Configuring Omron CP1W-AD041 and CP1W-DA041 on CP1E and CP1L PLCs

Overview

The Omron CP1W-AD041 and CP1W-DA041 are analog expansion units for the CP-series compact PLCs (CP1E and CP1L). The AD041 adds four isolated analog input channels to any CP1E or CP1L CPU, while the DA041 adds four isolated analog output channels. Both modules mount to the right side of the CPU unit through a CP1W-CN811 flat-cable expansion connector and draw their 5 VDC logic power and 24 VDC field power directly from the bus. Range selection is performed with DIP switches on the module face; configuration and scaling are performed in CX-Programmer (version 9.x or later recommended).

This reference covers module selection, hardware installation, the CP1E/CP1L CIO memory map and addressing rules, scaling math, CX-Programmer configuration, verification steps, and a field troubleshooting matrix.

Module Identification and Variants

The CP-series analog expansion family includes six part numbers. Confirm selection before ordering because the variants are not interchangeable in the CIO map.

The CP1W-AD041 occupies four input words and two output words in the CIO map. The four input words carry the converted analog values; the two output words are used for range, averaging, and enable configuration bits and are not user-writable as process variables. The CP1W-DA041 occupies four output words (analog output values) and two input words (status/hold flags). The combined CP1W-MAD44 occupies four input words and four output words.

CP1W-AD041 Technical Specifications

CP1W-DA041 Technical Specifications

Compatibility with CP1E and CP1L CPU Models

The CP1W-AD041 and CP1W-DA041 attach to any CP1E or CP1L CPU. The maximum number of expansion units is three, regardless of CPU model. Verify CPU compatibility before ordering.

CIO Memory Map and Addressing Rules

The CP1E/CP1L allocates I/O in the CIO (Core I/O) area using a fixed, deterministic rule published in Section 8 of the W479 hardware manual. Once the rule is understood, addressing is identical regardless of which CPU model is used.

Built-in Digital I/O Map

• Digital inputs: Start at CIO 0.00 and occupy as many words as the CPU has onboard inputs. A CP1L-M40 with 24 inputs uses CIO 0 (16 bits) and CIO 1 (8 of 16 bits), leaving CIO 1 bits 08-15 unused.
• Digital outputs: Start at CIO 100.00 and occupy as many words as the CPU has onboard outputs. A CP1L-M40 with 16 outputs uses CIO 100 entirely.

Analog Expansion Allocation Rule

Per Section 8 of the W479 manual, analog expansion units are placed in the CIO map starting at the first fully unused input word for inputs and the first fully unused output word for outputs after the built-in digital I/O. Scan CIO 0 upward until you find a word with no assigned digital input bits; that word becomes analog input word 1. Repeat the scan starting at CIO 100 for outputs.

Worked Example: CP1L-M60 + CP1W-AD041

The CP1L-M60 has 36 inputs and 24 outputs:

This matches the field observation that the first analog input channel appears at CIO 3 on a CP1L-M60 host.

Worked Example: CP1L-M60 + CP1W-AD041 + CP1W-DA041

Adding a CP1W-DA041 to the same CPU extends the output area:

Worked Example: CP1L-M30 (smaller CPU)

The CP1L-M30 has 18 inputs and 12 outputs. CIO 0 holds all 18 input bits (16 in CIO 0, 2 in CIO 1 bits 00-01). CIO 1 bits 02-15 are unused, but because bits 00-01 are occupied the entire word is not free. The first fully free input word is CIO 2; the AD041 occupies CIO 2, 3, 4, 5. The first fully free output word is CIO 101 (CIO 100 has 12 of 16 bits used); the DA041 occupies CIO 101, 102, 103, 104.

Chained Expansion: Second AD041

When a second AD041 mounts to the right of the first AD041 with no digital expansion between them, the second unit occupies the next four free input words immediately after the first unit's last word:

• First AD041 on CP1L-M60: CIO 3, 4, 5, 6
• Second AD041: CIO 7, 8, 9, 10

This chain continues until you insert a digital expansion unit, which interrupts the analog block and reassigns digital I/O into the freed words.

Physical Installation and Wiring

1. Power down the CP1E/CP1L CPU. Remove the right-side cover plate on the CPU by pressing the tab on the bottom of the cover.
2. Remove the expansion I/O connector cover from the right side of the CPU (or of the previously installed expansion unit) to expose the flat-cable header.
3. Verify the CP1W-CN811 I/O connection cable (supplied with each expansion unit) is flat and undamaged. Insert one end into the CPU header and the other end into the AD041 or DA041 module header.
4. Lock the module onto the DIN rail or screw-mount bracket adjacent to the CPU. Torque the unit-locking screws on the top and bottom of the expansion module to 0.5 N·m.
5. Apply power and confirm the CPU's PWR LED is solid green before continuing to wiring.

The AD041 and DA041 each expose a removable screw-terminal block on the front face. Strip 7 mm of insulation from each conductor and torque the terminal screws to 0.5 N·m. Use shielded twisted pair (STP) cable for all analog runs, with the shield drain wire landed on the module's COM terminal and grounded at one end only (the PLC panel ground bar is preferred).

CP1W-AD041 Terminal Layout

For current inputs, the V INx- terminal must be tied to the I INx- terminal internally or at the terminal strip; voltage and current inputs cannot be used simultaneously on the same channel.

CP1W-DA041 Terminal Layout

DIP Switch Configuration

Each AD041 and DA041 has a 6-position DIP switch bank behind a small flip-up cover on the top of the unit. Switches 1-4 select the input or output range for channels 1-4; switches 5 and 6 select averaging and resolution modes. The exact switch mapping is reproduced in the W479 hardware manual; field engineers should print the W479 DIP switch page and clip it inside the panel door for technician reference.

Typical Range Switch Settings (AD041)

Because the exact switch combinations differ by firmware revision, the W479 page for the module should be consulted before each deployment. The DIP switches are authoritative; CX-Programmer settings configure alarms and additional scaling behavior only.

CX-Programmer Configuration and Scaling

1. Connect the CP1E/CP1L to the programming PC via USB (CP1L has built-in USB-B) or RS-232C (CP1E via CP1W-CIF01 option) and open the project.
2. From the PLC menu, open IO Table and Unit Setup. CX-Programmer will auto-detect the CPU and any installed expansion units, populating the rack image with the AD041 and DA041 in their correct physical slots.
3. Select the AD041 row, click the Analog tab, and set each channel's range to match the DIP switch positions. Set the conversion speed and averaging filter if required.
4. Click the Digital tab on the AD041; the four input words appear. Confirm the addresses match the CIO map derived above (for example, CIO 3.00 to CIO 3.15 for input 1 of a CP1L-M60 host).
5. Repeat for the DA041. The four output words appear under the Output tab.
6. Transfer the IO Table to the PLC: Options > Transfer > To PLC. Cycle power on the PLC so the new table takes effect.

Scaling: Raw Counts to Engineering Units

For a 0 to 10 V input, raw counts span 0 to 2EE0 hex (= 12000 decimal). To convert raw counts to engineering units, use the SCL instruction (referenced in the W483 instruction manual), or compute inline:

EngineeringValue = (RawCount - RawMin) * (EngMax - EngMin) / (RawMax - RawMin) + EngMin

Example: a 0 to 10 V pressure transducer produces 0 to 100 bar across the full scale.

D100 (engineering bar x10) = (CIO 3 - 0) * (1000 - 0) / (12000 - 0)
D100 = CIO 3 * 1000 / 12000

The ladder equivalent using the SCL3 instruction:

LD     Always_ON
SCL3   CIO 3  D200  D210  D220  D230

; D200 = source (CIO 3 raw count)
; D210 = slope (linear scaling coefficient)
; D220 = offset
; D230 = destination (engineering value, 0.1 bar units)

Bipolar Scaling for -10 to +10 V

For bipolar ranges, raw counts span 0 to 12000 representing -10 to +10 V. The relationship is linear: Voltage = (Raw / 12000) * 20 - 10. Treat the raw count as an unsigned 16-bit integer; do not sign-extend. For example:

Raw = 0x0E20 (= 3616 dec) corresponds to (3616/12000)*20 - 10 = -3.97 V
Raw = 0x1770 (= 6000 dec) corresponds to 0.00 V
Raw = 0x2EE0 (= 12000 dec) corresponds to +10.00 V

Analog Output Scaling

To drive a DA041 output to 75 % of span on a 0 to 10 V range, write raw count 9000 to the corresponding output word:

MOV    #9000  CIO 102    ; DA041 ch 1 = 7.5 VDC

To set the output to 4.000 VDC on a 0 to 10 V range, raw count = (4.000 / 10) * 12000 = 4800 decimal = 12C0 hex.

Verification and Commissioning

1. Apply a known reference signal (for example, 5.000 VDC from a calibrator) to AD041 channel 1. Open the Watch Window in CX-Programmer and read CIO 3.
2. Confirm the raw count reads approximately 6000 (±5 counts) for a 0 to 10 V range, or approximately 17D0 (±5 counts, equals 6096) for a 1 to 5 V range where 17D0 corresponds to 5.0 V at the top of the 1 to 5 V scale.
3. Force CIO 102 = 6000 from the Watch Window. Measure the DA041 output with a calibrated DMM. Expect 5.000 VDC ±2 mV into a 10 kΩ load.
4. Cycle the PLC power and re-verify the values hold. Analog outputs default to 0 V / 0 mA on power-up unless the hold-last-value bit (bit 12 of each output channel's configuration word) is enabled in the CX-Programmer startup routine.
5. Check the CPU for ERR/ALM indicators. If ERR is lit, the analog module may be drawing more 5 VDC than the CPU budget permits.

Troubleshooting Matrix