X4).

Note:
BS/BN unit 1) When an OS/ON unit is
mounted, studs should be
used L= 16mm .
If other length is used, a
assembling OS/ON unit
cannot be carried out
properly.
2) Be careful of direction of an
OS/ON unit.

Figure 4-22 Example of Single-sided Installation using a bracket

⑥ Insert an OS/ON unit, fix by studs L= 16mm Female- female type (ST16X4FF).

OS/ON unit Note:

1) BS/BN unit and an
OS/ON unit are
connected using
connectors (1 place).
Please insert them
securely.
If not, may cause
malfunction or failure.
2) Be careful of direction of
an OS/ON unit.

Figure 4-23 Example of Single-sided Installation using a bracket

⑦ Fix a cover (CV0000 or CV00DN) with screws (SCR6X4). (4 places of part )

Cver Note:
1)There are two kinds of
covers, please use the
covers to be fitted with the
bracket to be used .
At the time of using direct
mounting bracket BK0000
=> CV0000
At the time of using DIN rail
bracket BK00DN =>
CV00DN
2) Please attach a cover so
Figure 4-24 Example of Single-sided Installation using a bracket that a printing surface
becomes outside.
(If a printing surface is inner
side,. There are no problem
about functions and
assembling)

4-17
Stud selection (at one side mount) of the assembling in order of the right

M3
S tud kind M ale ｰ F em ale F em ale ｰF em ale
8m m 16m m 48m m 16m m 48m m
JTEKT type S T D 16X 4 S T 8X 4M F S T 48X 4M F S T 16X 4F F S T 48X 4F F

T he unit on the right side

U sing units
BS OS B rack
IF RY C over
BN ON et

○ ○
○ ○
B S **** ○ ○
B N **** ○ ○
○ ○
○ ○
○ ○
－
O S **** －
O N **** －
－
－
－
－
IF ****
－
－
○ ○
○ ○
－
－
R Y ****
－
－
○ ○
○ ○
○ ○
C over
○ ○
(for R Y
－
unit)
○ ○
－
－
○ ○
○ ○
C over
－
○ ○
－
－
○ ○
○ ○
B raket
－
○ ○
－
－
Table 4-1 Stud selection (at one side mount) of the assembling in order of the right
4-18
4.4.3. Example of Both-Sides Installation Using a Bracket
Assembling from the right side

OS/ON unit OS/ON unit IF unit Bracket (BK0000 or BK00DN)

Cover BS/BN unit BS/BN unit
(CV0000 or CV00DN) Cover (CV0000 or CV00DN)

Screw M3X6mm Screw M3X6mm

4 places (SCR6X4) 4 places
(SCR6X4)

Note)
1) Recommendation bolting
torque is 0.5 N-m.
2) Screws and studs should
be metal .
3) Brackets, covers, screws
and studs are not attached
to a unit. Please prepare
separately.
4) Please use a grounding
wrist band properly for
electrostatic discharge
damage prevention .

Stud between OS/ON-covers Stud between Stud between BS/BN-OS/ONStud between IF-cover
L= 16mm ( 16mm or more ) BS/BN-bracket L=16mm L= 16mm ( 16mm or
Fimale-female type L= 8mm ( 8mm or Male-female type more )
4 places (ST16X4FF) more) 4 places (STD16X4) Fimale-female type
Male-female type 4 places (ST16X4FF)
4 places (ST8X4MF)

Stud between BS/BN-OS/ONStud between bracket Stud between BS/BN-IF

L=16mm OS/ON L=8mm
Male-female type L= 16mm (16mm or Male-female type
4 places (STD16X4) more) 4 places (ST8X4MF)
Male-male type
4 places (ST16X4MM)
Figure 4-25 Example of Both-Sides Installation Using a Bracket

4-19
① Studs (L= 16mm and Male- female type:STD16X4) are fixed on a cover (CV0000 or CV00DN) with
screws (SCR6X4).(4 places of ○ )

Figure 4-26 Bracket fixing

* When IF unit is not used but it mounts BS (or BN) unit first, the studs to be used are L= 8mm and
male-female type (ST8X4MF).

② An IF unit is inserted and fixed by L= 8mm of studs, and male-female type (ST8X4MF).

IF unit Note)
1) Studs should use L= 8mm .
If other length studs are used,
assembling of a BS/BN unit
cannot be properly.
2) Be careful of direction of IF unit.

Figure 4-27 IF unit assembling

③ A BS/BN unit is inserted,fixed by L= 16mm of studs, and a male-female type (STD16X4).

Note)
BS/BN unit 1) BS/BN unit and IF unit are
connected using connectors (2
places). Please insert them
securely. If not, may cause
malfunction or failure.
2) When mount OS/ON unit , Studs
should be used L= 16mm . If
other length is used, a
assembling IF unit cannot be
carried out properly. Other
length may cause malfunction
or failure.
3) Be careful of direction of an
BS/BN unit.

Figure 4-28 BS/BN unit assembling

4-20
④ An OS/ON unit is inserted and fixed by L= 16mm of studs, and maleーfemale type (STD16X4).

Note）
OS/ON unit 1) BS/BN unit and OS/ON unit
are connected using a
connector (1place). Please
insert them securely.If not,
may cause malfunction or
failure.
2) Be careful of direction of an
BS/BN unit.

Figure 4-29 OS/ON unit assembling

⑤ Insert a bracket (BK0000 or BK00DN) and fixed by L= 8mm of studs, and maleー female type
(ST8X4MF).
Note）
Bracket 1) There are two kinds of
brackets.
Direct mounting bracket
BK0000
DIN rail bracket BK00DN
2) When mount IF unit next ,
studs should use L= 16mm .

Figure 4-30 Bracket assembling

⑥ Insert a BS/BN unit and fixed by L= 16mm of studs, andmaleー female type (STD16X4).

BS/BN ﾕﾆｯﾄ Note）

1) When mount OS/ON unit ,
Studs should be used L=
16mm .
If other length is used, a
assembling IF unit cannot be
carried out properly.
Other length may cause
malfunction or failure.
2) Be careful of direction of an
BS/BN unit.

Figure 4-31 BS/BN unit assembling

4-21
⑦ An OS/ON unit is inserted and fixed by L= 16mm of studs, and female‐female type (ST16X4FF).

OS/ON unit Note）

1) BS/BN unit and OS/ON
unit are connected
using a connector
(1place).
Please insert them
securely. If not, may
cause malfunction or
failure.
2) Be careful of direction of
an BS/BN unit.

Figure 4-32 OS/ON unit assembling

⑧ Fix Cover (CV0000 or CV00DN) with screws (SCR6X4).(4 places of ○ part )

Cover Note）
1) There are two kinds of
covers, please use the
covers to be fitted with the
bracket to be used .
At the time of using direct
mounting bracket BK0000
=> CV0000
At the time of using DIN
rail bracket BK00DN =>
CV00DN
2) Please attach a cover so
that a printing surface
becomes outside.
(If a printing surface is
inner side,. There are no
problem about functions
and assembling)
Figure 4-33 Cover fixing

4-22
Stud selection

M3
S tud kind M ale ｰ F em ale F em ale ｰF em ale
8m m 16m m 48m m 16m m 48m m
JT EKT type S T D 16X 4 S T 8X 4M F S T 48X 4M F S T 16X 4F F S T 48X 4F F

T he unit on the right side

U sing units
BS OS B rack
IF RY C over
et
BN ON
○ ○
○ ○
B S **** ○ ○
B N **** ○ ○
○ ○
○ ○
○ ○
－
O S **** －
O N **** －
－
－
－
－
IF ****
－
－
○ ○
○ ○
－
－
R Y ****
－
－
○ ○
○ ○
○ ○
C over
○ ○
(for R Y
－
unit)
○ ○
－
－
○ ○
○ ○
C over
－
○ ○
－
－
○ ○
○ ○
B raket
－
○ ○
－
－
Table 4-2 Stud selection, Assembling from the right side
4-23
4.4.4. Example of Direct Installation Type
Assembling
from the
back(wall) Control panel Stud between
side IF-control panel
L= 16mm (16mm or
more)
IF Unit Male-male type
BS/BN Unit 4 places (ST16X4MM)

Stud between
OS/ON Unit
BS/BN-IF
L=8mm
BS/BN Unit Male-female type
4 places (ST8X4MF)
OS/ON Unit
Stud between
BS/BN-OS/ON
L=16mm
Male-female type
4 places (STD16X4)

Screw Stud between

M3X6mm Cover Stud between cover BS/BN-OS/ON
4 places (CV0000 or OS/ON L= 16mm (16mm or
(SCR6X4) CV00DN) L= 16mm (16mm or more)
more) Male-female type
Female-female type 4 places (STD16X4)
Note:
4 places (ST16X4FF)
1) Recommendation bolting
torque is 0.5 N-m.
2) Screws and studs should
be metal . Figure 4-34 Example of Direct Installation Type
3) Brackets, covers, screws
and studs are not attached
to a unit. Please prepare
separately.
4) Please use a grounding
wrist band properly for
electrostatic discharge
damage prevention .

4-24
 ① Fix studs L= 16mm Male- male type (ST16X4MM) to a control panel. (4 places of ○ part)

82
64 82

132

Figure 4-35 Example of Direct Installation Type

※When IF unit is not used but mounts BS (or BN) unit first, studs to be used are L= 8mm and
Male-male type (ST8X4MM).

② Insert IF unit, and fix by studs L= 8mm Male-female type (ST8X4MF).

1) Studs should be used L=

8mm .
If other length is used, a
assembling BS/BN unit cannot
be carried out properly.
3) Be careful of direction of an IF
IF unit unit.

Figure 4-36 Example of Direct Installation Type

③ Insert BS/BN unit, and fix by studs L= 16mm Male-female type (STD16X4).

Note:
1) BS/BN unit and IF unit are
connected using a
connectors (2 places).
Please insert them securely.
If not, may cause
malfunction or failure.
2) Studs should use L=
16mm .
If other length studs are
BS/BN unit used, assembling of a
OS/ON unit cannot be
carried out properly.
3) Be careful of direction of an
BS/BN unit.

Figure 4-37 Example of Direct Installation Type

4-25
④ Insert OS/ON unit, fix by studs L= 16mm Male-female type (STD16X4).

Note:
1) BS/BN unit and OS/ON
unit are connected using
a connector (1 place).
Please insert them
securely.
If not, may cause
malfunction or failure.
OS/ON unit, 2) Be careful of direction
of an OS/ON unit.

Figure 4-38 Example of Direct Installation Type

⑤ Inserts/BN unit, fix by studs L= 16mm Male-female type (STD16X4).

Note:
1) OS/ON unit , Studs should
use L= 16mm .
If other length studs are
used, assembling of a
OS/ON unit cannot be
carried out properly.
2) Be careful of direction of an
BS/BN unit BS/BN unit.

Figure 4-39 Example of Direct Installation Type

4-26
⑥ Insert OS/ON unit, fix by studs L= 16mm Female-female type (ST16X4FF).

Note:
1) BS/BN unit and OS/ON
unit are connected using
a connector (1 place).
Please insert them
securely.
If not, may cause
malfunction or failure.
2) Be careful of direction
of an OS/ON unit.

OS/ON unit

Figure 4-40 Example of Direct Installation Type

⑦ Fix a cover (CV0000) with screws (SCR6X4). (4 places of ○ part)

Note:
1) Cover , please use CV0000
for direct mounting.
2) Please attach a cover so
that a printing surface
becomes outside.
(If a printing surface is inner
side,. There are no problem
about functions and
assembling)
Cover

Figure 4-41 Fix a cover

4-27
Stud selection (at direct mount ) of the assemble in order of the bottom

M3
S tud kind M ale ｰ F em ale F em ale ｰF em ale M aleｰM ale
8m m 16m m 48m m 16m m 48m m 8m m 16m m
JT EKT type STD16X4 ST8X4MF ST48X4MF ST16X4FF ST48X4FF ST16X4MM ST8X4MM
A bottom unit
U sing units
BS OS B ra P an
IF R Y C over
BN ON cket el
○ ○
○ ○
B S **** ○ ○
○ ○
B N **** －
－
○ ○
○ ○
－
O S **** －
－
O N **** －
－
－
○ ○
○ ○
－
IF **** ○ ○
－
－
○ ○
－
－
－
R Y **** －
○ ○
－
○ ○
○ ○
C over ○ ○
－
(for R Y －
－
unit) －
－
○ ○
○ ○
－
C over ○ ○
－
－
－

Table 4-3 Stud selection (at direct mount ) of the assemble in order of the bottom

4-28
4.4.5. Cover, Bracket, Screw Selection

Assemble unit Cover Braket Screw Asse Stud

Moun
type Installatio type, required type, required type, required mble selectio
ting
n number number number number n
Bracket One 4.4.2 Table 4-1
5 or less CV0000 1 BK0000 1 SCR6X4 2
installation side
unnecess
11or less - BK0000 2 SCR6X4 2
ary
Both 4.4.3 Table 4-2
5 or less CV0000 2 BK0000 1 SCR6X4 2
sides
DIN rail One 4.4.2 Table 4-1
5 or less CV00DN 1 BK00DN 1 SCR6X4 2
bracket side
installation unnecess
11 or less - BK00DN 2 SCR6X4 2
type ary
Both 4.4.3 Table 4-2
5 or less CV00DN 2 BK00DN 1 SCR6X4 2
sides
Direct mount One unnecess 4.4.4 Table 4-3
5 or less CV0000 1 - SCR6X4 1
Type side ary
Table 4-4 Cover, Bracket, Screw Selection
* Cover
When an operator's finger
Unit installation number cannot reach or touch a
The number of the units fixed to one bracket. board (please implement risk
RY**** unit is treated as three units. assessment and judge by
Locate IF**** on the right side of BS/BN****. a customer.)
Locate OS/ON**** on the left of BS/BN****. Customer can omit a cover
by his responsibility.

Mounting
One side: Mount one side of one bracket.
Both sides: Mount both sides of one bracket.

One side : Example Both-sides mounting

5 units mounting Example (2 left-hand side,
3 right-hand side)

Assemble type
Bracket installation DIN rail bracket installation Direct

4-29
4.5. Wiring of TOYOPUC-Plus Safety
4.5.1. Terminal Block
TOYOPUC-Plus Safety module is using two kinds of following terminal blocks.
Please use recommendation wire size .

Number Maker/type Recommendation wire

Unit name Current rating
of poles size
10 poles Phoenix contact company
BSxxxx DFMC1.5/10-ST-3, 5-LR 0.50 mm²
BNxxxx 12 poles Phoenix contact company 0.75 mm² 8A
DFMC1.5/12-ST-3, 5-LR (AWG18 equivalent)
OSxxxx 10 poles Phoenix contact company
ONxxxx DFMC1.5/10-ST-3, 5-LR
Table 4-5 Terminal Block
Wiring with a bare wire should always use a solderless contact, because you are easy to cause the short circuit
failure by whiskers.
The following rod terminal with an insulating sleeve or following equivalent product by a phoenix contact
company should be used for solderless contact.

wire size Product

Type Maker Remarks
mm2 AWG number
0.50 20 AI0.5-10WH-GB 3203150
Phoenix contact
0.75 18 AI0.75-10GY 3201288
When using MTW cables,
0.75 18 H1.0/16 9025950000 Weidmüller
select this product
Table 4-6. Terminal Block
As for the crimping tool, the dedicated tool is prepared by every terminal maker. Refer to each maker's
instructions for use. When the incorrect tool was used, or when solderless terminal and a wire are incorrect, a
wire cannot be stuck by pressure properly but may cause loose connection etc.

The Example of a tool : Maker:

Phoenix contact CRIMPFOX 6 (old type CRIMFOX ZA3) Crimping section Trapezoid
CRIMPFOX 10S (old type CRIMFOX UD6-4) Crimping section Quadrangle
Widemüller PZ 4 Crimping section Trapezoid
Madoka system UA-520 Crimping section Quadrangle (made by Osada)
(Note: This is already discontinued and can not be purchased.
In case of using UA-520N which is the successor to UA-520, it may be difficult to
remove the sleeve from the terminal block since the unevenness for preventing
looseness is formed on all four sides. Therefore, we do not recommend it.)

Information : Although Japan and Europe generally indicate with cross section showing (mm2) of wire size, ,
USA indicating with AWG (American Wire Gauge).
Please convert a wire mm2 from AWG, or conversely, refer to the following table.

AWG-cross section conversion table

AWG(#) 30 28 26 24 22 20 18 17 16 14
Wire diameter
0.2546 0.3211 0.4094 0.5106 0.6438 0.8118 1.024 1.150 1.291 1.628
(mm)
Wire cross
0.05097 0.08097 0.1288 0.2047 0.3256 0.5174 0.8226 1.037 1.309 2.081
section (mm2)
Table 4-7 AWG-cross section conversion table
The Example of a wire
Maker: NICHIGOH MTW wire
Product number 0003 00050□ Trade name MTW+H05 V-K 0.50mm2
Finish outer diameter 2.6mm
0003 00075□ Trade name MTW+H05V-K 0.75mm2
Finish outer diameter 2.7mm
4-30
4.5.1.1. Wiring Manner

Refer to the the below, for wirings on the terminal block of each module.

The connection manner

Please push a wire with a solderless terminal into a terminal hole.

The removal manner

Please draw a wire with pushing a release button attached beside the terminal hole.

release button

② ①

Figure 4-42 . Wiring Manner

Please draw a wire with pushing a release button

attached beside the terminal hole.

4-31
4.5.1.2. How to Remove Terminal Block

Please refer to the the below, for removal of a terminal block.

① Insert a minus driver etc.

②Turn

Figure 4-43 Remove Terminal Block

4-32
4.5.2. Power Supply Wiring
Directions for wiring power supply lines.
① The power supply wiring for systems should separate from the power supply wiring for I/O for the
countermeasure against noises.

Using a common power supply

L

N
Note 1)
The power supply (24VDC) must satisfy one of the following requirements.。
ex. 230VAC  Safety mains transformer to IEC 61558/VDE 0570 Part 2-6: “Special requirements on
The power safety transformers for general applications (IEC 61558-2-6:1997)“.
supply ,which  Switch mode power supply to IEC60950-1 :"Information technology equipment - Safety -
satisfy the
requirements of the Part 1" and to IEC50178 : ""Electronic Equipment for Use in Power Installations".
right Furthermore the power supply unit must be suitable for supplying its SELV circuits in
accordance with IEC60950-1.
－ 24VDC ＋
F2 IO_PWR+ BS/BN/OS/ON unit

IO_PWR- IO power

F3 DC24V BS/BN unit

F1
0V Unit power

Note2)
F1: 0.75A (1 for 1 BS/BN unit, built-in poly fuse )
F2,3: Please determine a fuse capacity according to the kinds of module, number, and the current
specification of the connected device .

Note3) Purpose: Electric shock protection

Because Plus Safety is not conforming to the protection level IP2X, please always
grounding 0V to protective earth.
(By grounding the output side (0V) of the SELV power supply, PELV circuit of IEC60204-1
"machine safety - mechanical electric device part 1:general requirements" )

Note 4)
The notes and conditions for using the circuit protector (hereinafter: CP) for F3 are shown below.

If CP is used for F3, Plus Safety may not start up normally.

Please use CP under the following conditions.
Plus SafetyMaximum number of connected units
Rated current of CP
(Total number of units of IF **** and BS ****)
1A Please use CP with rated current 3A.
3A Up to 4 units
5A Up to 12 units

Currently, please use it as it is if it is upgrading normally with the equipment used in the number of
sheets larger than the maximum number of connections in the table.

Figure 4-44 Using a common power supply

4-33
Using a separated power supply
(The purpose, which prevents influencing system operation by the load change of IO modules.)

N
Note 1)
The power supply (24VDC) must satisfy one of the following
ex.230V AC ex.230V AC requirements.。
 Safety mains transformer to IEC 61558/VDE 0570 Part 2-6:
The power The power “Special requirements on safety transformers for general
supply ,which satisfy supply ,which applications (IEC 61558-2-6:1997)“.
the requirements of the satisfy the  Switch mode power supply to IEC60950-1 :"Information
right requirements of the
right technology equipment - Safety - Part 1" and to IEC50178 :
""Electronic Equipment for Use in Power Installations".
－ ＋ － ＋ Furthermore the power supply unit must be suitable for supplying
24VDC 24VDC its SELV circuits in accordance with IEC60950-1.

F2 IO_PWR+ BS/BN/OS/ON unit

I/O power
IO_PWR-

F3 BS/BN unit
DC24V
F1
Unit power
0V

Note2)
F1: 0.75A (1 for 1 BS/BN unit, built-in poly fuse )
F2,3: Please determine a fuse capacity according to the kinds of module, number, and the current
specification of the connected device .

Note3) Purpose: Electric shock protection

Because Plus Safety is not conforming to the protection level IP2X, please always
grounding 0V to protective earth.
(By grounding the output side (0V) of the SELV power supply, PELV circuit of IEC60204-1
"machine safety - mechanical electric device part 1:general requirements" )

Note 4)
The notes and conditions for using the circuit protector (hereinafter: CP) for F3 are shown below.

If CP is used for F3, Plus Safety may not start up normally.

Please use CP under the following conditions.
Plus SafetyMaximum number of connected units
Rated current of CP
(Total number of units of IF **** and BS ****)
1A Please use CP with rated current 3A.
3A Up to 4 units
5A Up to 12 units

Currently, please use it as it is if it is upgrading normally with the equipment used in the number of
sheets larger than the maximum number of connections in the table.

Figure 4-45 Using a separated power supply

4-34
Cascade wiring is available for Unit power supply, I/O power supply.(Maximum 8A)

Example of wiring (Example of I/O power supply)

BS/OS unit BS/OS unit BS/OS unit

IO_ IO_ IO_ IO_ IO_ IO_

PWR* PWR*- PWR* PWR*- PWR* PWR*-

power

- +

terminal

Above-mentioned Example:
The consumption current of each unit
assumed 3.0A , 2.0A, 1.5A, the total current
is 6.5A.

Figure 4-46 Cascade wiring

4-35
4.5.3. Input/output Signal Wiring

Directions when wiring input/output signal lines.

①Input/output signal lines should be separated from high voltage or large current lines as much as
possible (100mm or more), and avoid parallel wiring .
②Please separate Input/output signal lines from AC power supply lines.
③Input/output signal lines should be located at separate ducts from power circuit cable ducts at
inside or outside of a control panel.
④When using metal piping type wirings, please ground a pipe certainly.
⑤Please use the total wiring length within 300 m.
However, when multi-core cable or metal piping type wiring of ④ is used, input check pulse
error may occur due to the stray capacitance of the wiring, so please use the total wiring length
within 150 m as a guide.
When an input check pulse error occurs, add a resistor (resistance value: 1.2 KΩ, power rating:
1/2 W) between the input terminal and 0 V of the I / O power supply as follows.

DC2V 0V
1P1 1N1 BS1600
TB2
Resistor

1.2KΩ,1/2W

R0
IN00

L0
I_COM00

P1
IO_PWR+

N1
IO_PWR－

Figure 4-47 Add Resistor

4-36
4.5.4. IO Bus Wiring
Into IO bus, there are two kinds, Internal IO bus and Remote IO bus.

(1) Internal IO bus

Use it for connection between a CPU module, between internal extension IO modules and Remote
slave station modules, and internal extension IO modules.
A CPU module and a Remote slave station module are a master (master station),
Internal extension IO modules become slaves (slave station).
We recommend users using internal IO bus for modules expansion in the same control panel.
(2) Remote IO bus
Use it for connection between a CPU module and Remote slave station modules.
A CPU module masters, Remote slave station modules become a slave.

4.5.4.1. IO Bus Configuration

The Internal IO bus up to 50m or less as the total length

Internal Internal Remote

Internal Internal Internal Remote extension extension slave
extension extension extension slave IO IO station
IO IO IO station

The Remote IO bus up to maximum

length of 50m or less between each
node.

Internal Internal CPU Internal Internal Remote

(Remote
extension extension extension extension slave
master
IO IO IO IO station
station)

Internal IO bus
Control
Remote IO bus panel

Figure 4-48 IO Bus Configuration

4-37
4.5.4.2. I/O bus Cable
There are two kinds of cables in the Internal I/O bus. There is one kind of cable in the Remote I/O bus.
Refer to the following tables for the kind of I/O bus cable.
No. Wiring Length Recommendation cable
place

Internal Inside 8 poles LAN cable without shield

I/O bus of (5e or more categories)
Control 1m or
Box less ※
１

1m 8 poles LAN cable with shield

(5e or more categories)
Outside ｜
of
Control 50 m
※１
Box
Remote Inside NICHIGO COMMUNICATION ELECTRIC WIRE CO.,LTD,
I/O bus of UNI-FLEX-IE5e - AWG26×4P (Twist Pair Type)
Control
Box
Outside
of 50m or
Control less
Box

Tyco Electronics

※1 The total extension length is 50m or less.

※2 We recommend users to use Remote IO bus connection at outside of control panels.
Reason: The outside cabinet cables short circuit or disconnect probability is much higher than inside
cabinet cables. If short circuit happened, the trouble-shooting of short circuit position is much easier for the
remote IO bus system
Table 4-8 I/O bus Cable
JTEKT preparing the following cable.
No. Purpose Type
1 Internal IO bus cable (with no CB****SI ****=0005 0.05m
shield) ****=0015 0.15m
2 Internal IO bus cable (with shield) CB****SI ****=0500 5m
****=1000 10m
****=1500 15m
****=2000 20m
****=2500 25m
****=3000 30m
****=3500 35m
****=4000 40m
****=4500 45m
****=5000 50m
3 Remote IO bus cable CB****SR ****=0500 5m
****=1000 10m
****=1500 15m
****=2000 20m
****=2500 25m
****=3000 30m
****=3500 35m
****=4000 40m
****=4500 45m
****=5000 50m
Please refer to "Chapter 11.2.4 Cable" for details.
Table 4-9 I/O bus Cable
4-38
4.5.5. Connection with a Standard PLC

FG terminal
(when using a
double shielded
cable )

M3.5 terminal (FG)

(when using a
double shielded
cable) ＦＧ

Connector
Tyco Electronics Amplifier corporation Cable length
D2100S housing: 1-1318120-3 x1 (1) The single shielded cable total
D2100S extension
Rise contact: 1-1318107-1 x3 Maximum 3m (a connector is
Crimping tool: 91595-1 included) (restrict to the wiring in a
cabinet)
(2) The double shielded cable
total extension
A maximum of 50m (a connector
Recommendation cable is included) (wiring cabinet outside
Sleeve terminal (FG) is possible)
(when using a double
(1) Single shielded cable Nichigou
shielded cable ) communicaion Wire
- RO-FLEX-CMDTPS 1Px20AWG (0.5mm2)
(2) Double shielded cable Kurashige Denkko
Inc.
- UL2464-2SB2x20AWG
Figure 4-49 Connection with a Standard PLC
The product is connectable with a Standard PLC and SN-I/F communication.
Connect directly by the above-mentioned connection of TOYOPUC standard PLC with SN-I/F.
And, connection with a PLC ,which does not have SN I/F, is available using a Gateway module

TOYOPUC standard PLC with SN-I/F Gateway module

TOYOPUC-PC10G TCC-6353 NGW-DL (Device network) TAF-6291
TOYOPUC-PC3JG-P TIC-6088 SNGW-PF (Profibus) TAF-6293
TOYOPUC-Plus TCC-6740 SNGW-CL (CC-Link) TAF-6295
(when using Plus EX)
etc.

Table 4-10 Gateway module

Use a twisted-pair cable for connection with a Standard PLC.
Recommend twisted-pair cable.

Cable Maker Type Remarks

Single Nichigou Please use the cables of
RO-FLEX-CMDTPS
shielded cable communication UL listing registration
1P×20AWG(0.5mm2)
Cable cables for the export
Double Kurashige facility to North America
shielded cable Denkko, Inc. UL2464-2SB2x20AWG or Canada.

Table 4-11 Recommend twisted-pair cable

4-39
 JTEKT preparing the following cable.
No. Cable Termination Main purposes Type
processing
Single Connector Connection with EX_SIOSNIF_CN2-*** ***=005 0.5m
shielded for TOYOPUC-Plus ***=015 1.5m
1
cable TOYOPUC-P ***=030 3.0m
lus
Sleeve Connection with TXY-6670 0.5m
terminal TOYOPUC-PC TXY-6671 1.5m
2 10G or PC3 TXY-6672 3.0m
JG-P

Nothing (cut General purpose TXY-6673 3.0m

3
off)
Double Connector Connection with CB****SP ****=0500
shielded for TOYOPUC-Plus 5.0m
4
cable TOYOPUC-P
lus
Sleeve Connection with CB****S10 ****=0500
terminal TOYOPUC-PC 5.0m
5
10G or PC3
JG-P
Nothing (cut General purpose CB****SF ****=0500
6
off) 5.0m
Table 4-12 JTEKT preparing cables
Please refer to "Chapter 11.2.4 Cable" for details.

4.5.5.1. Directions at Wiring

When connect cables, be sure that the power is off.
In order to avoid the malfunction by external noise, communication wirings must avoid parallel wirings or close
wirings with with high voltage, such as a power lines, or heavy current lines.

When using communication-cable of a single shielding cable, please wire only inside of a control panel. And, the
maximum length of a cable is 3m.

When using communication-cable of a single shielding cable, please wire only inside of a control panel.
And, the maximum length of a cable is 3m.

When using communication-cable of a double shielding wire , the wiring at outside of a control panel is also
available. And, the maximum length of a cable is 50m.
Please be sure to connect an outside shielding wire to FG.

4-40
4.6. Connection with Programming Software
Please use the software (PCwin-Safe-Plus) exclusive use for programming of TOYOPUC-Plus-Safety.
PCwin-Safe, and PCwin-Safe-J or PCwin cannot be used.
For writing an user program to TOYOPUC-Plus Safety from PCwin-Safe-Plus, there is a method of using a
commercial USB cable (USB2.0 conformity and A-B type) or other method by using a USB memory.
When a USB cable is used, connect a A type connector side of a USB cable to the USB port of the personal
computer which is installed programming software, and connect the B type connector side (square shape) to
USB connection I/F of a CPU module.
When using a USB memory, connect with USB memory I/F. And, please refer to the instructions manual of
PCwin-Safe-Plus for the writing of the user program to TOYOPUC-Plus Safety.
And please avoid permanent connection of a USB cable.

Programming
software
PCwin-Safe-Plus PCwin-Safe-J PCwin-Safe PCwin
Connectable
PLC

TOYOPUC-Plus Safety ○ × × ×
TOYOPUC-PCS-J × ○ × ×
TOYOPUC-PCS × × ○ ×
TOYOPUC standard PLC × × × ○
Table 4-13 Connection with Programming Software

The personal computer

installed PCwin-Safe-Plus
A type B type
connector connector

USB cable (USB2.0

conformity A-B type) USB Memory

USB connection I/F which transfers an user

program to a CPU module

USB memory I/F which transfers an user

program to a CPU module

Figure 4-50 Connection with Programming Software

4-41
 The relation of the connecting cables which TOYOPUC-Plus Safety and other
PLC use is shown in the following figure.

USB2.0 cable (cable

recommendation made by Elcom)

USB-A USB-B

TOYOPUC-Plus Safety

Dedicated cable
RS-232C type
USB-A USB-B
USB type RS-232C
TOYOPUC-PCS-J
USB-B
RS-422
RS-422

TOYOPUC-PC10 Series
TOYOPUC-Plus Series
Connect TOYOPUC-Plus Safety
by USB2.0 cable.
The same as TOYOPUC-PCS-J
TOYOPUC-PC3J Series TOYOPUC-PCS and PC10 series

Connect TOYOPUC-PCS by the cable only for TOYOPUC.

The same as PC3J series.
Figure 4-51 Connecting cables for TOYOPUC-Plus Safety and other PLC

4-42
4.6.1. Notes on USB connection between personal computer and TOYOPUC-Plus Safety

Please never insert and/ or remove the USB cable from the personal computer port while the AC power supply
of the personal computer is in use.
When you connect the PLC and the personal computer with a USB cable, please confirm chapter 4.6.3.
beforehand and follow the procedure on chapter 4.6.1.4.
Otherwise, USB port of PLC may break down.

4.6.2. Cause of USB port failure on PLC

If AC power supply of the computer or the shield is not grounded, the USB port may break due to the
reasons below. If the USB port on PLC is broken, communication with PCwin will not be possible but
there will be no problem with operation or other functions of PLC.

① ①The USB port on PLC may break down when connecting with a USB cable due to the current
leakage from the AC adaptor or PC, which is occurred by a potential difference between the metal
connectors of USB cable and PLC.
Metal part of USB connector
Personal computer PLC
AC adaptor
AC plug(3 wicks) DC cable
FG
Outlet Potential
USB cable difference
current
Unearth in leakage FG
Possibility that
earth line Shield Shield
Potential Potential PLC breaks
Earth Earth
AC plug(2 wicks) difference difference down.
Unearth in
earth line

Unground
ed earth
Earth

Figure 4-52 Cause of USB port failure on PLC

② The USB port on PLC may break down due to the current leakage coming from AC power supply of PC.
Some PC models have shield wire connected to 0V (GND signal) of USB, which can cause current
leakage when there is a shield wire disconnection of USB cable, or a poor connection between the
metal connectors of USB cable and PC.

Personal computer PLC

Ｖbus Vbus
DC cable D+ D+
D- USB cable D-
0V 0V
FG FG
Disconnection of shield line
leakage
current
Possibility that
Loose connection of metal part PLC breaks down
including the turn
Shield Potential of the leakage of
Earth(FG) current.
difference

Figure 4-53 Cause of USB port failure on PLC

4-43
4.6.3. Prior confirmation for USB connection
Please confirm the following matters before USB connection.
1) Please confirm the conduction status of USB cable shield line before using it.
Do not use the USB cable with a disconnected shield line.
Confirmation of shield line connection USB cable

The resistance between

the metal parts is several
ohms or less

*Please confirm the conduction while lightly winding the cable.

Figure 4-54 Prior confirmation for USB connection

2) Please check if the USB connector and port are firmly in contact, by slightly moving the connector to all
possible directions. Please do not use the USB port if a non-conduction status is observed even momentarily.
Confirmation of the metal contact * Please confirm the conduction states
while moving all directions.
personal computer USB connector
USB cable

The resistance between the metal parts and chassis of the

Shield personal computer is several ohms or less

Figure 4-55 Prior confirmation for USB connection

3) The following cables are recommended in order to protect the USB port from breaking due to a current
leakage from the personal computer.

USB cable
Profile
Manufacturer Type Length
Elecom U2C-BN07BK 0.7m A(male)-B(male) Type
U2C-BN10BK 1.0m
U2C-BN15BK 1.5m * RoHS directive conformity
U2C-BN20BK 2.0m product
U2C-BN30BK 3.0m
U2C-BN50BK 5.0 m
Table 4-14 Cables are recommended
4) The USB standard stipulates that the maximum length of a USB cable is up to 5 meters.
The total extended distance must be within 5 meters when using a device such as relay plug.

4-44
4.6.4. Procedure for USB connection between PC and TOYOPUC-Plus Safety PLC
Please connect USB cable by either of the following procedures 1) to 4).
1) When an AC power plug of PC is a 3 core cable with earth pole

PLC
Personal computer
USB cable
Outlet AC plug(3 wicks)
AC adaptor
(2) (3)
(1)

Earth * The earth pole must be grounded. The order of connecting a USB cable to a PLC
(1) -> (2) -> (3)

The order of removing a USB cable from a PLC

(3) -> (2) -> (1)

Figure 4-56 Procedure for USB connection between PC and TOYOPUC-Plus Safety PLC

2)When an AC adaptor power plug has a ground wire

Personal computer
PLC
USB cable
Outlet AC plug(2 wicks) AC adaptor
(2) (3) (4)

(1)
Earth Ground line

The order of connecting a USB cable to a PLC

Connect ground wire (1) -> (2) -> (3) -> (4)
* Using the same ground for AC power supply
The order of removing a USB cable from a PLC
(4) -> (3) -> (2) -> (1)

Figure 4-57 Procedure for USB connection between PC and TOYOPUC-Plus Safety PLC

4-45
 3) When an AC adaptor power has 2 core cable without a ground wire

Personal computer PLC

USB cable
Outlet AC plug(2 wicks) AC adaptor
(2) (3) (4)

Earth (1) Personal computer side

Connecting with
fixed screw.
Serial port
Ground line
Ground shield wire of PC
* Using the same ground for AC power supply The order of connecting a USB cable to a PLC
(1) -> (2) -> (3) -> (4)

The order of removing a USB cable from a PLC

(4) -> (3) -> (2) -> (1)

Figure 4-58 Procedure for USB connection between PC and TOYOPUC-Plus Safety PLC

4) When driving PC with its battery (without using AC power supply)

No need to ground the PC

PLC
Personal computer
USB cable

(1) (2)

The order of connecting a USB cable to a PLC

(1) -> (2)

The order of removing a USB cable from a PLC

(2) -> (1)

Figure 4-59 Procedure for USB connection between PC and TOYOPUC-Plus Safety PLC

4-46
4.7. Unit Selection /Assemble Manners Selection

Procedure Description Reference clause

1 Unit selection Please select a unit according to a required Chapter 2.1-2.3
input/output point and functions.
2 CPU operation mode Please select CPU operation mode according to Chapter 2.4
selection required input/output points and functions.
· Stand-alone mode
· Remote 1 mode
· Remote 2 mode
3 Assemble selection · Selection from the following.
(1) Bracket installation type Chapter 4.3.3
(2) DIN rail bracket installation type Chapter 4.3.2
(3) Direct type Chapter 4.3.1
4 Stud/Cover/Bracket Stud
selection · Length : 8mm / 16mm / 48mm Chapter 4.4,
· (male-female)/(female-female)/(male-male) Type Chapter 11.2.1
Cover
· The cover for using direct mounting bracket
(type: CV0000) Chapter 4.4,
· The cover for using DIN rail attachment Chapter 11.2.3
(type: CV00DN)
· No cover Chapter 4.4,
Bracket Chapter 11.2.3
· Direct mounting bracket (type: BK0000)
· DIN rail bracket (type: BK00DN)
· No bracket
5 Assemble Manners Using a bracket,One-side mounting Chapter 4.4.4
Using brackets ,Both-sides mounting Chapter 4.4.3
Direct mounting Chapter 4.4.2

Table 4-15 Unit Selection /Assemble Manners Selection

4-47
5. Trail Operation
5.1. Points to Be Checked at Test Run
Procedure Description Reference clause
1 Confirmation before Chapter 5.2 Chapter 5.2
power supply Please confirm according to the point to
reconnecting be checked before power supply
reconnecting.
2 Switch setting (1) A basic unit (BS/BN****) needs the (1) 2.2.2 (2) - ①
module setting operation by station
number switches setting

(2) When using Extension IO module, (2) 2.2.2 (2) - ②

connect with an internal IO bus cable,
but termination switch setting is
required for a termination module.

There are two termination modules,

please set the both modules.
(3) 2.2.1 (3) - ④
(3) When SN-I/F is used, IF unit (IF****)
needs Termination switch setting
3 Cable connection (1) Power cable 1.2 Refer to the
· Basic unit (BS/BN****) needs configuration example
connection of power supply for units (1) 2.2.2(2) - ⑧、⑨
(TB1) and power supply for IO (two 2.2.3(2) - ①、②
places, TB1 and TB2).
· An option unit (OS/ON****) needs
connection of the power supply for IO
(two places, TB1 and TB2).

(2) Internal IO bus cable

The cable is required when using (2) 2.2.2(2)、4.5.4
Extension IO module. Please use the
correct specified (more than 8 cores
LAN cable and category 5e) cable.

(3) Remote IO bus cable (3) 2.2.1(3) - ⑧、4.5.4

The cable is required when using the
Remote slave station module. Please
use the specified cable.
CPU can be installed at only the
termination location of a
communication line (Remote IO bus).
(Only one port is available between 2
(4) 2.2.1(3) - ⑤、4.5.5
ports)）

(4) SN-I/F cable

The cable is required when making
connection with a standard
PLC(PC10G, Plus, etc.).
Please use the specified cable.
Table 5-1 Points to Be Checked at Test Run 1/3

5-1
 Procedure Description Reference clause
4 Connect the power Connect the power supply -
supply.

USB
I/F
CPU module

When a power supply is not turned on

(LED does not light up), please confirm
connection of a power cable and power
supply voltage.
5 Program writing A program is not written at shipment. Program creation :
Please write a program (user program) Refer to
by the customer. PCwin-Safe-Plus
For writing a user program, there are 2 instructions manual
manners. One is using a commercial T-A63*N chapter
USB cable (USB2.0 conformity and A-B and Chapter 7/8
type) and the other is using a USB
memory.
(The dedicated programming software
PCwin-Safe-Plus is required for creation
and writing of a program)
(1) 2.2.1(3) - ②
(1) In the case of using a USB cable 2.5.1.1
A type connector side of a USB cable is 4.5
connected to the USB port of a personal Writing operation :
computer which is installed Refer to
PCwin-Safe-Plus, B type connector side PCwin-Safe-Plus
(square shape) is connected to USB instructions manual
connection I/F of CPUmodule. T-A63*N Chapter
Please start writing after changing to the 12.2.
maintenance mode.
(2) 2.2.1(3) - ③、
(2) In the case of using a USB memory 2.5.1.1
USB memory (in advance, it is 2.5.2.2(2)、
necessary to make data conversion of 4.5
the user program, and to write a Data conversion
program in a USB memory by operation :
PCwin-Safe-Plus) is connected with a Refer to
USB memory I/F. PCwin-Safe-Plus
Please start writing after changing to the instructions manual
maintenance mode. T-A63*N Chapter 15.
After writing completion, please reconnect 2.5.2.1
the power supply or change to the RUN
mode.
Table 5-2 Points to Be Checked at Test Run 2/3

5-2
 Procedure Description Reference clause
6 Station number error When the station number of a basic unit
reset (BS/BN****) is changed, Station number
error (error 92) is caused.
When it causes, station number error 2.5.1.4
reset operation is needed.
And, please be sure to implement 2.5.1.3
Reset/RUN operation after station number
error reset.
(Unless Reset / RUN operation is
implemented, station number error reset
does not become valid)
7 Clock setting After power supply reconnecting or Reset
/ RUN operation, Clock-not-setting (alarm
AF) may be caused.

Alarm

USB Refer to
I/F PCwin-Safe-Plus
CPU module
instructions manual
T-A63*N chapter 12.6.
At the time of occurrence,Please
implement time setting by using
PCwin-Safe-Plus.
8 RUN confirmation Please confirm becoming RUN mode.

RUN
mode
USB
I/F

CPU module Chapter 6.2 6.4 or 6.5

When not becoming RUN mode, please Refer to
confirm the Error description using PCwin-Safe-Plus
PCwin-Safe-Plus, and take measures. instructions manual
(Checking, such as switch setting, wiring, T-A63*N Chapter 12.5.
and a program)
Table 5-3 Points to Be Checked at Test Run 3/3

5-3
5.2. Point to Be Checked before Power Supply connecting

■ Parameter setting
・ Please confirm the following parameters setting to be correct by PCwin-Safe-Plus.
① Are IO module settings and actual module configuration same?
② Settings of I/O parameters like ("wiring method", "symbol", "input error detection time", "input
method", "input discrepancy detection error category") are correct?
③ Are settings of link parameter correct?

■ Switch settings
・ Are the station number switch settings of a base unit correct?
・ Is the termination switch setting of an internal IO bus on a base unit correct?
・ Is the termination switch setting of SN-I/F (MODBUS) on IF unit correct?

■ Mounting of unit modules

・ A IF unit and an option unit are mounted on a base securely ?
・ Each unit and modules are mounted using metal studs?
・ IO bus cables connect between modules properly?
When an internal IO bus cable exceeds 1m, use a shield cable, and the maximum total
extension length must be 50m or less.
Remote IO bus cable, the maximum length between nodes is 50m or less.

■ Wirings of a terminal block

・ Is a terminal block attached to the module securely?
・ Is a cable connected to each terminal correct?
・ Is cable size suitable?

■ Protective cover
・ A protective cover is attached securely?
(2 protective covers are required at both ends when both-sides installation)

5-4
6. Error Classifications
Errors caused in TOYOPUC-Plus Safety.

6.1. Error Rank

The errors caused in TOYOPUC-Plus Safety is divided into three error ranks, alarm, minor errors, and critical(major)
errors.

Error rank Alarm Minor error Critical(Major) error

Meaning The minor errors The error mainly The error caused by
resulting from caused by safety TOYOPUC-Plus Safety
TOYOPUC-Plus Safety devices connected to system. Operation of an
system. Continuation of TOYOPUC-Plus user program and
safety control system Safety,a power supply safety control system
operation and operation or wirings. Operation of operation are difficult.
of an user program are an user program can be
possible . continued, but
operations of a safety
control system is
difficult.
Examples of error Clock Non-setting. Input discrepancy Power down
Input discrepancy detection error ( IO I/O bus communication
detection error ( IO parameter setting) error
parameter setting). External 24V supply
voltage check error
Operational status of a Outputs can be All outputs shut off, All outputs shut off,
safety control system possible and , a safety safety status of safety status of
control system can control system, is control system, is
operate continuously. maintained. maintained.
Operation continued
Running state of an user Operation continued Operation continued Stop
program
LED for status indication Yellow Purple Red
Shutdown (all output No-shutdown Shutdown Shutdown
OFF)
Restoration Power
measure supply
○ ○ ○
reconnection
Reset
operation *1
○ ○ ○
Reset flag
operation *2
× ○ ×
Automatic
release
× × ×
Table 6-1 Error Rank
*1: Function selection switch
The restoration by operation of a function selection switch means restart of a TOYOPUC-Plus Safety system.
Maximum 40 seconds is required to start.
*2: Reset flag operation
The following V flags are available reset flags.
Error contents Error code Reset flag address
Safety I/O error (IO module 43 V4E
detection)
Table 6-2 Reset flag
When the above-mentioned errors have caused, and set ON of a corresponding reset flag Figure 6-1
will reboot the safety PLC system like function selection switch operation.
The sequence program which turns on a reset flag by the input from the push button of a Function selection switch
operation panel is designed, a Safety PLC can be rebooted by a push button operation.

6-1
6.2. Error Code List
Error Code Cause*2
Detection *5
Error RUN Output At
Detailed Error contents External At At mai
code *1
Internal *3 *3 rank status state
Sta RU nten
rt N anc
e
13 Power down △ ◎ Critical Stop OFF ○ ○
21 Program memory CRC ◎ － Critical Stop OFF ○ ○
check error
Supplementing Critical
23 information CRC check ◎ － Stop OFF ○ ○
error
31 Scan time over ◎ － Critical Stop OFF ○ ○
32 System RAM error ◎ － Critical Stop OFF ○ ○
35 System management ◎ － ○ ○
processor error
00 Hardware error ◎ － ○ ○
01 Processing time monitor ◎ － ○ ○
error
Data between OFF
02 microprocessors error ◎ － Critical Stop ○
03 Hardware check error ◎ － ○ ○
04 System timer error ◎ － ○
05 Stack error ◎ － ○ ○
06 Interruption error ◎ － ○
07 Schedule action error ◎ － ○
43 Safety I/O Error (IO module detection) Minor Run OFF
15 I/O power-supply-voltage △ ◎
check error
21 Input pulse check error △ ◎
Input discrepancy error Minor / Run / OFF/
22 detection △ ◎ Alarm Run *4 Run *4
*4
31 Output pulse check error △ ◎ Minor Run OFF
32 Output read back data △ ◎
discrepancy error
33 Output relay contact error △ ◎
41…46 Microprocessor ◎ －
communication error
I/O bus communication
52…FF error ◎ △
48 I/O table verification error ◎ － Critical Stop OFF
71 Application instruction ◎ － Critical Stop OFF
error 1
84 Communication board
error
85 Link parameter error
86 Link communication error
Link module assignment
89 error
92 Station no. error
94 Station no. setting error
A3 RTC error ◎ － Critical Stop OFF
AB Memory writing error ◎ － Critical Stop OFF
AD Data error ◎ － Critical Stop OFF
AE Data error unconfirmed ◎ － Minor Run Run
AF Clock non-setting ◎ － Minor Run Run
B0 MP-B and MP-A ◎ － Critical Stop OFF
communication error
B1 I/O bus communication ◎ △ Critical Stop OFF
error
*1Detailed code : The code stored in the error related information 3 at ERR43 (error in safety I/O)
*2 Cause factor : ◎ Possibility is very high, ○Possibility is high, △low possibility, － no possibility
*3 Cause factor: External = external factors, such as wiring, power supply,
Internal = TOYOPUC-Plus Safety System internal factor
*4 It is based on IO parameter set value (input discrepancy detection error category) .
Table 6-3 Error Code List

6-2
6.3. Special Register for Error Information Storage
At error detection, the PLC stores an error code, error related information, and error detection time in the
special register for error information storage (S register and ExS register).

The S register has 8 layers of shift register structures, and can memorize the error information up to 8 times.
When an error becomes 8 times or more, it will disappear in order of the error information stored first.
The error information stored in the register can be read from PCwin-Safe-Plus.

The ExS register has 64 layers of shift register structures, and can memorize the error information up to 64
times. When an error becomes 64 times or more, it will disappear in order of the error information stored first.
Error 0 - Error 7 information are same value of S register and ExS register.
The error information stored in the register can be read from PCwin-Safe-Plus.

Register contents
New error Upper byte Lower byte

↓ S200 ExS000 Error code

Error 0 Information S201 ExS001 Error information 2 Error information 1

Error 1 Information S202 ExS002 Error information 4 Error information 3

S203 ExS003 Error detection time (second)

…

Error 7 Information S204 ExS004 Error detection time (minute)

S205 ExS005 Error detection time (at the time)
… … …

S206 ExS006 Error detection time (day)

S207 ExS007 Error detection time (month)
Error 63 Information S208 ExS008 Error detection time (year)

Error detection time

↓ S209 ExS009 －
(day of week)

Disappear from
older error.

Table 6-4 Special Register for Error Information Storage

(1) Error related information is stored by the hexadecimal number.
(2) Error detection time indicates the present time of a built-in clock with a BCD code, and indicates a single
digit with 1 byte.
(For example, "0102" shows "12".))
Year data shows 2 digits of under a Christian year, and, as for week day data, 0-6 stands for Sun.-Sat.
(3) The error information stored in the special register of error information is not cleared even after error
recovery.

6-3
6.4. Error Code Contents

※ Head of four digits of error codes ( [*] indication in a table) shows the A or B side of redundancy system
of TOYOPUC-Plus Safety. And which side detects the error.
Example

A013
A-side detected Power down
the error. detection
Relat
Error Val
Error contents ed Contents Description
Code ue
info.
*0 13 Power down - - System power supply (24VDC) voltage dropped.
*0 21 Program memory CRC check - - Safety program written in built-in ROM is NG by
error CRC check.
*0 23 Supplementing information - - Parameter is NG by CRC check.
CRC check error
*0 31 Scan time over - - Execution time of the system program exceeded
specified time.
*0 32 System RAM error 1 Detectio 01 System RAM
n
classifica
tion
4 Classific 01 NG was detected with the address check of
ation system RAM.
02 NG was detected with the cell check of system
RAM.
*0 35 System management processor - - Serious error of a microprocessor system
error caused.
1 Classific 00 Hard error.
ation 01 Processing time monitor error.
02 Data verification error between CPU-MP-A and
CPU-MP-B
03 Hardware check error
04 System timer error
05 Stack error
06 Interruption error
07 Schedule running error
*0 43 Safety I/O error - - An error was detected at I/O part of CPU module
(IO module detection) or IO module by self diagnostic tests.
1 Unused 00 00 fixing
2 Slot 00 Slot number ,where an error is detected (HEX
H code).
～
0F b7 b6 b5 b4 b3 b2 b1 b0
H

00: CPU module

01-1F: Remote slave station
module
Internal extension
module (a station
number add 20)
* In the case of 0, errors
have caused in
CPUmodule or the
Remote slave station
module.
3 Classific 13 System error
ation 14 System power-supply-voltage check error
15 I/O power-supply-voltage check error
21 Input pulse check error
22 Input discrepancy detection
31 Output pulse check error
32 Output read back data discrepancy error
Table 6-5 . Error Code 1/5
6-4
 Error Related
Error contents Contents Value Description
Code info.
*0 43 Safety I/O error 3 Classifica 41 Communication between microprocessors
(IO module detection) tion establishment failure
42 Communication error between microprocessors
Serial communication error
43 Communication error between microprocessors
Communication format error
45 Communication error between microprocessors
Input data verification error
46 Communication error between microprocessors
Output data verification error
52 I/O bus communication error
Serial communication error
I/O bus communication master-station
55 transmitting timeout error (slave station
receiving timeout)
I/O bus communication
56 Transmitting processing error
I/O bus communication
57 Receiving processing error
I/O bus communication
58 Function incorrect call
I/O bus communication
63 Communications executive flag error
I/O bus communication
64 Link parameter size error
I/O bus communication
65 Link parameter response error
I/O bus communication
66 Link parameter setting error
I/O bus communication
80 Counter of status data error
I/O bus communication
81 I/O data transmitting source station number error
I/O bus communication
82 Information size of I/O data error
I/O bus communication
83 Counter of I/O data error
I/O bus communication
84 Master-station I/O data comparison error
I/O bus communication
85 Slave station I/O data comparison error
I/O bus communication
91 Master-station station number duplication error
I/O bus communication
92 Slave station station number duplication error
I/O bus communication
FF Other errors
4 Address 00H ～ I/O Address, where errors were detected.
1FH I00-0FH: BS/BN unit address
10-1FH: OS/ON unit address
*0 48 I/O table verification - - IO module set by a parameter is different from
Error actual mounted module
1 unit 00 Base unit
01 Option unit
Table 6-6 . Error Code 2/4

6-5
 Error Related Content Valu
Error contents Description
Code info. s e
*0 48 I/O table verification Error 2 Slot 00H Slot number ,where errors were detected (HEX
～ code).
0FH
b7 b6 b5 b b3 b2 b1 b0

00: CPU module

01-1F: Remote slave station
modulemodule
1-3: Internal Extension
Module (Station Number Adds
20)
* In the case of 0, errors have
caused in CPUmodule or the
Remote slave station module.
Examples)
00100000: Error by the internal expansion IO
(station number 21) module of a CPU module
00000001: Error by a Remote slave station
module (station number 01)
01100010: Error by the internal expansion IO
(station number 23) module of a Remote slave
station module (station number 02)
3 Registra Module code set by a parameter
tion
data
4 Mountin Module code of a mounted module .
g data
*0 71 Application instruction - - Operand or operation result of an application
error 1 instruction are outside a stipulated range.
1 Step L Lower- step number of an application instruction
2 number H Upper-step number of an application instruction
3 Serial L Lower- Serial number of an application
number instruction
4 H Upper-Serial number of an application instruction
*0 84 Communication board - - -
error 1 分類 81 RAM check error
83 ROM check error
84 CPU check error
85 I/O bus communication error error
86 Communication error between MP(s)
89 Schedule error
8A Process error
2 Station → Station Number (0x31, 0x32)
*0 85 Link parameter error 1 -
Error 01 Inappropriate relay link area top address
02 Inappropriate register link area top address
03 Inappropriate relay link transmitting area top
address
04 Inappropriate register link transmitting area top
address
05 Relay link area overflow
06 Register link area overflow
20 Inappropriate network address
22 Communication method was not defined.
23 Inappropriate node number for a module.
25 Inappropriate link parameter subcode
26 Inappropriate token monitor timeout
27 Wrong minimum permissible frame interval
41 Wrong safety link area top address for other
node
42 Safety link area over flow for own node
43 Safety link area over flow for other nodes
50 Staion number setup error
2 Link → Link number(No.1-No.8)
3 Data 00 FLnet
Table 6-7 . Error Code 3/5
6-6
 Error Rela Content Val
Error contents ted Description
Code info. s ue
*0 86 Link communication error - -
1 10 Self-node number duplication error
20 Communication format error
21 Data size error
22 CRC error
40 Communication status comparison error
41 Sequence counter error
51 I/O data comparison error
60 Receiving timeout
61 Transmitting timeout
62 Sequence counter timeout
70 MP-C processing error
Common memory transmitting area address
A0 duplication (common memory 1)
Common memory transmitting area address
A1 duplication (common memory 2)
E0 Token monitor timeout
2 Station → Station number(0x31, 0x32)
3 Node → Node number
*0 89 Link module assignment error - - -
*0 92 Station number error - - - The station number is changed from the previous
station number.
1 Data Station number after change
2 Data Station number before change
*0 93 Station number switch error - - - The station number was changed during the
power supply ON.
1 Data Present station number
2 Data Previous station number
*0 94 Station number setting error - - - Station numbers other than defined number
(00, 01-1F, 21-23) has been set
1 Data Present station number
*0 A3 RTC error - - RTC errorwere detected by initial processing.
1 Error 01 Initialization error
02 Reading error
03 Writing error
*0 A Memory write error - - - Error caused by writing to a flash ROM.
B 1 Data 01 Internal memory
04 External memory
2 Error 02 CRC error
10 Initialization error
11 Error during deletion
12 Error during writing
13 Error during comparison
14 Error during reading
*0 AD Data error - - - Backup data cannot be restored.
*0 A Data error unconfirmed - - - After data error (ER AD) caused, the data
E confirmation is not carried out by
PCwin-Safe-Plus.
*0 AF Clock non-setting - - - Clock data has not been set
*0 B0 Between MP-A and MP-B - - Communication error caused between MP-A and
communication error MP-B.
1 Classific 01 Processing timeout.
ation 10 Serial communication error was detected.
11 Receiving processing error
12 Transmitting processing error
20 Function unjust call.
30 Data receiving error.
32 Response error
FF Other error/s was/were detected.
Table 6-8 . Error Code 4/5

6-7
 Relat
Error Val
Error contents ed Contents Description
Code ue
info.
*0 B1 I/O bus communication error - - Errors caused in I/O bus communication.
1 Classific 00 Synchronization error
ation 01 Receiving flame transfer error
10 Serial communication error
11 Receiving processing error
12 Transmitting processing error
20 Function incorrect call error
33 I/O data transmitting source station number error
34 Information size of I/O data error
35 Counter of I/O data error
36 Master-station I/O data comparison error
38 Counter of status data error
40 Circuit connection error
41 master-station station number duplication error
42 slave station station number duplication error
Connection station discrepancy errors (the
43 connection conditions of a link parameter and a
module differ.)
61 Communications executive flag error
62 Link parameter size error
63 Link parameter response error
64 Link parameter setting error
FF Other errors were detected.
3 Station 00 Station No. where the error is detected.
number H
～ b7 b6 b5 b4 b3 b2 b1 b0
7F
H
00: CPUmodule
01-1F:Remoute slave module
1-3: Internal Extension
Module (Station
Number Adds 20)
* In the case of 0,
errors have caused in
CPUmodule or the
Remote slave station
module.
Examples)
00100000 : Error by the internal expansion IO
(station number 21) module of a CPU module
00000001: Error by a Remote slave station
module (station number 01)
01100010: Error by the internal expansion IO
(station number 23) module of a Remote slave
station module (station number 02)
Table 6-9 . Error Code 5/5

6-8
6.5. Error Handling
Please refer to the maintenance guidance (Pcwin-Safe2) for the details of error handling.

Error
Error contents Handling
code
0013 Power down ・ Please confirm the system power supply voltage is 24VDC.
・ Please confirm voltage 20.4VDC or more .
・ Please confirm wiring of terminal blocks and connections properly.
・ Please confirm whether power supply environment is stable .
・ Supply voltage is 24VDC, and even reconnect the power supply, but the error
recurs
Please replace a base unit. (Replace in order of a basic unit, an option unit,
and IF unit)
0021 Program ・ Please reconnect the power supply.
memory CRC ・ When the error recurs, please re-write the user program.
check error ・ When the error still recur, please replace a CPU module. （(Replace in order
of a basic unit, an option unit, and IF unit)
・ When recurring the failure, after confirming whether IF unit is mounted
correctly, Please re-write a user program. （In the case of the writing from
Pcwin-Safe-Plus, Please confirm whether the recommending USB cable is
used.）
0023 Supplementin ・ Please reconnect the power supply.
g information ・ When the error recurs, please re-write the user program.
CRC check ・ When the error still recur, please replace a CPU module. (Replace in order
error of a basic unit, an option unit, and IF unit)
・ When recurring the failure, after confirming whether IF unit is mounted
correctly, Please re-write a user program. （In the case of the writing from
Pcwin-Safe-Plus, Please confirm whether the recommending USB cable is
used.）
0031 Scan time · Please reconnect the power supply.
over · When the error still recur, please replace a CPU module.
0032 Abnormalities · Please reconnect the power supply.
in system · When the error still recur, please replace a CPU module.
RAM
0035 Abnormalities ・ When other errors have occurred at the same time, Please solve the error.
in a system ・ When these errors cause alone, Please re-reconnect a power supply.
management ・ When the error still recur, please replace a CPU module. (Replace in order
processor of a basic unit, an option unit, and IF unit)
0043 Abnormalities Error related
Treatment
in safety I/O information 3
13 · Please reconnect the power supply.
System Error · When the error recurs, please replace the module which
corresponds from the error related information 2.
(Replace a basic unit )
14 · Please confirm whether unit power supply of the module
Power-Supply-Volt related information 2 is stable (more than DC20.4V). (Are
age Check Error terminal blocks and wiring connected properly?)
· Even if a unit power supply is stabilized , when the failure
recurring, Please replace a basic unit.
15 · Please confirm whether IO power supply of the module
I/O related information 2 is stable. (Are terminal blocks and
Power-Supply-Volt wiring connected properly?)
age Check Error · And please confirm whether I/O power supply is stable
(more than DC20.4V).。
· When still recurring, Please replace units (a basic unit,
an option unit).

Table 6-10 Error Handling 1/4

6-9
 Error
code Error contents Handling
0043 Abnormalities Error related Handling
in safety I/O information 3
(IO module 21 input pulse ・ Please confirm whether wiring has short circuit in the input
detection) check error address of the module which corresponds from the error
related information 2 and 4.
・ When there is an option unit, Please confirm assembling
properly.
・ Please confirm whether the input manners/ parameters
are correct in PCwin-Safe-Plus.（When the parameter
setting is a dry contact and the device which outputs test
pulses, such as light curtain, is connected, the error
causes.）
・ Please confirm whether I/O power supply supply is
stable (more than DC20.4V).
・ If there is not above-mentioned conditions, Please
replace the related unit.
・ When the error caused in the basic unit, please replace a
basic unit
・ When the error caused in the option unit, please replace
in order of an option unit then a basic unit.
22 ・ Incoming signal conditions differ in the pair of the input
inputs discrepancy address of the module which corresponds from the
detection related information 2 and 4.
・ Please confirm whether there is any disconnection.
・ Discrepancy detection time is set by an I/O parameter
(1.0 to 9.9 seconds).
Setting according to the characteristics of the connected
I/O equipment . (The recommendation value of
discrepancy detection time is 1 second. when a
recommendation value but this error occurs, a bigger
value than 1 second can be set , but risk assessment is
required)
・ When using a door switch, the error may be caused by
poor switch installation. When using a door switch, the
error may be caused by poor switch installation. And
when door opening/closing operation is slow, or stop
operation during opening/closing, the error may cause.
Be careful about the switch installation or door
operation .
・ When the error recurring, failure of a connected device
can be considered. Please confirm whether the
connected device working properly.
・ When there are no abnormality in a connected device
and parameters, Please replace the related unit.
(When the error caused in the basic unit, please replace
a basic unit. When the error caused in the option unit,
please replace in order of an option unit then a basic
unit.）
31 ・ Please confirm whether there is a short circuit or faulty
output pulse check wiring at the external wiring of the output address of
error module which corresponds from the related information
32 2 and 4.
output read back ・ Please confirm whether the over-current (more than 2A)
data discrepancy at the output address of the related module. (The internal
error over-current protection circuit may be working.)
・ Please confirm whether I/O power supply supply is
stable (more than DC20.4V).
・ When there is an option unit, please confirm
assembling properly.
・ When there are no above-mentioned errors, please
replace modules. (When the error caused in the basic
unit, please replace a basic unit. When the error caused
in the option unit, please replace in order of an option
unit then a basic unit.）
Table 6-11 Error Handling 2/4

6-10
 Error Error contents Handling
code
0043 Abnormalities Error related
in safety I/O information 3 Handling
(IO module 41, 45, 46 ・ Please reconnect a power supply.
detection) Between ・ When recurring, replace a module which corresponds
microprocessors from the related information 2. (replace a basic unit )
(MP-A,MP-B)
Communication error
52～FF ・ Please reconnect a power supply.
I/O-bus ・ Please confirm a assemble properly, when there are an
communication option unit and an IF unit.
error ・ When recurring, Please confirm whether IO bus cable
connected to module which corresponds from the related
information 2 is mounted correctly.
・ In the case of using an internal IO bus , Please confirm
whether setting of a terminator is correct.
・ In the case of using a Remote IO bus , Please confirm
whether both(2) of Remote IO bus I/F of CPU module
are used.
・ In the case of CPU module, Only one I/F of a Remote IO
bus can be used .
・ When still recurring, Please replace related module.
・ In the case of the Remote slave station module, Replace
in order of a basic unit and IF unit.
・ In the case of Extension IO module : A basic unit is
replaced.
0048 I/O table ・ Please confirm whether the mounted unit is the same as the parameters using
comparison PCwin-Safe-Plus.
error ・ When recurring, Please replace the related unit.
0071 Application ・ Please look for the application instruction which corresponds from 1, 2, 3, and
instruction 4 of related information.
error 1 ・ Please confirm whether the set value is correct.
0092 Station ・ Please implement station number error reset operation (refer to 2.5.1.4 ).
number error ・ Then, please make reset / RUN (refer to 2.5.1.3) operation.
・ When recurring, Please replace a module of the related station number.
(After replacement, the station number error may cause. In that case, please
implement station number error reset operation. )
0093 Station ・ Please confirm station number switch setting.
number ・ When a station number is correct, please reconnect the power supply.
switch error ・ When the station number is different, please reconnect the power supply after
setting a station number switch properly.
(When the errors in error 92 station number cause, please implement station
number error reset operation (refer to 2.5.1.4 ))
・ When recurring, Please replace the module of the related station number.
00A3 Clock access ・ Please reconnect the power supply.
error ・ When the error recurs, please replace a CPUmodule
00AB Memory write ・ Please reconnect the power supply.
error ・ When recurring, Please confirm whether IF unit is mounted correctly and
re-write a program.
・ When still recurring, Please replace a basic unit of a CPU module.
00AD Data error ・ After confirming the contents of the register in PCwin-Safe-Plus, Please
reconnect the power supply.
・ The error recurs , please replace a CPU module
00AE Data error ・ Please reset the error by a function selection switch operation (refer to
unconfirmed 2.5.1.4 )
00AF Clock ・ Please set the clock data by PCwin-Safe-Plus
non-setting ・ When recurring, Please replace the basic unit of a CPU module.
Note)
・ No electricity for the long period (15 days after the super capacitor in a CPU
module is in full charged ) , the error generates.
00B0 Communicati ・ Please reconnect a power supply
on error ・ When the error recurs, please replace a CPU module.
between
MP-A and
MP-B
Table 6-12 Error Handling 3/4

6-11
 Error
code Error contents Handling
00B1 I/O bus ・ Please reconnect a power supply
communicatio ・ When the error recurs, please confirm whether IO bus communication-cable
n error of the related I/O module from the information 3 is mounted correctly . 4
core cable for FL-net cannot be used. (see the usable cable to 11.2.4
clause)
・ When using the Remote IO bus, please confirm whether both of Remote IO
bus I/F of a CPU module are used. In the case of a CPU module, I/F of a
Remote IO bus can use only one.
・ When using the internal IO bus , please confirm whether setting of a
terminator is correct.
・ Please confirm setting of the internal expansion IO module or the Remote
slave station module station number properly.
・ Please confirm whether the unit power supply of an internal expansion IO
module or a Remote slave station module is supplied properly.
・ In case of using the internal IO bus,please confirm whether there is any short
circuit of IO bus cable. (see the checking manners to 4.2.3 clause)
・ Please confirm whether the parameters set by PCwin-Safe-Plus and the
mounted units are same.
・ When still recurring, please replace in order of a basic unit, an option unit, IF
unit (when the error at CPU or Remote slave station ), and finally replace the
IO bus communication-cable.
Table 6-13 Error Handling 4/4

6.6. Special Relay for Error Information Output

When TOYOPUC-Plus Safety detects errors, a special relay turns on according to a error rank and a error
classification.
This special relay can be used in an user program, and can design a interlock circuit and a error information
circuit.

(1) Special relay for error rank identification

Error rank Special relay address

Alarm V003
Minor error V002
Critical(Major) error V001
Table 6-14 Special relay for error rank identification

6-12
(2) Special relay for error code identification

Error Error classification Special Error code Error contents

rank relay
address
Critical CPU error V0C0 32 System RAM error
error 35 System management
processorerror
B0 MP-A and MP-B
communication error
Power supply error V0C1 13 Power down
Memory data error V0C2 21 Program memory CRC
check error
23 Supplementing information
CRC check error
AD Data error
I/O bus error V0C3 B1 I/O bus communication error
Module parameter error V0C5 42 IO module parameter error
I/O configuration error V0C8 48 I/O table comparison error
User program error V0C9 31 Scan time over
71 Application instruction error 1
Memory error V0CA AB Memory write error
Minor Safety I/O error V0E0 43 Safety I/O error
error
Alarm Data error unconfirmed V0CB AE Data error unconfirmed
RTC error V0F5 A3 RTC error
AF Clock non-setting
Table 6-15 Special relay for error code identification

6-13
7. Maintenance
7.1. Maintenance Check
In order to use a programmable controller for a long period , we recommend periodical inspections(1-time per
year) . Please implement the maintenance check item shown in the following table at periodical inspection.
Using a check sheet to avoiding a checking miss. Also, controlling a check result as a history, it will be useful
for the next check or investigation at trouble at next time.

Inspection place Inspection contents Judging criteria

PLC PLC
Existence of No
(1) Become dirty. (1) Become dirty.
(2) dusty (2) dusty
(3) dew condensation (3) dew condensation
LEDs Lighting confirmation LED lighting properly,
There is no LED which
turned off.
PLC case damage Covers, brackets, etc. are
confirmation not deformation or
damaged
Mounting condition Units are fixed by studs
confirmation of covers/units firmly.
Covers are fixed with
PLC entirely screws firmly.
PLC Wiring connection
Wires must be inserted in
confirmation at terminal
terminal blocks firmly.
blocks
IO bus cable confirmation Cable connectors must be
fixed firmly and fixed
properly
Switch/s setting confirmation
No damage
of IF unit
Looseness of connector/s No-Loosen
If there is a lock
mechanism, must be
locked properly.
Looseness of terminal block/s All locks must be locked
It is not slanting.
Power supply Measurement of input DC24V must be within the
power supply voltage rated voltage
Communication-cable Damage
- The shielding wire is cut off.
No-damage
- Some shields lines are
projected.
Wirings Power suppy / IO Damage
cable - Cable is disconnected.
- Some cables have No-damage
projected.
- Terminals block is distorted.

Table 7-1 Maintenance Check

7-1
7.2. Periodical Inspection of Spare Parts
Even if a new product is deposited as a spare part. The product is not new for ever. PLC products have a
secular change and rotation is required. And, recommend to implment operation confirmation test periodically
( once per year is recommendable).During that time, please confirm the production stoppage information about
each module on our HP. And we would like to ask you purchase new spare parts , if neccesary.

The below, we show Inspection items about spare parts, and precautions at unit replacement

Inspection place Inspection contents Judging criteria

Confirmation of operation by
power-on condition
Operation When confirmation is not
Confirmation
Normal operation
easy, request operation
PLC

confirmation and overhaul

to our company.
Version confirmation
The version must be supported at object
Version When unknown, confirm to
equipment
our company.
device
Peripheral

Program data Backup data can be used ? There is the newest backup data for the
objective equipment ?
.
Table 7-2 Periodical Inspection of Spare Parts
No. Item
1. Prepare the instructions manual.
2. Does the objective product type match with spare part type?
3. Is the software version correct?
Keep the space where a removed product will be placed.
4.
Cover the place with a cloth or paper to avoid the product dirty.
Be careful not-dropping screws or studs at replacement.
5.
The tip of a screwdriver may better be magnetism.
Before removing wiring of terminal blocks or connectors, confirm mark tubes or markings .
6. Take a memo so that restoration may be possible.
(The mark tube and the signal name sometimes differ .There is also wiring without a mark tube.)
7. Placing the removed product and the replacement product side by side, the switch settings set the same.
8. Make visual confirmation of whether there are any abnormality at unit connection connectors.
A connector with a lock mechanism, lock securely.
9.
When there are anxiety, remove, attach once again and confirm.
After replacement, before switching on a power supply, please recheck whether wirings/connectors, etc.
10.
are correct
11. When a CPU replacement , prepare backup data.
12. Keep the present condition of the removed device or unit for returning again.
13. Use the tool whose size suited.
14. Don't apply too much power for wirings
15. Always check the voltage, Take care the short-circuit at check
16. Working under bright environment using lights.
Table 7-3 Precautions at unit replacement

7-2
8. General Specifications
8.1. General data (valid for all modules)
(1) General specification
No Item Description
1 Power supply Rated voltage: 24VDC (tolerance: 20.4VDC - 28.8VDC)
Current: maximum 0.3A (IF****+BS/BN****+OS/ON****)
2 Power 7.2W
consumption
3 Ambient 0～55℃
temperature
4 Air humidity 10 – 95% RH (non-condensing)
5 Ambient No aggressive gasses permitted
6 Oscillations(Vi IEC60068-2-6 Frequency Accel. Amplitude Runs
bration) Conformity 5…8.4Hz － 3.5mm 20 cycles
8.4～150Hz 1.0g － (1 octave/min)
7 Shock impact IEC60068-2-29 Conformity (10g 1000 ±10 times, X,Y,Z Direction)
8 Isolation EN50178 Conformity (Rated insulation voltage 71V)
voltage
9 Insulation EN50178 Conformity (DC500V 0.5MΩ or more)
resistance
10 Voltage Instantaneous-power-failure permission time:：10ms or less
interruption Intervals : 1 second or more
Table 8-1 General specifications
(2) Electromagnetic field environment specification (EMC)
N Item Standard Specification
o
1 Discharge of static electricity IEC-61000-4-2 Contact discharge: ±4 kV
Air discharge : ±8 kV
2 Burst immunity test IEC-61000-4-4 Signal connections : ±0.5kV
Electrical fast transient test Direct current inputs : ±0.5kV
Functional earth: ±0.5kv
3 Serge-proof IEC-61000-4-5 Between ground：±0.5kv
4 Conducted interference of radio IEC-61000-4-6 0.15～80MHz
frequency electromagnetic field 10V
80%
5 Radioactivity, radio frequency IEC-61000-4-3 Indoor：80～1000MHz/ 10V/m
electromagnetic field immunity 1.4～2.0GHz / 3V/m
2.0～2.7GHz / 1V/m
Table 8-2 Electromagnetic field environment specification (EMC)

8-1
8.2. CPU Functional Specification

Specification
No Item
Stand-alone Remote 1 Remote 2
1 Program method Stored program method
2 Program control method Cyclic computing type
3 Input/output control method Image register method
4 Processing speed 9.0ms / Scan 10.5ms / Scan 17.5ms / Scan
5 Basic instruction PS: 16 kinds PN : 16 kinds
6 Timer instruction PS: 4 kinds PN : 4 kinds
7 Application instruction PS: 8 kinds PN : 48 kinds
8 Object size 64K WORD (built-in memory: 64kB) *1 (PS+PN)
9 Memory device Program and comment: Microcomputer built-in FROM
Data: CMOS RAM *2
Data-register (PN): FRAM
11 External input/output point *3 128 points 256 points 2048 points
12 Internal output number PS M:2048 pts K: 768 pts .※4 L: 2048 pts ※5
PN M:2048 pts . K: 768 pts L: 2048 pts .※5
13 Timer function PS:256 pts PN:512 pts
14 Rising edge and falling-edge PS:512 pts PN:512 pts
detection
15 Data register present value PS:512 Byte PN:1024 Byte
16 Register extension PS:512 Byte PN:1024 Byte
17 Link relay point *6 (PS+PN)1024 pts
18 Facility information 128K Byte
19 Memory communication function SN-I/F or MODBUS-RTU 1 port (select with a parameter)

※1: It may be set to 16kW or less according to the conversion efficiency of a translate.
※2: Data is not maintained at power supply shutdown. Only error history information is maintained.
※3: The addresses for external input/output are Q000 - 07F 128 points (stand-alone) ,I, Q000 - 0FF 256
points (Remote 1) and I, Q000 - 7FF 2048 points (Remote 2).
※4: K works as a internal relay. It cannot be used as a keep relay.
※5: Reserving area (it cannot be used now.)
※6: The area of an expansion link relay (EL) is used as the communication area of SN-I/F communication.
(Please refer to the next chapter.)
Table 8-3 CPU Functional Specification

8-2
8.3. Communication Function
SN-I/F communication or MODBUS-RTU (slave) can be selected by parameters.

8.3.1. SN-I/F communication

SN-I/F is the dedicated serial communication for transmitting and receiving data between TOYOPUC-Plus
Safety and a Standard PLC or a Gateway module.
TOYOPUC-Plus Safety will be a master-station and a standard PLC becomes a slave station,
communication starts automatically only by connection of a communication cable.
A communication area changes with parameters.
Mode 0 (only PS) selection, PS:EL000 - EL03FF,
Mode 1 (PS+PN) selection, PS:EL000 - EL01FF, PN:EL200 - EL03FF.
TOYOPUC-Plus Safety starts communication in a maximum of 40 seconds after a power supply ON
(reset). Connection confirmation is repeated until it can confirm the connection with the partner. After
confirmation, start transmission and reception of I/O data.
When communication stops on the way, Connection confirmation is repeated until it can confirm connection
confirmation again. After being able to take confirmation, transmission and reception of I/O data are
resumed. Therefore, there is no communication error status in SN-I/F , there is under normal
communication status only .During normal communication, the bit 0 of the special register S130 turns on.
And, the status information (RUN condition or abnormal condition) of a standard PLC is included in the
special register S130.
SN-I/F Communication specification
Item specification
Communicatio
288kbps
n speed
Transmission 2-lines
method Half-duplex
Communicatio
Twisted-pair cable
n-cable
Transmission Total extension length Maximum 50m
distance (If a cable length 3m or more, use a double shielded cable)
Number of
connected 1 to 1 (one: master / one: slave)
stations
Input：256points
Relay
Mode 0 Output：256points
Communicatio (only PS) Register Input：32 bytes
n point ※1 Output：32 bytes
Communicatio Input：256 points
n byte number PS
Mode 1 Output：256 points
(PS+PN) Input：256 points
PN
Output：256 points Standard PLC
Output：EL000～0FF EV E00～EFF
Relay
Mode 0 Input：EL100～1FF EV F00～FFF
(only PS) Register Output：EL200～2FF S140～14F
Communicatio ※1 Input：EL300～3FF S150～15F
n area
Output：EL000～0FF EV E00～EFF
PS
Mode 1 Input：EL100～1FF EV F00～FFF
(PS+PN) Output：EL200～2FF S140～14F
PN
Input：EL300～3FF S150～15F
Install at S130
Bit position Contents At 0 At 1
SN-I/F Communicati communic
Bit 0*2
communication on stop ation
RUN condition of
Bit 1 Stop RUN
Standard PLC
Status flag
Standard PLC occurrenc
Bit 2 None
Major failure e
Standard PLC occurrenc
Bit 3 None
Minor failure e
Standard PLC occurrenc
Bit 4 None
Alarm e
Table 8-4 SN-I/F Communication specification

※1: TOYOPUC-Plus Safety side, it becomes relay handling.

8-3
 ※2: Because a communication error is not in SN-I/F, the confirmation of normal communication should use
this bit. In addition, when communication is impossible, SN-I/F is always implementing the communication
retry.

8.3.2. MODBUS-RTU Communication (slave)

It is connectable with a control device,display unit, PLC, PC, etc which have MODEBUS-RTU
communication I/F (master function.
(1) MODBUS-RTU specification
Item Specification
Interface standard RS-485
Communication method Start stop synchronous system
Transmission route Twisted pair wire with shield
0. 3, 0.6, 0.9, 1.2, 2.4, 4.8, 9.6, 19.2, 38.4, 57.6,115.2k bps
Communication speed (by setting)
Transmission distance Maximum 1km (Total length)
Transmission form 1: N, 1:1
Number of stations Maximum 255 stations
Start bit ... 1 bit
Data length ... 8 bits
Parity....yes/no Odd/even number (setting)
Data format Stop bit ... 1 or 2 bit (setting)
Error detection Parity check, CRC check
Table 8-5 MODBUS-RTU specification
(2) The supported MODBUS function codes
TOYOPUC-Plus Safety supporting the following 3 kinds of function codes.
Function code Function Maximum data read
01, 02 Bit-data read 2000 (0x7D0)
03 WORD data read 125 (0x7D)
Table 8-6 Supported MODBUS function codes
Please refer to the disclosed web pages for the MODBUS specification details, such as a communications
protocol etc .

(3) Address map

When accessing the register area of TOYOPUC-Plus Safety by MODBUS communication, access using a
MODBUS address. The address map to be used changes by function code.
Address map for bit access commands
Use this address map by the function code 01 (0x01) and the bit access command of 02
(0x02). Access over between registers cannot be performed.
Area TOYOPUC-Plus
MODBUS address
Safety address
(bit address)
(Bit address)
Safety (PS) P000 - P1FF 0x0000 - 0x01FF
K000 - K2FF 0x0200 - 0x04FF
V000 - V0FF 0x0500 - 0x05FF
T000 - T0FF 0x0600 - 0x06FF
L000 - L7FF 0x0800 - 0x0FFF
I/Q000 - I/Q7FF 0x1000 - 0x17FF
M000 - M7FF 0x1800 - 0x1FFF
EL000 - EL3FF 0x4000 - 0x43FF
Non-safety(PN) P000 - P1FF 0x8000 - 0x81FF
K000 - K2FF 0x8200 - 0x84FF
V000 - V0FF 0x8500 - 0x85FF
T/C000 - T/C1FF 0x8600 - 0x87FF
L000 - L7FF 0x8800 - 0x8FFF
X/Y000 - X/Y7FF 0x9000 - 0x97FF
M000 - M7FF 0x9800 - 0x9FFF
EL000 - EL3FF 0x4000 - 0x43FF
Table 8-7 Address map for bit access commands
Address map for word access commands
8-4
Use this address map by the word access command of the function code 03 (0x03).
Access over between registers cannot be performed.
Area TOYOPUC-Plus
MODBUS address
Safety address
( Word address)
(Word address)
Safety (PS) P00W - P1FW 0x0000 - 0x001F
K00W K2FW 0x0020 - 0x004F
V00W - V0FW 0x0050 - 0x005F
T00W - T0FW 0x0060 - 0x006F
L00W - L7FW 0x0080 - 0x00FF
I/Q00W - I/Q7FW 0x0100 - 0x017F
M00W - M7FW 0x0180 - 0x01FF
S0000 - S03FF 0x0200 - 0x05FF
N0000 - N00FF 0x0600 - 0x06FF
D0000 - D00FF 0x1000 - 0x10FF
EL00W - EL3FW 0x4000 - 0x403F
Non-safety(PN) P00W - P1FW 0x8000 - 0x801F
K00W - K2FW 0x8020 - 0x804F
V00W - V0FW 0x8050 - 0x805F
T/C00W - T/C1FW 0x8060 - 0x807F
L00W - L7FW 0x8080 - 0x80FF
X/Y00W - X/Y7FW 0x8100 - 0x817F
M00W - M7FW 0x8180 - 0x81FF
S0000 - S03FF 0x8200 - 0x85FF
N0000 - N01FF 0x8600 - 0x87FF
D0000 - D01FF 0x9000 - 0x91FF
EL00W - EL3FW 0x4000 - 0x403F

Table 8-8 Address map for word access commands

8-5
 Memory Area/Addressing
Memory areas

Data maintained after

Address range

switching off
Specifier

Number of Number of
BIT Address WORD Address
Use BITs WORDs

PS PN PS PN PS PN PS PN
I/X Input I/Q000 - X/Y000 – I/Q00W - X/Y00W -
2048 2048 128 128
Q/Y Output I/Q7FF X/Y7FF I/Q7FW X/Y7FW
M000 - M000 - M00W – M00W -
M Flag 2048 2048 128 128
M7FF M7FF M7FW M7FW
K00W – K00W - Only
K Hold flag K000 - K2FF K000 - K2FF 768 768 48 48
K2FW K2FW PN
V00W - V00W -
BIT

V Special flag V000 - V0FF V000 - V0FF 256 256 16 16

V0FW V0FW
T/C000 - T00W – T/C00W -
T/C Timer/Counter T000 - T0FF 256 512 16 32
T/C1FF T0FW T/C1FW
L00W - L00W -
L Communication L000 - L7FF L000 - L7FF 2048 2048 128 128
L7FW L7FW
P000 – P000 – P00W – P00W –
P Edge detection 512 512 32 32
P1FF P1FF P1FW P1FW
Data exchange
EL EL000-EL3FF 1024 EL00-EL3FW 128
with gateways
D0000-0 – D0000 -0– 512 1024 D0000 – D0000 –
D Data register 256 512 ✔
D00FF-F D01FF-F byte byte D00FF D01FF
N0000-0 – N0000-0 – 512 1024 N0000 – N0000 –
N Value register 256 512 ✔
WORD

N00FF-F N01FF-F byte byte N00FF N01FF

S0000-0 – S0000-0 – 2048 2048 S0000 – S0000 –
S Special register 1024 1024 ✔
S03FF-F S03FF-F byte byte S03FF S03FF
ExS0000-0– ExS0000-0 – 1280 1280 ExS0000 – ExS0000 –
ExS Special register ExS027F 640 640 ✔
ExS027F-F ExS027F-F byte byte ExS027F

Table 8-9 Memory Area/Addressing

(1) Input/output (I/Q)
The address area I/Q000 to I/Q7FF, X/Y000 to X/Y7FF is reserved for physical outputs.

(2) Flags (M)

Use it as an internal relay of an user program. The flags are set to 0 during the initialisation of the program.

(3) Hold flags (K)

In PS program, use it as an internal relay of an user program, and it is set to 0 at the time of initial setting of a
program.

(4 Special flags (V)

Provide additional information on the state of the TOYOPUC-Plus Safety.

(5) Tmer (T) Current value register (N)

Use it for a timer function. When the counter value during timer operation reaches the set value, a timer (T)
turns on. This counter value is stored in the current value register (N) of the same address timer (T).

(6) Link relay (L) (reserved area)

Please do not use it.

(7) Edge detection (P)

It works as a flag used for edge detection (rising/falling edge).

(8) For a standard PLC communication (EL)

Use it by SN-I/F communication with a Standard PLC.
8-6
 Please refer to Chapter8.3 Communication Function

(9) Data register (D)

TOYOPUC-Plus Safety, Use a bit address as an internal relay of an user program.
It is set to 0 at the time of initial setting of a program.

(10 Special registers (S)

It contains data of an error history, time/date, etc.
The contents of register are maintained at power supply OFF.

The data treated by TOYOPUC-Plus Safety are BIT, WORD, and BYTE address and locations are as follows.
Bit address WORD address Byte address
Q000 (LSB) (LSB)
Q001
Q002
Q003
Q00L Low BYTE
Q004
Q005
Q006
Bit Q007 (MSB)
address Q00W
Q008 (LSB)
area
Q009
Q00A
Q00B
Q00H High BYTE
Q00C
Q00D
Q00E
Q00F (MSB) (MSB)
D0000-0 (LSB) (LSB)
D0000-1
D0000-2
D0000-3
D0000L Low BYTE
D0000-4
D0000-5
D0000-6
WORD D0000-7 (MSB)
address D0000
area D0000-8 (LSB)
D0000-9
D0000-A
D0000-B
D0000H High BYTE
D0000-C
D0000-D
D0000-E
D0000-F (MSB) (MSB)
Table 8-10 TOYOPUC-Plus Safety BIT, WORD, and BYTE address

8-7
8.4. Real I / 0 Address Assignment
Real I/O (I/Q) address allocation shown in the following figure.

(1) At stand-alone mode

station No. 0x23 0x22 0x21 0x00
CPU module [0x00] (basic unit => option unit)
=> extension module [0x21] (basic unit => option unit)
=> extension module [0x22] (basic unit => option unit)
=> Extension module [0x23]
Addresses are assigned in order of (basic unit => option
unit). When no-module is mounted, address are assigned
by omission.
- Addresses are reserved by BLANK setting (16 points).
- A basic unit of a CPU module cannot be BLANK setting.
- When BLANK setting of the basic unit is made, module
setting of an option unit cannot be performed.
BLANK setting is possible.
CPU module
No. 00-- Fix

station 0x23 0x22 0x21

0x00
No. (Extension IO (Extension IO (Extension IO
(CPU module)
module) module) module)
Unit Base※１ Base※１ Base※１ Base
Address 60H – 6FH 40H – 4FH 20H – 2FH 00H – 0FH
Unit Option※２ Option※２ Option※２ Option※１
Address 70H – 7FH 50H – 5FH 30H – 3FH 10H – 1FH

Max. 128 points (～7FH)

※1: BLANK setting is possible.

※2: Module setting cannot be performed when a Base unit is BLANK.
When a Base unit is not mounted, module setting and BLANK setting cannot be performed.
Figure 8-1 Stand-alone mode

8-8
(2) At Remote 1 / Remote 2 mode

Station 0x22 0x21 0x00 0x22 0x21 0x01 0x22 0x21 0x1F
No.

CPU Remote slave St. Remote slave St.

(Station .00) (Station No 01) (Station No 1F)

Max.32

CPUmodule 【0x00】(Base unit⇒Option unit)

⇒ Extension module【0x21】(Base unit⇒Option unit)
⇒ Extension module【0x22】(Base unit⇒Option unit)
⇒ Extension module【0x23】(Base unit⇒Option unit)

Remote slave module 【0x01】(Base unit⇒Option unit)

⇒ Extension module【0x21】(Base unit⇒Option unit) Remote 1
mode
⇒ Extension module【0x22】(Base unit⇒Option unit)
Maximum 3
⇒ Extension module【0x23】(Base unit⇒Option unit) stations
IO:256 Remote 2
points mode
Maximum
Remote slave module 【0x03】(Base unit⇒Option unit) 31 stations
⇒ Extension module【0x21】(Base unit⇒Option unit) IO:2048
points.
⇒ Extension module【0x22】(Base unit⇒Option unit)
⇒ Extension module【0x23】(Base unit⇒Option unit)

Remote slave module 【0x1F】(Base unit⇒Option unit)

⇒ Extension module【0x21】(Base unit⇒Option unit)
⇒ Extension module【0x22】(Base unit⇒Option unit)
⇒ Extension module【0x23】(Base unit⇒Option unit)
Addresses are assigned as above
When module is not mounted, Addresses are omitted

- Addresses are reserved by BLANK setting (16 points).

- Base unit of CPU module cannot perform BLANK
setting.
- When BLANK setting of Base unit is made, module
setting of Option unit cannot be performed.
BLANK setting is possible.
- BLANK setting of the Remote slave station module
cannot be performed.

Figure 8-2 Remote 1/Remote 2 mode

8-9
station 0x23 0x22 0x21 0x00
No. (Extension IO (Extension IO (Extension IO (CPU module)
module) module) module)
Unit Base※１ Base※１ Base※１ Base
Address 60H – 6FH 40H – 4FH 20H – 2FH 00H – 0FH
Unit Option※２ Option※２ Option※２ Option※１
Address 70H – 7FH 50H – 5FH 30H – 3FH 10H – 1FH

Remote 1
station 0x23 0x22 0x21 0x03
No. (Extension IO (Extension IO (Extension IO (CPU module)

Remote 2
module) module) module)
Unit Base※４ Base※４ Base※４ Base※３
Address ･････ ･････ ･････ ･････
Unit Option※２ Option※２ Option※２ Option※２
Address F0H – FFH ･････ ･････ ･････
Remote 1:Maximum 256 points (- FFH)

station 0x23 0x22 0x21

0x1F
No. (Extension IO (Extension IO (Extension IO
(CPU module)
module) module) module)
Unit Base※４ Base※４ Base※４ Base※３
Address ･････ ･････ ･････ ･････
Unit Option※２ Option※２ Option※２ Option※２
Address 7F0H – 7FFH ･････ ･････ ･････
Remote 2 Maximum 2048 points (- 7FFH)

※1: BLANK setting is possible.

※2: When a Base unit is BLANK, module setting cannot be performed.
When a Base is not been mounted, module setting and BLANK setting cannot be
performed.
※3: BLANK setting cannot be performed.
※4: BLANK setting is possible.
(Only when Remote slave station module setting )
Table 8-11 Remote 1/Remote 2 mode

8-10
8.5. Special Flags(relay)
Special relay shows operational status, an abnormal condition, etc. of TOYOPUC-Plus Safety.

Special relay list (1/2)

Address Name Setting Description
V001 Major(critical) error 0: No Error turn on by a major failure occurrence.
1: Error Occurrence
V002 Minor error 0: No Error turn on by a minor failure occurrence.
1: Error Occurrence
V003 Warning(alarm) 0: No Alarm turn on by alarm occurrence.
1:Alarm Occurrence turn off by alarm release.
V004 Always TRUE Always 1 Always turn on regardless of an operating
state.
V005 Always FALSE Always 0 Always turn off regardless of an operating
state.
V006 1st scan 0: Termination of 1st turn on by reset.
Scan turn off by 1st END processing of an user
1: Reset program.
1st Scan Implementing
V026 During stop 0: User Program Running turn off during user program running.
1: User Program Stop turn on by running stop.
V027 RUN 0: User Program Stop turn on during user program running.
1: User Program turn off by running stop.
Running
V040 PS program is RUN. 0: User Program Stop turn on during user program running.
1: User Program turn off by running stop.
Running (The same operation as V027)
V041 PN program is RUN. 0: User Program Stop turn on during user program running.
1: User Program turn off by running stop.
Running
V04E Safety I/O error reset 1: reset command System restart will be made when turned
command on at error (error 43) occurrence in
safety I/O.
When the errors of safety I/O have not
caused, even if it turns on, clear this flag,
without doing anything.
V050 PS program 0: No Error turn on, if there exists an application
Application instruction 1: Error instruction error iny PS.
error turn off, if there is nothing.
However, only the instruction with a
prohibited matter is applicable.
V054 Zero (Z) turn on, when an operation result is 0.
V055 Borrow (BO) turn on, when an operation result is
negative.
V056 Carry (CY) turn on, operation result is overflow
V070 0.1-second clock Periodic 0.1 second
change at every 50ms.
V071 0.2-second clock Periodic 0.2 second
change at every 100ms.
V072 1-second clock Periodic 1 second
Duty 50% of clock
V073 2-second clock Periodic 2 seconds
Duty 50% of clock
V074 60-second clock Periodic 60 seconds
Duty 50% of clock
V078 Scanning clock Clock turn on /off for every scan
Table 8-12 Special Flags(relay) 1/2

8-11
Special relay list (2/2)
Address Name Setting Description
V0C0 CPU error 0: No Error turn on by error detection of CPU module.
1: Error
V0C1 Power supply error 0: No Error turn on by detection of power down.
1: Error turn off by reset or power supply reconnect.
V0C2 Memory data error 0: No Error turn on by program or parameter data error
1: Error detection
V0C3 I/O bus error 0: No Error turn on by I/O bus error detection.
1: Error
V0C4 Module special error 0: No Error turn on, when module(s) are special error
1: Error After error reset, turn off.
V0C5 Module parameter 0: No Error turn on, when CPU cannot recognize IO module
error 1: Error correctly.
V0C6 Parameter error 0: No Error turn on at error in parameter.
1: Error
V0C7 IO module error 0: No Error turn on by error detection of IO module.
1: Error turn off by error reset.
V0C8 I/O configuration error 0: No Error turn on by configuration error detection of IO
1: Error module.
(The number of special card, or assignment of an
I/O Address)
V0C9 User program error 0: No Error turn on by user program-related error detection.
1: Error turn off by error reset.
V0CA Backup memory error 0: No Error turn on by error detection of a backup memory.
1: Error
V0E0 IO module error 0: No Error turn on by error detection of IO module.
1: Error turn off by error reset.
V0E1 Scan time excess 0: No Error turn on, when scan time is exceeded.
error 1: Error turn off by reset or power supply reconnecting.
V0E2 Application instruction 0: No Error turn on at error A/B071,
error 1: Error
V0E8 PS program scan 0: No Error turn on by the scanning Time over detection of PS.
Time over 1: Error turn off by reset or power supply reconnecting.
V0F5 Clock error 0: No Error turn on at error detection of a built-in clock.
1: Error
Table 8-13 Special Flags(relay) 2/2

8-12
8.6. Special registers
Special register store the error history of TOYOPUC-PCS, time information, etc.

Special register list(1/2)

Address Name Description
S001 15(ms) Fixed binary
S002 15(ms) Fixed binary
S003 15(ms) Fixed binary
S004 Time (seconds) Current date and time of the internal real-time clock. BCD
S005 Time (minutes) The data are stored in BCD format with 1 number (A single
S006 Time (hours) per BYTE. (Example: ‘0102’ => 12 minutes) digit/byte)
S007 Time (day)
S008 Time (month) Year data shows lower double digits of Christian
S009 Time (year) year,
S00A Time (day of the And, week data, 0-6 correspond to Sun.-Sat.
week)
S019 Time (minutes, Current date and time of the internal real-time clock. BCD
seconds) The data are stored in BCD format with 2 numbers (Double
S01A Time (day, hours) per BYTE.Example: ‘1234’ => 12 minutes and 34 digits/byte)
S01B Time (year, month) seconds
S050※ Error state modules When safety I/O error (error 43) occurrence, it binary
S06F shows which slot IO module caused the error by bit
position.
S0C0 15(ms) Fixed binary
S0C1 15(ms) Fixed binary
S0C2 15(ms) Fixed binary
S0C3 15(ms) Fixed binary
Table 8-14 Special registers(1/2)

※ Errors module information

When safety I/O error (error 43) occurrence, it shows which slot IO module caused the error by bit position.
Turn ON to Indicate an error occurrence.
If for example, S050-2 is 1, it means that errors had caused in Extention IO module (0x22) of CPU module.
(yellow part)
When two or more errors cause, two or more bits are set to "1."

MSB Bit LSB Station

Address
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
S050 - - - - - - - - - - - - 3 2 1 0 CPU
S051 - - - - - - - - - - - 3 2 1 0 0x01

S06E - - - - - - - - - - - - 3 2 1 0 0x1E
S06F - - - - - - - - - - - - 3 2 1 0 0x1F

Extention IO module(0x23)
Extention IO module(0x22)
Extention IO module(0x21)
CPU module or remote IO module
Table 8-15 Special registers

8-13
Special register list (2/2)
Address Name Description
S0E0 Program Change part bit A:PN program, bit 9 :P S program, bit 8: Parameter bit
S0E1 change Time (min./sec.) The present time of the built-in clock is stored. BCD
S0E2 history 1 Time (day/hour) Data indicates 2digit with a BCD code by 1 byte. (2digit/byte)
S0E3 Time (year/mon.) (For example, "1234" shows "12(minute) and 34
(second)".)
S0E4 Program Change part bit A:PN program, bit 9 :P S program, bit 8: Parameter bit
S0E5 change Time (min./sec.) The present time of the built-in clock is stored. BCD
S0E6 history 2 Time (day/hour) Data indicates 2digit with a BCD code by 1 byte. (2digit/byte)
S0E7 Time (year/mon.) (For example, "1234" shows "12(minute) and 34
(second)".)
S0E8 Program Change part bit A:PN program, bit 9 :P S program, bit 8: Parameter bit
S0E9 change Time (min./sec.) The present time of the built-in clock is stored. BCD
S0EA history 3 Time (day/hour) Data indicates 2digit with a BCD code by 1 byte. (2digit/byte)
S0EB Time (year/mon.) (For example, "1234" shows "12(minute) and 34
(second)".)
S0EC Program Change part bit A:PN program, bit 9 :P S program, bit 8: Parameter bit
S0ED change Time (min./sec.) The present time of the built-in clock is stored. BCD
S0EE history 4 Time (day/hour) Data indicates 2digit with a BCD code by 1 byte. (2digit/byte)
S0EF Time (year/mon.) (For example, "1234" shows "12(minute) and 34
(second)".)
S0F0 Program Change part bit A:PN program, bit 9 :P S program, bit 8: Parameter bit
S0F1 change Time (min./sec.) The present time of the built-in clock is stored. BCD
S0F2 history 5 Time (day/hour) Data indicates 2digit with a BCD code by 1 byte. (2digit/byte)
S0F3 Time (year/mon.) (For example, "1234" shows "12(minute) and 34
(second)".)
S0F4 Program Change part bit A:PN program, bit 9 :P S program, bit 8: Parameter bit
S0F5 change Time (min./sec.) The present time of the built-in clock is stored. BCD
S0F6 history 6 Time (day/hour) Data indicates 2digit with a BCD code by 1 byte. (2digit/byte)
S0F7 Time (year/mon.) (For example, "1234" shows "12(minute) and 34
(second)".)
S0F8 Program Change part bit A:PN program, bit 9 :P S program, bit 8: Parameter bit
S0F9 change Time (min./sec.) The present time of the built-in clock is stored. BCD
S0FA history 7 Time (day/hour) Data indicates 2digit with a BCD code by 1 byte. (2digit/byte)
S0FB Time (year/mon.) (For example, "1234" shows "12(minute) and 34
(second)".)
S0FC Program Change part bit A:PN program, bit 9 :P S program, bit 8: Parameter bit
S0FD change Time (min./sec.) The present time of the built-in clock is stored. BCD
S0FE history 8 Time (day/hour) Data indicates 2digit with a BCD code by 1 byte. (2digit/byte)
S0FF Time (year/mon.) (For example, "1234" shows "12(minute) and 34
(second)".)
S130 Status Please refer to Chapter 8.3.1.
S131 Frequency of Flaming error Frequency of the flaming error caused in communication between
Standard PLC and Plus Safety is set
S132 Frequency of Parity error Frequency of the parity error caused in communication between
Standard PLC and Plus Safety is set
S133 Frequency of Overrun error Frequency of the overrun error caused in communication between
Standard PLC and Plus Safety is set
S200 Error data Please refer to Chapter 6.3.
～
S24F
S2D0 CPU ID ID number of CPUmodule is stored. In the case of Plus Safety:
0x100E
S2D1 CPU Version The version of CPU module is stored.
S2D2 Version date Days and The version date of CPU module is stored.
months
S2D3 Version date Year
S2D4 Minor version number Mminor version number is set
Minor version number is used for a minor change of a system program.

Table 8-16 Special registers(2/2)

8-14
9. Safety Programming
9.1. Instruction
TOYOPUC-Plus Safety can use the instruction of 16 kinds of basic instructions, 4 kinds of timer instructions, 3
kinds of counter instructions, application instruction PS:5 kinds, and PN:45 kinds.

9.1.1. Basic Instruction (16 Kinds)

№ Symbol Language Function

Start of an operation with
1 STR
NO (A contact)
Start of an operation with
2 STR NOT
NC (B contact)
Series connection (A
3 AND
contact)
Series connection (B
4 AND NOT
contact)
Parallel connection (A
5 OR
contact)
Parallel connection (B
6 OR NOT
contact)

7 AND STR Series connection of blocks

Parallel connection of
8 OR STR
blocks

9 OUT Coil output

10 PTS Edge detection, rising edge

Edge detection, trailing

11 NTS
edge
Multi-coil branch start
12 FPS
Multi-coil branch
13 FRD
Termination of multi-coil
14 FPP branch

15 FST Unconditional output

16 NOT Inversion

Table 9-1 Basic Instruction (16 Kinds)

9-1
9.1.2. Timer Instruction (4 Kinds)

No Classification Function Symbol Operation

Timer Direct set
1 TMRH 10ms timer: Max setting 655.35 seconds.
10ms timer
Direct set
2 TMR 100ms timer: Max setting 6553.5 seconds.
100ms timer
Integration Direct set
10ms integration timer: Max setting 123.45
3 timer 10ms integration TMRSH
seconds.(※1)
timer
Direct set 100ms integration timer: Max setting 1234.5
4 100ms integration TMRS
seconds. (※1)
timer
(※1) The data of an integration timer is canceled at power supply OFF.
Table 9-2 Timer Instruction (4 Kinds)
9.1.3. Counter Instruction (3 Kinds)
No Classification Function Symbol Operation
Up counter Direct set Up counter, setting range is 1-65535 .
1 Up counter CNT When reach the set value, turn on the specified
device (C000~C1FF)
Down counter Direct set Down counter, setting range is 1-65535 .
2 Down counter CNTD When reach the set value, turn on the specified
device (C000~C1FF)
Up-and-down Direct set Up-and-down counter, setting range is
counter Up-and-down 1-65535.
3 CNTH
counter When the current value equals to a setting value ,
turn on the specified device (C000~C1FF).
Table 9-3 Counter Instruction (3 Kinds)
9.1.4. Application Instruction (Common to PS/PN) (5 Kinds)

No Classification No. instruction Symbol Function

Main program Start of a main sequence
start START program.
1 FUN448 START

Main program END End of a main sequence

2 Label end FUN452 END program

Program end PEND End of a sequence program

3 FUN456 PEND containing subroutines

1-byte direct
4 transmission FUN90 MOVE
Data
MOVE
transfe WMOVE S D Transfer S data to D.
2-byte direct
r
5 transmission FUN0 WMOVE

Table 9-4 Application Instruction (Common to PS/PN) (5 Kinds)

9-2
1.START：Main program start (FUN448)
(1) Symbol

(2) Function
This indicates the start of main program.
After the "END" command, the program returns to the step of main instruction.

(3) Flag: No change

(4) Program examples:

For START, END, and PEND commands, any condition (contact) cannot be added.
The initial program can be executed only once at power-on or reset/start.
START command makes nothing happen.
Main program

2.END :End the main program. (FUN452)

(1) Symbol

(2) Function
This indicates the end of main program.
With this instruction, each module's I/O is refreshed.
After execution of this command, the program will start to be executed with START command.(Restart from
the top of main program)

(3) Flag: No change

(4) Program examples:

Refer to START command.

3.PEND: Program ends (FUN456)

(1) Symbol

(2) Function
This indicates the end of user's program area.

(3) Flag：No change

(4) Program example

Refer to START command

9-3
4.MOVE：1-byte direct transfer (FUN90)
(1)Symbol

(2)Function
Transfer the data of OP1 register to OP2 register.
The data of OP1 register is saved at this time.

(3)Flag：No change

(4)Program example
If M000 turns on, the program which transfers lower-level 8 bit data of data register D0000 to 8 bits of
upper levels of data register D0100.

5.WMOVE：2-byte direct transfer (FUN0)

(1)Symbol

(2)Function
Transfer the data of OP1 register to OP2 register.
The data of OP1 register is saved at this time.

(3)Flag：No change

(4)Program example
When X001 turns ON from OFF, the program which transfers the data of data register D0123 to
X/Y020 – X/YO2F

9-4
9.1.5. Application command (instruction) (PN) (40 kinds)

comman
No Classification Symbol Function
d
2 digits hexadecimal =H
1 =H W=H S H
constant comparison (=) Comparison of a register
4 digits of hexadecimal with a constant or
2 W=H
constant comparison (=) between two registers. If
3 Byte data comparison (=) =N =N S=H, S1=S2 , then a
W=N S1 S2
WORD data comparison contact is closed.
4 W=N
(=)
2 digits hexadecimal <>H
5 <>H W<> S H
constant comparison (≠) Comparison of a register
4 digits of hexadecimal with a constant or between
6 W<>H
constant comparison (≠) two registers. If S≠H,
7 Byte data comparison (≠) <>N <>N S1≠S2 , then a contact is
W<>N S1 S2
WORD data comparison closed.
8 W<>N
(≠)
2 digits hexadecimal >H
9 >H W>H S H
constant comparison (>)
Comparison of a register
4 digits of hexadecimal with a constant or
10 W>H
constant comparison (>) between two registers. If
11 Byte data comparison (>) >N >N
S>H, S1>S2 , then a
W>N S1 S2 contact is closed.
WORD data comparison
12 W>N
(>)
Compa 2 digits hexadecimal >=H
13 rison >=H W>=H S H
constant comparison (≧)
4 digits of hexadecimal Comparison of a register
14 W>=H with a constant or between
constant comparison (≧)
two registers. If S≧H, S1
Byte data comparison >=N
≧S2 , then a contact is
15 >=N W>=N S1 S2
(≧) closed.
WORD data comparison
16 W>=N
(≧)
2 digits hexadecimal <H
17 <H W<H S H
constant comparison (<) Comparison of a register
4 digits of hexadecimal with a constant or between
18 W<H two registers. If S<H,
constant comparison (<) S1<S2 , then a contact is
19 byte data comparison (<) <N <N closed.
W<N S1 S2
20 byte data comparison (<) W<N
2 digits hexadecimal <=H
21 <=H W<=H S H
constant comparison (≦)
4 digits of hexadecimal Comparison of a register
22 W<=H with a constant or between
constant comparison (≦)
two registers. If S≦H, S1
Byte data comparison <=N
≦S2 , then a contact is
23 <=N W<=N S1 S2
(≦) closed.
WORD data comparison
24 W<=N
(≦)
2 digits hexadecimal MOV MOV
25 Data WMOV H D Transfer a hexadecimal
constant transfer
transfe constant H (2 or 4 digits) to
4 digits of hexadecimal WMOV D.
26 r
constant transfer
Binary 8 bits ->2 digits Convert a binary data in S
27 Data BCD
BCD conversion BCD to BCD data , then store
conver WBCD S D
in D
Binary 16 bits -> 4
28 sion WBCD Store in D.
digits BCD conversion
Table 9-5 Application command (instruction) (PN) (40 kinds) 1/2

9-5
No Classification comman Symbol Function
d
29 2 digits BCD -> 8 bits BIN Convert a BCD data
binary conversion BIN stored in S to a binary
WBIN
4 digits BCD -> 16 S D
data. then store in D
30 bits binary conversion WBIN
Store in D.
WORD data binary Add S1 contents and S2
addition W+ S1 S2 D contents and store a result
31 W+ in D.
All data is treated as a
binary number.
WORD data binary Subtract S2 contents from
subtraction W- S1 S2 D S1 contents, Store a result
32 W- in D.
All data is treated as a
binary number.
WORD data binary Make the multiplication of
multiplication W* S1 S2 D S1 Store a result in D.
33 Arithm W* All data is treated as a
etical binary number. contents
functio and the S2 contents,
ns WORD data binary W/ Divide S1 contents by S2
division S1 S2 D
contents, store a quotient
in D.
34 W/
Store remainder in D+1.
All data is treated as a
binary number.
WORD data binary WINC
After "+1" of D contents ,
increment S D compare it with S1
35 WINC
contents . data is treated
as a binary number.
WORD data binary WDEC "-1" of D contents
36 decrement WDEC D
Data is treated as a binary
number.
Byte data logical AND AND Perform logical AND
37 AND
S1 S2 D (AND) of S1 contents and
S2 contents,
Store a result in D.
Byte data logical addition OR Perform logical addition
S1 S2 D
38 OR (OR) of S1 contents and
Logical S2 contents,
operati Store a result in D.
on Byte data inversion NOT Invert contents of S (all bit
39 NOT S D change 1 to 0, 0 to 1),
Store a result in D.
Byte data exclusive OR XOR Perform exclusive OR
40 XOR
S1 S2 D
(XOR) of S1 contents and
S2 contents,
Store a result in D.
Table 9-6 Application command (instruction) (PN) (40 kinds) 2/2

9-6
9.1.5.1. Comparison

1.=H：2 digits hexadecimal constant comparison（=）

(1) Symbol

(2) Function
Compare a 2 digits hexadecimal constant with 8 bit data of a register, If same, it will be
a-contact-closed condition..

(3) Program example

① When X000~X007 is "23" of BCD data, turn on Y00F.

② When X000 is ON and 8 bits of lower-bit of data register D1000 is hexadecimal "FF"
turn on Y00F.

③ When X000 is ON, or when 8 upper bits of data register D1000 are hexadecimal "AA",
turn on Y00F.

2.W=H：4 digits of hexadecimal constant comparison（=）

(1) Symbol

(2) Function
Compare 4 digits of hexadecimal constant with 16 bit data of a register, and if same, it will be in
a-contact-closed condition.

(3) Program example

① When X000~X00F is hexadecimal "1234. Turn on Y00F,

② When X000 is ON and a data register D1000 is hexadecimal "FFFF", turn on Y00F.

③ When X000 is ON, or a data register D1000 is hexadecimal "AAAA", turn on Y00F.

9-7
3.=N：Byte data comparison（=）

(1) Symbol

(2) Function
Compare 2 x 8 bit data, and if same, it will be a-contact-closed condition.

(3) Program example

① If register D0002 lower-8 bit of data are same with upper-8 bits of data register D0001,turn on Y011.

② If lower-8 bits of a data register D1000 and X010~X017 X000 is same , turn on Y011.

③ If X000 is ON, or lower-8 bits of a data register D1000 and upper-8 bits of D1000 are same, turn
on Y011.

4.W=N：WORD data comparison（=）

(1) Symbol

(2) Function
Compare 2 x 16 bit data, and if same, it will be in a-contact-closed condition.

(3) Program example

① When a counter C000 current value (current value register N000 value) and a counter C001 current
value (current value counter N001 value) are same, turn on Y123.

② If X000 is ON, and the contents of X010~X01F and D1000 are same, turn on Y123.

9-8
 ③ If X000 is ON, or the contents of the data register D1000 and the contents of the data register D1001
are same, turn on Y123.

5.<>H：2 digits hexadecimal constant comparison（≠）

(1) Symbol

(2) Function
Compare 2 digits hexadecimal constant with 8 bit data of a register, and if not same, it will be in
a-contact-closed condition.

(3) Program example

① When X000~X007 is not hexadecimal "23." ,turn on Y00F

② When X000 is ON, and lower-8 bits of a data register D1000 are not hexadecimal "FF" ,turn on Y00F.

③ When X000 is ON, or upper-8 bits of a data register D1000 are not hexadecimal "AA", turn on Y00F.

6.W<>H：4 digits of hexadecimal constant comparison（≠）

(1) Symbol

(2) Function
Compare 4 digits of hexadecimal constant with 16 bit data of a register, and if not same, it will be in
a-contact-closed condition.

(3) Program example

① When X000~X00F is not hexadecimal "1234", turn on Y00F.

9-9
 ② When X000 is ON, and a data register D1000 is not hexadecimal "FFFF", turn on Y00F.

③ When X000 is ON, or a data register D1000 is not hexadecimal "AAAA", turn on Y00F.

7.<>N：Byte data comparison（≠）

(1) Symbol

(2) Function
Compare 2 x 8 bit data, and if not same, it will be in a-contact-closed condition.

(3) Program example

① If lower-8 bits of data register D0002 is not same with upper-8 bits of data register D0001, turn on
Y011.

② If X000 turns on and lower-8 bits of data register D1000 and X010~X017 are not same, turn on
Y011.

③ If X000 is ON, or lower-8 bits of data register D1000 and upper-8 bits of D1000 are not same, turn
on Y011.

8.W<>N：WORD data comparison（≠）

(1) Symbol

(2) Function
Compare 2 x 16 bit data, and if not same, it will be in a-contact-closed condition.

(3) Program example

① When the current value (current value register N000 value) of a counter C000 and the current value
9-10
 (current value counter N001 value) of a counter C001 are not same, turn on Y123.

② If X000 is ON, and the contents of X010~X01F and D1000 are not same, turn on Y123.

③ If X000 is ON, or the contents of the data register D1000 and the contents of the data register D1001
are not same, turn on Y123.

9.>H：2 digits hexadecimal constant comparison（＞）

(1) Symbol

(2) Function
If 2 digits hexadecimal constant is compared with 8 bit data of a register and register data is larger
than a constant, It will be in a-contact-closed condition.

(3) Program example

① When X000~X007 is larger than hexadecimal "23", turn on Y00F.

② When X000 turns on and lower-8 bits of a data register D1000 is larger than hexadecimal "12", turn
on Y00F.

③ When X000 is ON or upper-8 bits of f a data register D1000 is larger than hexadecimal "AA", turn on
Y00F.

10.W>H：4 digits of hexadecimal constant comparison（＞）

9-11
 (1) Symbol

(2) Function
Compare 4 digits of hexadecimal constant with 16 bit data of a register, and if the register data is
greater than the constant, it will be in a-contact-closed condition.

(3) Program example

① When X000~X00F is larger than hexadecimal "1234", turn on Y00F.

② When X000 turns on and a data register D1000 is larger than hexadecimal "5555", turn on Y00F.

③ When X000 is ON, or a data register D1000 is larger than hexadecimal "AAAA", turn on Y00F.

11.>N：Byte data comparison（＞）

(1) Symbol

(2) Function
Compare 2 x 8 bit data, If the 1st data value is larger than the 2nd data value, it will be in
a-contact-closed condition.

(3) Program example

① If upper-8 bits of data register D0001 are larger than lower-8 bits of data register D0002, turn on
Y011.

② If X000 turns on and , lower-8 bits of data register D1000 are larger than the value indicated with
X010~X017, turn on Y011.

③ If X000 is ON or lower-8 bits of data register D1000 are larger than upper-8 bits of D1000 ,turn on
Y011.

9-12
12.W>N：WORD data comparison（＞）

(1) Symbol

(2) Function
Compare 2 x 16 bit data, If the 1st data value is larger than the 2nd data value, It will be in
a-contact-closed condition.

(3) Program example

① When a counter C000 current value (current value register N000 value) is larger than a counter C001
current value (current value counter N001 value), turn on Y123.

② If X000 turns on, and the value indicated with X010~X01F is larger than the contents of D1000,
turn on Y123.

③ If X000 is ON, or data register D1000 contents are larger than data register D1001 contents, turn
on Y123.

13.>=H：2 digits hexadecimal constant comparison（≧）

(1) Symbol

(2) Function
Compare a 2 digits hexadecimal constant with 8 bit data of a register, if register data is more than a
constant It will be in a-contact-closed condition.

(3) Program example

① When X000~X007 is more than hexadecimal "23", turn on Y00F.

② When X000 turns on, and lower-8 bits of data register D1000 is more than hexadecimal "12", turn on
Y00F.

9-13
 ③ When X000 is ON, or upper-8 bits of data register D1000 is more than hexadecimal "AA", turn on
Y00F.

14.W>=H：4 digits of hexadecimal constant comparison（≧）

(1) Symbol

(2) Function
Compare 4 digits of hexadecimal constant with 16 bit data of a register, if register data is more than a
constant , it will be in a-contact-closed condition.

(3) Program example

① When X000~X00F is more than hexadecimal "1234", turn on Y00F.

② When X000 turns on, and a data register D1000 is more than hexadecimal "5555", turn on Y00F.

③ When X000 is ON, or a data register D1000 is more than hexadecimal "AAAA", turn on Y00F.

15.>=N：Byte data comparison（≧）

(1) Symbol

(2) Function
Compare two 8 bit data, if the 1st data value is greater than the 2nd data value, It will be in
a-contact-closed condition.

(3) Program example

① If upper-8 bits of data register D0001 is equal or more than lower-8 bits of data register D0002 ,
turn on Y011.

② If X000 turns on, and lower-8 bits of data register D1000 are more than the value indicated with
X010~X018, turn on Y011.
9-14
 ③ If X000 turns on, or lower-8 bits of data register D1000 are same or more than upper-8 bits of D1000,
turn on Y011.

16.W>=N：WORD data comparison（≧）

(1) Symbol

(2) Function
Compare two 16 bit data, If the 1st data value is more than the 2nd data value, it will be in
a-contact-closed condition.

(3) Program example

① When a counter C000 current value (current value register N000 value) is more than the current value
(current value counter N001 value) of a counter C001, turn on Y123.

② If X000 turns on, and the value indicated with X010~X01F is more than the contents of D1000, turn on
Y123.

③ If X000 turns on, and data register D100 contents are more than the contents of data register D1001,
turn on Y123.

17.<H：2 digits hexadecimal constant comparison（＜）

(1) Symbol

(2) Function
Compare 2 digits hexadecimal constant with 8 bit data of a register, if register data is smaller than a constant,
it will be in a-contact-closed condition.

(3) Program example

① When the value indicated in hexadecimal X000~X007 as register 8 bit data is smaller than
hexadecimal "23", turn on Y00F.

9-15
 ② When X000 turns on, and lower-8 bits of data register D1000 are smaller than hexadecimal "12",
turn on Y00F.

]③ When X000 turns on, or upper-8 bits of data register D1000 are smaller than hexadecimal "AA",
turn on Y00F.

18.W<H：4 digits of hexadecimal constant comparison（＜）

(1) Symbol

(2) Function
Compare 4 digits of hexadecimal constant with 16 bit data of a register, if register data is smaller
than a constant, It will be in a-contact-closed condition.

(3) Program example

① When X000~X00F is smaller than hexadecimal "1234", turn on Y00F.

② When X000 turns on, and a data register D1000 is smaller than hexadecimal "5555", turn on Y00F.

④ When X000 turns on, or a data register D1000 is smaller than hexadecimal "AAAA", turn on
Y00F.

19.<N：Byte data comparison（＜）

(1) Symbol

(2) Function
Compare 2 x 8 bit data, if the 1st data value is smaller than the 2nd data value, It will be in
a-contact-closed condition.
9-16
 (3) Program example
① If lower-8 bits of data register D0002 are smaller than upper-8 bits of data register D0001, turn on
Y011.

② If X000 turns on, and lower-8 bits of data register D1000 are smaller than the value indicated with
X010~X017, turn on Y011.

③ If X000 turns on, or lower-8 bits of a data register D1000 are smaller than upper-8 bits of D1000,
turn on Y011.

{bmc PEX_ltN_3.bmp}

20.W<N：Byte data comparison（＜）

(1) Symbol

(2) Function
Compare 2 x 16 bit data, if the 1st data value is smaller than the 2nd data value, it will be in
a-contact-closed condition.

(3) Program example

① When a counter C000 current value (current value register N000 value) is smaller than counter C001
current value (current value counter N001 value), turn on Y123.

③ If X000 turns on, and X010~X01F is smaller than the contents of D1000, turn on Y123.

③ X000 turns on, or if the contents of the data register D1000 are smaller than the contents of the data
register D1001, turn on Y123.

9-17
21.<=H：2 digits hexadecimal constant comparison（≦）

(1) Symbol

(2) Function
Compare 2 digits hexadecimal constant with 8 bit data of a register, if register data is less than a
constant , it will be in a-contact-closed condition.

(3) Program example

① When X000~X007 is less than hexadecimal "23", turn on Y00F.

② When X000 turns on, and lower-8 bits of data register D1000 are less than hexadecimal "55", turn on
Y00F.

③ When X000 turns on, or upper-8 bits of data register D1000 are less than hexadecimal "AA", turn on
Y00F.

22.W<=H：4 digits of hexadecimal constant comparison（≦）

(1) Symbol

(2) Function
Compare 4 digits of hexadecimal constant with 16 bit data of a register, if register data is less than a
constant, it will be in a-contact-closed condition.

(3) Program example

① When X000~X00F is less than hexadecimal "1234", turn on Y00F.

② When X000 turns on, and data register D1000 is less than hexadecimal "5555", turn on Y00F.

③ When X000 is ON, or data register D1000 is less than hexadecimal "AAAA", turn on Y00F.

9-18
23.<=N：Byte data comparison（≦）*

(1) Symbol

(2) Function
Compare two 8 bit data, if the 1st data value is less than the 2nd data value, it will be in
a-contact-closed condition.

(3) Program example

① When upper-8 bits of data register D0001 is less than lower-8 bits of data register D0002, turn on
Y011.

② When X000 is ON, and lower-8 bits of data register D1000 is less than the value indicated with
X010~X017, turn on Y011.

③ When X000 is ON, or lower-8 bits of data register D1000 is less than upper-8 bits of D1000, turn
on Y011.

24. W<=N: WORD data comparison（≦）*

(1) Symbol

(2) Function
Compare 2 x 16 bit data, and if the 1st data value is less than the 2nd data value, it will be
a-contact-closed condition.

(3) Program example

① When a counter C000 current value (current value register N000 ) is less than a counter C001 current
value (current value counter N001 ), turn on Y123,

② When X000 is ON and the value indicated with X010~X01F is less than the contents of D1000, turn
on Y123.

③ When X000 is ON, or data register D1000 contents is less than the contents data register D1001,
turn on Y123.

9-19
9-20
9.1.5.2. Data Transfer

25.MOV：2 digits hexadecimal constant transfer (FUN 100)

(1) Symbol

(2) Function
Store a hexadecimal constant in a register. The range of a constant is 0~FF.

(3) Flag No change

(4) Program example

When M000 turns on, the program which stores hexadecimal "3F" in lower-8 bits of data register
D0000

26.WMOV：4 digits of hexadecimal constant transfer (FUN 101)

(1) Symbol

(2) Function
Store a hexadecimal constant in a register. The range of a constant is 0~FFFF.

(3) Flag No change

(4) Program example

When X001 is set to ON from OFF, the program which transfers hexadecimal "AAAA" to Y010 - Y01F

9-21
9.1.5.3. Data Conversion

27.BCD：8 bits of binaries ->2 digits BCD conversion (FUN 154)

(1) Symbol

(2) Function
Convert binary data stored in the register of OP1 to BCD data and store it in the register of OP2.

(3) Flag
C B Z > = < E
Y O R


Error Flag(ER) ： When the data stored in the register of OP1 is cconverted to a BCD code, if the data
exceeding maximum 99, turn on the flag.

(4) Program example

When X000 is ON, convert binary data stored in the lower- byte of D0000L to 2 digits BCD data . And
store in D0000H.

28.WBCD：16 bits binaries -> 4 digits of BCD conversion (FUN 4)

(1) Symbol

(2) Function
Convert binary data stored in the register of OP1 to BCD data and Store it in the register of OP2.

(3) Flag
C B Z > = < E
Y O R


Error Flag(ER) ：When convert the data stored in OP1 register to a BCD code, and if exceeding
maximum 9999. The flag turn on.

(4) Program example

When X000 is ON, convert the binary data stored in D0000 to 4 digits of BCD . Store it in D0001.

9-22
29.BIN：2 digits BCD -> 8 bits of binary conversion (FUN 152)

(1) Symbol

(2) Function
Convert BCD data stored in the OP1 register to binary data , Store it in the OP2 register.

(3) Flag
C B Z > = < E
Y O R


Error Flag(ER) ： When the data stored in OP1 register is not a BCD format , the flag turns on.

(4) Program example

When X000 is ON, convert 2 digits BCD data stored in D0000 lower-byte to binary data.
Store it in D0000 upper- byte.

30.WBIN：4 digits of BCD -> 16 bits of binary conversion (FUN 3)

(1) Symbol

(2) Function
Convert BCD data stored in OP1 register to binary data . Store it in OP2 register .

(3) Flag
C B Z > = < E
Y O R


Error Flag(ER) ： When the data stored in OP1 register is not a BCD format , the flag turns on.

(4) Program example

When X000 is ON, convert 4 digits of BCD data stored in D0000 to binary data and store it in D0001.

9-23
9.1.5.4. Arithmetic Operation

31.W+：WORD data binary addition (FUN 92)

(1) Symbol

(2) Function
Add the contents of OP1 register and the contents of OP2 register, and store a result in OP3 register.
All data is treated as a binary number.

(3) Flag
C B Z > = < E
Y O R
 

Cary Flag(CY) ： When the result of addition causes a carry , the flag turns on.
Zero Flag(Z) ： When the result of addition is 0. the flag turns on.

(4) Program example

When X001 is ON, add a counter C000 current value (N000 contents) and a counter C001 current
value (N001 contents) , then store a result in D0234.

32.W-：WORD data binary subtraction (FUN 93)

(1) Symbol

(2) Function
Subtract the contents of OP2 register from the contents of OP1 register, Store a result in OP3 register.
All data is treated as a binary number.

(3) Flag
C B Z > = < E
Y O R
 

Borrow Flag(BO) ： When digit lowering causes by subtraction results (OP2 contents were larger
than OP1 contents.), the flag turns on.
Zero Flag(Z) ： When subtraction result is 0, the flag turns on.

(4) Program example

When X001 is ON, subtract a counter C001 current value (N001 contents) from a counter C000 current
value (N000 contents), store a result in D0234.

9-24
33.W*：WORD data binary multiplication (FUN 94)

(1) Symbol

(2) Function
Make the multiplication of the contents of OP1 register, and the contents of OP2 register, store a result
in the register of OP3. All data is treated as a binary number.

(3) Flag
No change

(4) Program example

When X001 is ON, make multiplication by a counter C000 current value (N000 contents) and counter
C001 current value (N001 contents) . Store results in D0234 and D0235.

34.W/：WORD data binary division (FUN 175) #

(1) Symbol

(2) Function
Divide the contents of OP1 register by the contents of OP2 register, and store a quotient in OP3 register
and a remainder in the next register of OP3.

(3) Flag
C B Z > = < E
Y O R


Error Flag(ER) ： When the contents of OP2 register is 0, the flag turns on

(4) Program example

When X001 is ON, divide a counter C000 current value(N000 contents) by a counter C001 current
value (N001 contents). Store a quotient in D0234 and store remainder in D0235.

9-25
35.WINC：WORD data binary increment (FUN 63)

(1) Symbol

(2) Function
Carry out comparison with the contents of OP1 register after the contents of OP2 register +1.
Treat data in a binary number.

(3) Flag
C B Z > = < E
Y O R
↑ ↑ ↑

Cary Flag (CY) : After operation, when the contents of OP2 register overflow,the flag turns on.
Zero Flag (Z) : After operation, when the contents of OP2 register is 0, the flag turns on.
Equal Flag (=) : After operation, when the contents of OP2 register is same with the contents of
OP1 register,the flag turns on.

(4) Program example

When X001 is set to ON from OFF, make the contents of D0123 +1.

36.WDEC：WORD data binary decrement (FUN 64)

(1) Symbol

(2) Function
Make the contents of OP1 register -1. Treat data in a binary number.

(3) Flag
C B Z > = < E
Y O R
↑ ↑

Borrow Flag (BO) : When an operation result becomes negative (i.e., when the data before
operation is 0). The flag turns on
Zero Flag (Z) : When an operation result is 0.the flag turns on

(4) Program example

When X001 is set to ON from OFF, make the contents of D0123 -1.
If a result is 0, turns on Y010.

9-26
9.1.5.5. Logical Operation

37.AND：Byte data logical AND (FUN 13)

(1) Symbol

(2) Function
Carry out logical AND (AND) of the contents of OP1 register and the contents of OP2 register,
Store a result in OP3 register.

(3) Flag
C B Z > = < E
Y O R


Zero Flag(Z) ： When an operation result is 0 , the flag turns on.

(4) Program example

When X000 is ON, make logical AND between the data of X010-X017 and lower-8 bits of D1234, a
result is outputted to Y018 - Y01F.

38.OR：Byte data logical addition (FUN 14)

(1) Symbol

(2) Function
Carry out logical addition (OR) of the contents of OP1 register and the contents of OP2 register, Store a
result in the register of OP3.

(3) Flag
C B Z > = < E
Y O R


Zero Flag(Z) ： When an operation result is 0, the flag turns on.

(4) Program example

When X000 is ON, Carry out logical addition between X010-X017 data and with lower-8 bits of
D0123. A result is outputted to Y028 - Y02F.

9-27
39.NOT：Byte data inversion (FUN 9)

(1) Symbol

(2) Function
Invert the contents of OP1 register (each bit will be 0 →1 or 1→0 ).
Store the inverted data in the register of OP2.

(3) Flag
C B Z > = < E
Y O R


Zero Flag(Z) ： When an operation result is 0, the flag turns on.

(4) Program example

When X000 is ON, Invert all of the ON/OFF data of X010-X017.
The inverted results are outputted to Y028 - Y02F.

40.XOR：Byte data exclusive OR (FUN 18)

(1) Symbol

(2) Function
Carry out exclusive OR (XOR) of the contents of OP1 register and the contents of OP2 register,.Store a
result in OP3 register.

(3) Flag
C B Z > = < E
Y O R


Zero Flag(Z) ： When an operation result is 0, the flag turns on.

(4) Program example

When X000 is ON, Carry out exclusive OR of X010 - X017 data and lower-8 bits of D0123.
A result is outputted to Y018 - Y01F.

9-28
9.2. Basic rules on safety circuit
For TOYOPUC-Plus Safety safety control program, proper signals for safety control need to be used.
In the programming software PCwin-Safe-Plus for TOYOPUC-Plus Safety, as in PCwin-Safe, a proper signal
checking function is incorporated for safety control.
Proper signals (contact or coil) for safety control are marked with "S." And signals (contact or coil) improperly
used for safety control are marked with "U." By using the "S" and "U" marks, the safety control designer can
design programs with proper signals for safe control.

9.2.1. Definition of "S" (safety signal) mark

・ The "S" mark shall be indicated near the safe signal's contact or coil properly used for safety control.
・ The safe signal with "S" mark indicates that there is no circuit in which priority is given to non-safe signals.
・ Only if all outputs (Q area) are marked with "S," the safety control execution program is created, enabling
writing in TOYOPUC-PCS-J.
・ Among S-marked signals, the single output (Q area) is indicated by "S2."

9.2.2. Definition of "U" (user confirmation signal) mark

・ The "U" mark shall be indicated near the signal's contact or coil that is not properly used for safety control.
・ The U-marked signal indicates the OR circuit having a safe signal and a non-safe signal, in which priority
may be given to the non-safe signal, requiring confirmation or repair of circuit by the user.
・ As long as the non-safe signal is ON, the coil cannot be switched off even when the input signal is turned
off with the emergency stop button, etc. Therefore, it cannot be used because it is not a proper output (Q
area) for safety circuit.

9.2.3. Important points in rules

・ In the case of OR circuit between the safe signal "S" and the non-safe signal "-", "U" mark shall be put on
the relevant coil.
・ However, only if a self-maintaining contact is on the non-safe side, the coil of OR self-maintaining circuit
between the safe signal "S" and non-safe signal "-" becomes non-safe "-." (Cause "U" mark signal)
・ In the case of a circuit containing a U-marked contact, the output coil shall be marked with "U." (Derivative
"U" mark signal)
・ The B contact of double input and single input shall be indicated as a non-safe signal "-."

9-29
9.2.4. Basic Rules

I012 M000
(1) Basically, no "S" mark is put in S
the case of self-maintaining
circuits. M000

Cases where
1. "S" mark is not (2) No "S" mark is indicated if the シングル入力
Single input ダブル入力
Double input
put: input signal of TOYOPUC-PCS-J I*** I**** I****
is used at B contact. *

(3) No "S" mark is put in the EL EL***

area of communication area.

(1) "S" or "S2" mark is put in the S

case of outputs to Q***
TOYOPUC-PCS-J. S
Q***
*Only in the case where "S" mark
is put, writing use's program into S2
TOYOPUC-PCS-J is possible. Q***
Cases where
2. Single input
シングル入力 Double
ダブル入力 input
"S" mark is put:
S S S

(2) "S" mark is put on input signals S S

of TOYOPUC-PCS-J.
S S

S U
(1) "U" mark is put on the OR coil -
between safe and non-safe signal.
Contact without “S”
"S"の付かない接点
Cases where
3.
"U" mark is put I012 M000
S U
(2) "U" mark is put on the coil
containing a U-marked contact. M002

Output to EL Without “S” mark With "U” mark

Sなし U付き
area is not Output is possible even with "U" EL*** EL***
4
restricted. mark and without "S" mark. U

Table 9-7 Basic Rules

9-30
9.2.5. Conditions for "S" mark

No Identifier Circuit Description

S S
1. "S" mark is put on actual input.
S S
2. "S" mark is put on actual input.
Double S S
3. "S" mark is put on actual input.
Input
Control is performed through the B
I
contact, so "S" mark is not indicated
4
even though it is actual input.

S "S" mark is put on actual input's A

5
Single contact.
Input "S" mark is not put on single input's B
6
contact.
S
Double Q***
The Q area (output) cannot be written in
Output S
Q*** TOYOPUC-PCS-J unless "S" mark or
7 Q
"S2" mark is indicated at the time of
creating user's program.
Single S2
Output Q***

EL*** "S" mark is not put to sending and

8 EL
receiving signals.

M****
S

9-1 M****
S

S Whether the "S" mark can be put or not

M*** is determined by the contact
M, K, T, L, D
M**** combination logic.

M****
9-2

M***

V****
10 V, S, N

Table 9-8 Conditions for "S" mark

9-31
9.2.6. Coil mark depending on circuit
Marking a coil with "S" or "U" depends on the circuits consisting of various combinations of contacts as shown
below.

① Patterns in which "S" mark is not put on coil

■ Circuit patterns
No Circuit patterns Description
(1)-1 If a circuit is formed with only no-S mark
－ － contacts, "S" mark is not put on the relevant
coil.
Table 9-9 Patterns in which "S" mark is not put on coil

■ Examples of circuits
No Examples of circuits Description
Coil (M000) is formed with EL (EL100).
EL100 M000
1. Circuit condition: 8

Circuit patterns: (1)-1

Coil (M000) is formed by the coil contacts
M000 having no "S" mark.
M001
2. Circuit condition: 9-2

Circuit patterns: (1)-1

M000 Coil (M000) is formed in B contact's input

I002 I003 signal area (I002, I003).
3. Circuit condition: 4, 6
* That is also applied to
the single input. Circuit patterns: (1)-1

Table 9-10 Examples of circuits

9-32
② Patterns in which "S" mark is put on coil

■ Circuit patterns
No Circuit patterns Description Table
9-11
S S If a circuit is formed by S-marked contacts, Circuit
(2)-1
"S" mark is put on the relevant coil. pattern
s
- S S If the AND circuit is formed by the no-S
(2)-2 contact and the S-marked contact, "S" mark ■ E
is put on the coil. x
S S a
If the OR circuit is formed by the S-marked m
(2)-3 S contact and the S-marked contact, "S" mark p
is put on the coil. l
e
s of circuits
No Examples of circuits Description
Coil (M000) is formed by the S-marked
contact (M001).
M001 M000
1. S S Circuit condition:9-1

Circuit pattern:(2)-1
Coil (M000) is formed in S-marked input
I002 I003 M000 signal area (I002, I003).
S S S
2. Circuit condition: 1, 2, 3, and 5

Circuit pattern:(2)-1
Coil (M000) is formed by the no-S and
EL100 M001 M000 S-marked AND circuit.
S S
3. Circuit condition:8, 9-1, 9-2

Circuit pattern:(2)-2
I012 M003 Coil (M000) is formed by the OR circuit in
S S which A and B contacts are both S-marked.
4 M000 Circuit condition:1, 2, 3, 5, 9-1
S
Circuit pattern:(2)-3

Table 9-12 Examples of circuits

9-33
③ Patterns in which "U" mark is put on coil

If the OR circuit is formed by the no-S and S-marked contacts, "U" mark is put on the relevant coil.
This "U" mark indicates that it is not a combination of safe signals.
■ Circuit patterns
No Circuit patterns Description
S U If the OR circuit is formed by the S-marked
and no-S contacts, "U" mark is put on the
3.1. relevant coil. This is because safety cannot be
－ ensured due to inclusion of the no-S mark
contact.
Table 9-13 Patterns in which "U" mark is put on coil
If a U-marked contact is used, "U" mark is put on the relevant circuit's coil.
■ Circuit patterns
No Circuit patterns Description
U S U If the AND circuit is formed by the U-marked
3.2. contact and the S-marked contact, "U" mark is
put on the relevant coil.

S U
If the OR circuit is formed by the U-marked
(3)-3 U contact and the S-marked contact, "U" mark is
put on the relevant coil.

Table 9-14 Circuit patterns

■ Examples of circuits
No Examples of circuits Description

I012 M000 If the OR circuit is formed by the S-marked

S U contact (I012) and the no-S contact (M002),
1. "U" mark is put on the coil (M000).
M002

Circuit pattern:(3)-1

M005 M000 If the AND circuit is formed by the S-marked

M004
contact (M000) and the U-marked contact
U S U
2. (M005), "U" mark is put on the coil (M004).

Circuit pattern:(3)-2

I012 M000 If the OR circuit is formed by the S-marked

S U contact (I012) and the U-marked contact
3. (M002), "U" mark is put on the coil (M000).
M002
U
Circuit pattern:(3)-3

Table 9-15 Examples of circuits

9-34
9.2.7. Self-maintaining circuit pattern

■ Only OR circuit pattern

No Circuit patterns Description
A side
M***
contact － －
If the OR circuit's A and B contacts are both
(4)-1 － "-," the self-maintaining circuit's coil shall be
M*** marked with "-."
B side

A side M***
contact S －
The A contact is S-marked, but the B contact
(4)-2 － is marked "-," resulting in "-" for the
M*** self-maintaining circuit's coil.
B side
contact
A side M***
contac S S
When both A and B contacts are S-marked,
(4)-3 S the coil of the relevant self-maintaining circuit
M*** is marked with "S."
B side
contact
A side
M***
contact － U
If the A contact is marked with "-," and the B
(4)-4 S contact is S-marked, the self-maintaining
M*** circuit coil shall be marked with "U."
B side

A side M***
contact S U
The OR circuit has a U-marked contact, so the
(4)-5 U self-maintaining circuit coil shall be marked
M*** with "U."
B side
contact

Table 9-16 Self-maintaining circuit pattern

9-35
OR and AND combined circuit pattern
No Circuit patterns Description
A side
M***
－ － － Since the both contacts are "-," the OR circuit
shall be marked with "-."
(4)-6
－ Since the AND circuit has "-" and "-," the coil
M*** shall be marked with "-."
B side

M***
S － － The OR circuit shall be S-marked.
The coil is temporarily marked with "S"
－ because the AND circuit has the S-marked
(4)-7 M***
and "-" marked contacts. But the
self-maintaining circuit shall be marked with "-"
because its contacts are "-" marked.

S M*** S The OR circuit shall be S-marked.

－
The AND circuit is S-marked, and the
(4)-8
S self-maintaining circuit's contact is S-marked,
M*** resulting in the S-marked coil.

－ S M*** S
Initially, the self-maintaining circuit's contact is
marked with "-." But it would be S-marked if
－⇒S the coil is marked with "S."
M***
The AND circuit is S-marked, so the coil is
M*** also marked with "S." Since the coil is
S S⇒U
A side － S-marked, the self-maintaining circuit's
(4)-9
contact shall become S-marked. But the A
－⇒S
M*** contact is marked with "-," so the coil shall be
U-marked.
M***
－ S U
If the circuit has a U-marked contact, the coil
U shall be U-marked.
M***

Table 9-17 OR and AND combined circuit pattern

9-36
■ Examples of circuits
No Examples of circuits Description
1. A side Since the OR portions of the A and B sides
I01 M01 M00 form a self-maintaining circuit, the entire OR
2 S 4S 0 S
portion should not be S-marked.
But, due to the AND circuit between "-" and
M00 M001
"S" (M014), the M000 can be marked with "S."
0 S

B side Circuit pattern:(4)-2, (4)-10

On the A side, an S-marked circuit is formed.

A side Also, on the B side, the self-maintaining
I012 M016 M000 contact (M000) and the S-marked contact
S S S (M014) forms the AND circuit, which should
be marked with "S."
M000M014 As a result, the OR circuit between the A and
2. S S B sides can be marked with "S."
For that reason, the self-maintaining circuit is
B side
S-marked.

Circuit pattern:(4)-8

EL100 M016 M000

S S The OR circuit is formed by combination of "-"
and "-," so it shall be marked with "-."
M000 M001 Due to the AND circuit consisting of "-" and
S
"S," the self-maintaining contact is S-marked.
But the OR portion consists of "-" and "S," so
EL100 M016 M000 the entire coil shall result in "U" mark.
3. S U

M000 M001
U

Although it is temporarily S-marked, Circuit pattern:(4)-9

it would be U-marked if the
self-maintaining contact is marked
with "S."

Since the OR circuit contains the U-marked

contact (M001), it shall be U-marked, and also
EL100 M016 M000 the AND circuit shall be marked with "U."
4 S U
As a result, the coil, as well as the
M000 M001 self-maintaining contact, shall be U-marked.
U U
Circuit pattern:(4)-11
Table 9-18 Examples of circuits

9-37
10. Application Examples
10.1. Example of operation ready circuit
This shows an example of operation ready circuit configured only with BS0808 Module.
(1) I/O diagram
BS0808
DC24V 0V

I_COM08
E-Stop IN08 I008
Double input setting IN09
I_COM09 I009

I_COM0A
safety fence close IN0A I00A
Double input setting IN0B
I_COM0B I00B

Operation ready button IN0C

N I00C
Single input setting I_COM0C
Reset button IN0D
I_COM0D
I00D

Operation ready OFF IN0E

check 1 I00E
Single input setting I_COM0E
Operation ready OFF IN0F
check 2
I_COM0F I00F

IO_PWR1+
IO_PWR1-

Q000 OUT00
CR1M-1 Operation ready
O_COM00
ON 1
Q001 O_COM01
CR1M-2 Operation ready
OUT01 ON 2
IO PWR0+

IO PWR0-
Auxiliary
contact
BS0808

Figure 10-1 Example of operation ready circuit

10-1
(2) Example of ladder program circuit

(1) Operation ready ON output

read-back check
1) OFF check
(safety requirement)
Check that the OFF check
signal is activated within one
second after output was
deactivated.
It enables detection of relay's
wiring problem or magnet's
adhesion on the output side.
2) ON check
Check that the ON check
signal is activated within one
second after output was
deactivated.
It enables detection of wiring
problems, such as breaking of
wire.

(2) Operation ready

condition-related system
Series connection of safety
device signal inputs

(3) Operation ready normal

condition system
Series connection of equipment
normal signals

(4) Operation ready instruction

It is activated by pressing the
operation ready button.
Also, the signal can be input
from Control PLC (PC10) via
SN-I/F.

(5)Operation ready button

anti-repeat
The anti-repeat function is to
prevent ON-OFF repeat of the
operation ready with one-time
pressing.

(6) Operation ready ON output

The ON output is maintained
with the operation ready
instruction.
The output is switched off by
turning off the operation ready
condition.

Figure 10-2 Example of ladder program circuit

10-2
11. Attachment
11.1. Connection with light curtain device
For light curtain devices, the output control signals are periodically tested with a test pulse (OFF pulse) to
check its control output circuit.
For the TOYOPUC-Plus Safety input module, on the other hand, the signals are read out three times at
intervals of 0.7ms, and the result is judged according to "decision by a majority."
If the light curtain's test pulse interval is coincidentally equal to the TOYOPUC-Plus Safety module's input
readout timing, it may be misjudged as shutoff of light curtain. Therefore, pay special attention to connection
with the light curtain.
Test pulses for light curtain devices vary according to light curtain device manufacturers. For more details,
refer to the relevant manufacturer's instruction manual. Setting of typical devices are shown in Table 11-1.

Example 1
Test pulse
Light curtain 100μS
Control output signal 0.7m

TOYOPUC-Plus-Safety 0.7m
Readout time
module Several μS

Figure 11-1 Connection with light curtain device

In the case of Example 1, the test pulse interval and the readout timing is the same (0.7ms), so the test
pulse is read twice, leading to misjudgment of OFF according to decision by a majority.

Example 2

1ms Test pulse

Light curtain 100μS
Control output signal

TOYOPUC-Plus-Safety 0.7ms
Readout time
module Several μS

Figure 11-2 Connection with light curtain device

In the case of Example 2, the test pulse interval is different from the readout timing, so the test pulse is read
out only once. As a result, OFF judgment will not be made.

Name Digital filter

Type Maker recommending value Remarks
Safety light curtain SF4B-H series Panasonic 0.7ms,1.0ms,1.3ms
Industrial
Devices SUNＸ
Safety light curtain F3SJ-B□□□□P25-01TS OMRON 0.7ms,1.0ms,1.3ms
Safety light curtain F3SN-B□□□□P OMRON 0.7ms,1.0ms,1.3ms
Door switch with an AZM200CC-T-1P2P SCHMERSAL 1.3ｍｓ Only
electronic lock stand-alone
connection can
be used.
Safety light curtain SL-C series KEYENCE 0.7ms,1.0ms,1.3ms
Safety light curtain C4000 series SICK 0.7ms,1.0ms,1.3ms
Safety laser scanner S3000 standard SICK 0.7ms,1.0ms,1.3ms
Safety laser scanner S300 standard SICK 0.7ms,1.0ms,1.3ms
Safety light curtain SE series IDEC 0.7ms,1.0ms,1.3ms

Table 11-1 Device with a test pulse output function

11-1
11.2. Option Product
About the following components for installation of a product, the user can purchase from from JTEKT
11.2.1. Stud
The purpose of studs, types, and appearance are shown.
Purpose of stud Type L Quantity/set
Between BS/BN unit - IF unit ST8X4MF 8mm 4
(Male- Female) (in a bag)
Between BS/BN/OS/ON/IF unit-Mounting plate STD16X4 16mm
Between BS/BN unit -OS/ON unit (Male- Female)
Between BS/BN unit -BS/BN unit
Between BS/BN/OS/ON/IF unit -Cover ST16X4FF 16mm
(Male- Female)
Between BS/BN unit -Mounting plate ST8X4MM 8mm
(Male- Female)
Between ST16X4MM 16mm
BS/BN/OS/ON/IF unit –Cover/Mounting plate (Male- Female)
Between BS/BN/IF unit-RY unit, ST48X4MF 48mm (Male-
Female)
Between cover/bracket -RY unit
Between cover/bracket-RY unit ST48X4FF 48mm(Female-
Female)
ST8X4FF 8mm
(Female- Female)
Table 11-2 Stud

・ST8X4MF、STD16X4

5.5mm
6mm L

M3

・ST16X4FF 6mm

5.5mm

M3IO_PWR+ M3

6mm＋ 6mm
・ST8X4MM、ST16X4MM

5.5mm
6mm L 6mm

M3 M3

Figure 11-3 Stud

11-2
11.2.2. Screw
Type of the screw for board fixing using studs are shown.

Type Diameter Length Quantity/set

SCR6X4 M3 6mm 4 (in a bag)

M3

6mm
Figure 11-4 Screw
11.2.3. Bracket/ Cover
Bracket/cover type and appearance are shown below.
No. Purpose of Bracket/ Type Name Remarks Quanti
Cover ty/set
1 Direct mounting bracket BK0000 BK0000 1
2 Direct mounting bracket DN0000 DN0000 For BK0000
1
DIN-Rail attachment
3 DIN-Rail bracket BK00DN BK00D Assembling product
N of BK0000 and 1
DN0000
4 Cover for direct TNP-6936 CV0000 For BK0000
1
mounting bracket using 90X140 t= 1
5 Cover for DIN-rail TNP-6940 CV00D For BK00DN
1
attachment using N 110X140 t= 1
Table 11-3 Bracket/ Cover
(1) Cover at using a direct mounting bracket BK0000

Grounding marking
(Safety DENKI GR1-S08)

2-⏀4.5 U-hole

Figure 11-5 Cover at using a direct mounting bracket

11-3
(2) Bracket for direct mounting DIN rail adapter DN0000

Figure 11-6 Bracket for direct mounting DIN rail adapter DN0000
(3) DIN rail bracket BK00DN

Figure 11-7 DIN rail bracket BK00DN

11-4
 (4) Cover for direct mounting bracket using CV0000

ｔ =1

Figure 11-8 Cover for direct mounting bracket

(5) Cover for DIN-rail attachment using CV00DN

ｔ =1

Figure 11-9 Cover for DIN-rail attachment

11-5
11.2.4. Cable
JTEKT sells cables which is harness assembly of cable, connector, pin and contact, etc.
The purpose of each cable, type, and appearance are shown.

No. Purpose Type Quantity/set

1 Internal IO bus cable CB****SI 1
(Non-shield , flat cable) ****=0005 0.05m
****=0015 0.15m
2 Internal IO bus cable CB****SI 1
(Shield ) ****=0500 5m
****=1000 10m
****=1500 15m
****=2000 20m
****=2500 25m
****=3000 30m
****=3500 35m
****=4000 40m
****=4500 45m
****=5000 50m
3 Remote IO bus cable CB****SR 1
****=0500 5m
****=1000 10m
****=1500 15m
****=2000 20m
****=2500 25m
****=3000 30m
****=3500 35m
****=4000 40m
****=4500 45m
****=5000 50m
4 SN-IF cable EX_SIOSNIF_CN2-*** 1
For TOYOPUC-Plus ***=005 0.5m
Single shielded cable ***=015 1.5m
***=030 3.0m
5 SN-IF cable CB****SP 1
For TOYOPUC-Plus ****=0500 5.0m
Double shielded cable
6 SN-IF cable TXY-6670 1
TOYOPUC-PC10G SN-I/F CABLE 0.5m
Single shielded cable TXY-6671 1
SN-I/F CABLE 1.5m
TXY-6672 1
SN-I/F CABLE 3.0m
7 SN-IF cable CB****S10 1
TOYOPUC-PC10G ****=0500 5.0m
Double shielded cable
8 SN-IF cable TXY-6673 1
Single shielded cable SN-I/F CABLE 3.0m
one side cut (Free)
9 SN-IF cable CB****SF 1
Double shielded cable ****=0500 5.0m
One side cut
Table 11-4 Cable

11-6
(1) Internal IO bus cable (Non-shield, flat cable)
Appearance and core wire number, Signal name

L JTEKTType メーカ型式 ﾒｰｶ

0.05m CB0005SI JTEKT
0.15m CB0015SI LD-GFT/BU015 Elecom

Figure 11-10 Internal IO bus cable (Non-shield, flat cable)

(2) Internal IO bus cable (Shield) Appearance and core wire number, Signal name

Shielded cable
Maker:Nichigou Boots
Boots Type:UNI-FLEX0.2mm(AWG25)4P(Green) Type:MB-6(Green)
Type:MB-6(Green)

RJ-45 Shielded Plag RJ-45 Shielded Plag

Maker:Tyco Electronics Maker:Tyco Electronics
Type:5-569552-3 Type:5-569552-3

Figure 11-11 Internal IO bus cable (Shield)

L Type
5m CB0500SI
10m CB1000SI
15m CB1500SI
20m CB2000SI
25m CB2500SI
30m CB3000SI
35m CB3500SI
40m CB4000SI
45m CB4500SI
50m CB5000SI

Table 11-5 Internal IO bus cable (Shield)

11-7
(3) Remote IO bus cable Appearance and core wire number, Signal name

Shielded cable
Industrial mini I/O Plug Industrial mini I/O Plug
Maker:Nichigou
Maker:Tyco Electronics Type:UNI-FLEX0.14mm(AWG26)4P(Green) Maker:Tyco Electronics
Type:2069578-1 Type:2069578-1

L Type
5m CB0500SR
10m CB1000SR
15m CB1500SR
20m CB2000SR
25m CB2500SR
30m CB3000SR
35m CB3500SR
40m CB4000SR
45m CB4500SR
50m CB5000SR

Figure 11-12 Remote IO bus cable

Table 11-6 Remote IO bus cable
(4) SN-IF cable (for TOYOPUC-Plus, single shielded cable)
Appearance and core wire number, Signal name
1-1827864-4
1-1827864-4 1-1318120-3
1-1318120-3
Tyco Electronics RO-FLEX-CMDTPS
RO-FLEX-CMDTPS
Tyco Electronics
(タイコエレクトロニクス) 1P x 20AWG (Maker:Nichigou) (タイコエレクトロニクス)
1P×20AWG（日合通信電線）
L+ A1 茶 1 SG
L- A2 青 茶2 L1+
SG A3 青 L1-
3
A4 Mark
ﾏｰｸﾁｭｰﾌﾞ
tube
40mm

L＝**

Figure 11-13 SN-IF cable

Mark tube
L- Type
Brown L1+
0.5m EX_SIOSNIF_CN2-005
Blue L1-
1.5m EX_SIOSNIF_CN2-015
Internal shield SG
3.0m EX_SIOSNIF_CN2-030
Table 11-7 SN-IF cable

11-8
(5) SN-IF cable (for TOYOPUC-Plus, double shielded cable)
Appearance and core wire number, Signal name
1-1827864-4
1-1827864-4 1-1827864-4
UL2464-2SB2x20AWG
RO-FLEX-CMDTPS 1-1318120-3
Tyco Electronics Tyco Electronics
(タイコエレクトロニクス) (KURAMOCHI) (タイコエレクトロニクス)
1P×20AWG（日合通信電線）
L+ A1 茶 1 SG
L- A2 青 茶2 L1+
SG A3 青 L1-
3
A4
Mark FG
ﾏｰｸﾁｭｰﾌﾞ
tube
40mm

L＝**

Figure 11-14 SN-IF cable

Mark tube
Brown L1+
Blue L1-
internal shield SG L Type
Outer shield FG 5m CB0500SP

Table 11-8 SN-IF cable

11-9
(6) SN-IF cable (for TOYOPUC-PC10G, single shielded cable)
Appearance and core wire number, Signal name

Figure 11-15 SN-IF cable

L Type Name
0.5m TXY-6670 SN-I/F CABLE 0.5m
1.5m TXY-6671 SN-I/F CABLE 1.5m
3.0m TXY-6672 SN-I/F CABLE 3.0m

Table 11-9 SN-IF cable

(7) SN-IF cable (for TOYOPUC-PC10G, Double shielded cable)

Appearance and core wire number, Signal name

AMP connector

L 型式
5m CB0500S10

Figure 11-16 SN-IF cable

11-10
 L Type
5m CB0500S10

Table 11-10 SN-IF cable

(8) SN-IF cable Single shielded cable one side cut

Appearance and core wire number, Signal name

Figure 11-17 SN-IF cable

L Type Name
3.0m TXY-6673 SN-I/F CABLE 3.0m(Free)

Table 11-11 SN-IF cable

11-11
(9) SN-IF cable Double shielded cable One side cut)
Appearance and core wire number, Signal name

Insulating
sleeve terminal

Figure 11-18 SN-IF cable

L Type
5m CB0500SF

Table 11-12 SN-IF cable UL2464-2SB2x20AWG

(Kuramo)

11-12
11.3. Safety Integrity Level and Performance Level

The Safety Integrity Level (SIL) to IEC 61508 is one of 4 levels to specify the
requirements of safety integrity of the safety functions which are assigned to all
elements of the chain. Level 4 is the highest and level 1 the lowest safety integrity
level.
The Safety Integrity Level is defined for the following operating modes:
low demand rate : whereby the rate of demand to the safety related system is no more
from once per year and is no greater than double the frequency of the repeat check.
with high demand rate/continuous demand : whereby the rate of demand to the safety
related system is no more than once per year or is greater than double the frequency
of the repeat check.
The average probability of a failure of a safety function with low demand rate is
specified by the PFD factor (average probability of failure to perform its design function
on demand).
The average probability of a failure with a function with high/continuous demand rate is
specified by the PFH factor (average probability of a dangerous failure per hour).
The following is an overview of the TOYOPUC-Plus Safety values.

ISO 13849-1
MTTFd High 100 years
CAT. 4
DCavg High *１ more than 98% ※１

PL E

IEC62061
Fault tolerance 1
SFF more than 99%
PFHD (T1=20year) /h 7.72×10-9
SIL Claim 3

IEC61508
System classification. type B
Fault tolerance 1
SFF more than 99%
PFD (T1=20year) 1.36×10-5
SIL 3
Proof test interval 20 years
*1 About 98%, according to ISO13840-1 Table 6 Note 2 “ A DC value greater than
99% for the complex systems is very hard to achieve. To be practicable, the number of
ranges was restricted to four. The indicated borders of this table are assumed within
an accuracy within an accuracy of 5%.“. Therefor the DCavg is recognized as “High”.
Table 11-13 SIL and Performance level

11-13
11.4. Relay MTTFd (Mean Time to Dangerous Failure)

When a RY unit is used combining PCS and PCS-J, MTTFd value of a relay will be calculated using the
following data.
B10d※１
Relay type (maker) Conditions
[cycle]
G7SA-3A1B (Omron)
AC-1 AC250V 6A
400,000
DC-1 DC30V 6A
G7SA-2A2B (Omron)

SFS3-L-DC24V (Panasonic)
DC30V6A
SFS3-DC24V (Panasonic)
Load:Resistance
500,000
( operation frequency :
SFS2-L-DC24V (Panasonic)
20 times/min.)
SFS2-DC24V (Panasonic)

※1 B10d：B10d stands for the number of cycles where 10% of the component fails to danger
※ These data are announced from the maker.
※ These data may change without a preliminary notice.

Table 11-14 Relay B10d

The formula which calculates MTTFd from B10d.

( ISO13849-1:2006 Annex C and D for details)

MTTFd = B10d / (0.1 x nop) nop：The number of average annual operation [cycle/year]
nop = ( dop x hop x 3600 ) / tcycle
dop: Average operation days per year [day/year]
hop: Average operating time per day [Time/day]
tcycle: Average time per 1 cycle [second/cycle]

Example computation
Condition examples
Average operation days per year dop=240 [day/year]
Average operating time per day hop=16 [hour/day]
Average-time cycle tcycle=300 seconds [ second/cycle]

nop =（240 x 16 x 3,600）/300 = 46,080 [cycle/year]

MTTFd = 400,000 / (0.1 x 46,080) = 86.8 [year]

11-14
11.5. Output Connectable Device List (Information)

The rated output current of the output circuit of Plus Safety is 0.5A / point (0.7A / available by special conditions).
Direct connectable devices are shown in the following table.

Direct connectable devices (Example)(1/2)

Device Type Maker Actuator rating Remarks
Voltage Consumption Consumption
power current
Safety relay G7SA-2A2B DC24 OMRON DC24V 360 mW 15 mA
G7SA-3A1B DC24 Corp. DC24V 360 mW 15 mA
G7SA-4A2B DC24 DC24V 500 mW 20.8 mA
G7SA-5A1B DC24 DC24V 500 mW 20.8 mA
Mini power G2R-2-SND DC24 DC24V - 21.8 mA
relay MY2N-D2 DC24 DC24V - 36.3 mA
MY4N-D2 DC24 DC24V - 36.3 mA
Terminal G6B-47BND DC24 DC24V - 42.8 mA
relay
Timer H3CR-A8 DC24V 0.8 W (33.3 mA)
AC24-48/DC12-48
H3YN-2 DC24 DC24V 1.1 W (45.8 mA)
H3YN-4 DC24 DC24V 1.1 W (45.8 mA)
Safety relay SFS2-DC24V Panasonic DC24V 360 mW 15 mA 2a2b
SFS3-DC24V DC24V 360 mW 15 mA 3a1b
SFS2-L-DC24V DC24V - 17 mA 2a2b,LED
indication
SFS3-L-DC24V DC24V - 17 mA 3a1b,LED
indication
SFS4-DC24V-D DC24V 500 mW 20.8 mA 4a2b
SFS5-DC24V-D DC24V 500 mW 20.8 mA 5a1b
SFS6-DC24V-D DC24V 500 mW 20.8 mA 3a3b
SFS4-L-DC24V-D DC24V - 22.8 mA 4a2b,LED
indication
SFS5-L-DC24V-D DC24V - 22.8 mA 5a1b,LED
indication
SFS6-L-DC24V-D DC24V - 22.8 mA 3a3b,LED
indication
Mini power RJ2S-CLD-D24 IDEC DC24V - 25.7ｍA
relay
Miniature RU4S-CD-D24 IDEC DC24V - 44.7ｍA
relay
Safety relay PZE X4P (777 585) Pilz DC24V - 95 mA
unit
Magnet SD-N35CX DC24V Mitsubishi DC24V 9W (0.38 A） Please use a
contactor SD-Q11 DC24V Electric DC24V - 55 mA surge absorber
SD-Q11 DC24V 1B Corp. DC24V - 55 mA at operation coil
SD-Q12 DC24V DC24V - 55 mA side
SD-Q19 DC24V DC24V - 75 mA
SD-T12 DC24V DC24V 2.2 W （ 92 mA ）
SD-T21 DC24V DC24V 2.2 W （ 92 mA ）

Table 11-15 Direct connectable devices (1/2)

Direct connectable devices (Example)(2/2)

11-15
 Device Type Maker Actuator rating Remarks
Voltage Consumption Consumption
power current
Magnet MSOD-2XT12KP 0.24A Mitsubishi DC24V 2.2 W （ 92 mA ） Please use a
switch DC24V Electric surge absorber
MSOD-2XT12KP 0.35A Corp. DC24V 2.2 W （ 92 mA ） at operation coil
DC24V side
MSOD-2XT12KP 0.7A DC24V 2.2 W （ 92 mA ）
DC24V
MSOD-2XT12KP 0.9A DC24V 2.2 W （ 92 mA ）
DC24V
MSOD-2XT12KP 1.3A DC24V 2.2 W （ 92 mA ）
DC24V
MSOD-2XT12KP 2.1A DC24V 2.2 W （ 92 mA ）
DC24V
MSOD-2XT12KP 3.6A DC24V 2.2 W （ 92 mA ）
DC24V
MSOD-2XT12KP 9A DC24V 2.2 W （ 92 mA ）
DC24V
MSOD-N35CXKP 22A DC24V 9W （ 0.38 A）
DC24V
MSOD-N35CXKP 29A DC24V 9W （ 0.38 A）
DC24V
MSOD-Q12CXKP 0.17A DC24V - 55 mA
DC24V
MSOD-Q12CXKP 0.24A DC24V - 55 mA
DC24V
MSOD-Q12CXKP 0.35A DC24V - 55 mA
DC24V
MSOD-Q12CXKP 0.5A DC24V - 55 mA
DC24V
MSOD-Q12CXKP 0.7A DC24V - 55 mA
DC24V
MSOD-Q12CXKP 1.3A DC24V - 55 mA
DC24V
MSOD-Q12CXKP 2.1A DC24V - 55 mA
DC24V
MSOD-Q12CXKP 3.6A DC24V - 55 mA
DC24V
MSOD-Q12CXKP 6.6A DC24V - 55 mA
DC24V
MSOD-T12KP 0.35A DC24V 2.2 W （ 92 mA ）
DC24V
MSOD-T12KP 0.7A DC24V 2.2 W （ 92 mA ）
DC24V
MSOD-T12KP 0.9A DC24V 2.2 W （ 92 mA ）
DC24V
MSOD-T12KP 1.3A DC24V 2.2 W （ 92 mA ）
DC24V
MSOD-T12KP 11A DC24V 2.2 W （ 92 mA ）
DC24V
MSOD-T12KP 2.1A DC24V 2.2 W （ 92 mA ）
DC24V
MSOD-T12KP 3.6A DC24V 2.2 W （ 92 mA ）
DC24V
MSOD-T12KP 5A DC24V 2.2 W （ 92 mA ）
DC24V
MSOD-T12KP 6.6A DC24V 2.2 W （ 92 mA ）
DC24V
MSOD-T12KP 9A DC24V 2.2 W （ 92 mA ）
DC24V

Table 11-16 Direct connectable devices (2/2)

11-16
Devices are not connectable directly (Example)
The devices following table are not connectable directly with the output of Plus Safety.
Using a RY unit or other measures.
Device Type Maker Actuator rating Reasons of not
Voltage Consumption Consumption connectable
power current directly
Magnet SD-N50 DC24V Mitsubishi DC24V 18 W （ 0.75 A） Consumption
contactor SD-N65 DC24V Electric DC24V 18 W （ 0.75 A） current is large.
SD-N80 DC24V Corp. DC24V 24 W （ 1.0 A）
SD-N95 DC24V DC24V 24 W （ 1.0 A）
SD-N125 DC24V DC24V 31 W （ 1.30 A）
SD-N150 DC24V DC24V 31 W （ 1.30 A）
SD-N220 DC24V DC24V 41 W （ 1.71 A）
Magnet MSOD-N50KP 42A DC24V 18 W （ 0.75 A）
switch DC24V
MSOD-N65KP 54A DC24V 18 W （ 0.75 A）
DC24V

Table 11-17 Devices are not connectable directly

11-17
11.6. Short Circuit Detection of Safety Input Circuit (Dry Contact Input)
In the dry contact input of TOYOPUC-PCS/ TOYOPUC-PCS-J, Short circuit detection was made by changing
common polarity.
For TOYOPUC-Plus Safety, Common polarities are both +. But, there are timing different self-diagnostic pulses
on COM0+ and COM1+, then, short circuit detection between terminals is possible by different timing pulses.

Figure 11-20 Figure 11-19

Dry contact input circuit of TOYOPUC-Plus Dry contact input circuit of TOYOPUC-PCS
Safety /TOYOPUC-PCS-J

11-18
11.7. Examples of Safety Input Circuit Incorrect Connection
(1) Parameter setting : dry contact

Parameter setting : dry Connection diagram Description

contact

Correct connection IN0

COM0+
IN1
COM1+

No error caused, but the system

Incorrect connection DC24V will be not Cat.4 but Cat.3
example 1 because short circuit detection
cannot be performed.

Connecting with IN0

external 24V instead COM0+
of COM*+
IN1
COM1+

IO Error 43 is caused (input pulse

ncorrect connection check error) (detailed code:21).
example 2 DC24V 0V

Connecting with
semiconductor outputs IN0
with check pulses, COM0+
such as light curtain,
IN1
COM1+

Table 11-18 Example of safety input circuit connection (dry contact)

11-19
 (2) Parameter setting : Semiconductor (with test pulses)

Parameter Connection diagram Description

setting :
Semiconductor
(with test pulses)
DC24V 0V
Correct
connection
IN0
COM0+
IN1
COM1+

DC24V Although it does not become error, because

Incorrect there is no diagnostic function at the
connection 1 connection device side, short circuit
detection cannot be performed and it is not
Contact outputs, IN0 Cat.4.
such as an COM0+ (Cat.3)
emergency stop
button, are IN1
connected COM1+
(connecting with
External 24V).
Although it does not become error, because
Incorrect there is no diagnostic function at the
connection 2 IN0 connection device side, short circuit
COM0+ detection cannot be performed and it is not
Contact outputs, IN1 Cat.4.
such as an (Cat.3)
emergency stop COM1+
button, are
connected
(connecting with
COM*+).
DC24V 0V Because pulses for diagnosis are outputted
Incorrect from COM*+, Malfunction may be made.
connection 3
IN0
COM0+
Device power
supply is supplied IN1
from COM*+. COM1+

Table 11-19 Example of safety input circuit connection (semiconductor contact input,
those with test pulses)

11-20
 (3) Parameter setting: Semiconductor (with no test pulse)

Parameter Connection diagram Description

setting:
Semiconductor
(with no test pulse)
DC24V 0V Note)
Correct In this setting, because it becomes a single
connection input, it is not Cat.4.
(Cat.2)
IN0
COM0+
IN1
COM1+

DC24V Although it does not become error, Category

Incorrect 4 can not be realized because the each
Example 1 signal of two channels becomes single
Contact outputs, inputs in PLC. It becomes 3 or less category.
such as an IN0 (Short circuit detection between channels
emergency stop COM0+ and discrepancy detection of 2 inputs cannot
button, are be performed)
IN1
connected
(connecting with COM1+
External 24V).
Although it does not become error, Category
Incorrect 4 can not be realized because the each
Example 2 IN0 signal of two channels becomes single
COM0+ inputs in PLC. It becomes 3 or less category.
Contact outputs, IN1 (Short circuit detection between channels
such as an and discrepancy detection of 2 inputs cannot
emergency stop COM1+ be performed)
button, are
connected
(connecting with
COM*+)
DC24V 0V Although it does not become error, Category
Incorrect 4 can not be realized because the each
Example 3 signal of two channels becomes single inputs
IN0 in PLC. It becomes 3 or less category.
Semiconductor (Discrepancy detection of 2 inputs cannot be
COM0+
outputs with performed, 2-channels short circuit detection
check pulses, IN1 will be done by the Input device side(light
such as light COM1+ curtaion) )
curtain, are
connected.

DC24V 0V Malfunction may be made because the pulse

Incorrect for diagnosis is outputted from COM*+.
Example 4

Device power is IN0

supplied from COM0+
COM*+.
IN1
COM1+

Table 11-20 Safety input circuit connection ( semiconductor contact input ,no test pulse)

11-21
11.8. Unit Version Change History
Unit Hardware Software Date Contents Remarks
version version
IF unit H.10 - - The first version

BS unit H.10 1.00 - - The first version

BN unit - 1.10 2015/09 - Correction of check pulse Please avoid
processing for a door switch etc. mixture
- Format revision of I/O bus installation with a
communication Ver.1.00 unit/s.

OS unit H.10 - - The first version

ON unit

RY unit H.10 - - The first version

Table 11-21 Unit Version Change History

11-22
The descriptive contents of this Manual are subject to change due to
better improvement of applicable product without prior notice.
This Manual is issued after careful check and review of the contents
thereof. However, should any doubt or any descriptive error be found in
the contents, please feel free to contact us.
It is prohibited to copy and transfer , wholly or partly, the descriptive
contents of this Manual to others.

1st Edition February 2015

6th Edition March 2022
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Manual No.

T-386-6-E
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JTEKT CORPORATION 2015-2022.

* The specification and other given in this manual are subject to change due to improvement without prior notice.
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