User’s Manual 2.

2.1 Main unit - The disposal size of the cable end should follow the dimensions described in this manual.
for HCA2C Series Programmable Controller Model Input Output Connection Drive 5V DC
- Tightening torque should be between 0.5 and 0.8 N•m.
Name type power power
- Twist the end of strand wire and make sure that there are no loose wires.
Points Type Points Type
This manual gives a detailed introduction of HCA2C specification. supply supply - Do not solder-plate the electric wire ends.
This manual should be read and understood before attempting to install or use the unit. - Do not connect more than the specified number of wires or electric wires of unspecified size.
capacity(mA
1. Product overview )
- Affix the electric wires so that neither the terminal block nor the connected parts are directly
1.1 Basic functions stressed.
HCA2C-8X 8 24VD 8 Transistor Terminal 24VD 350
[Up to 128 input/output points]
8YT C block C 3.3 24V DC input specification
Maximum number of input/output points (including I/O points of extension blocks and the main
HCA2C-8X 8 24VD 8 Relay Terminal 24VD 350
unit) is 128 points, up to max. 384 points when HC-LINK is used. Items 24V DC input specification
8YR C block C
[Powered extension units/blocks that can be connected] Main unit/ HCA2C input extension blocks HCA2C input
HCA2C Series input/output extension blocks can be connected. 2.2. I/O extension blocks extension blocks
Up to 7 HCA2C Series special function blocks can be connected. Model Input Output Connection I/O 5V DC 3. Generic specification and safety precautions Input circuit
[Program memory] Name Points Type Points Type type occupi power 3.1 Generic specification configuration
The PLC has a 8K EEPROM memory. ed supply
Items Specification
[Operation instructions] points capacity
Ambient 0 to 55°C when operating and -25 to 75°C when stored
Various instructions, such as floating-point and character string processing instructions and HCA8C-4E 4 24VD 4 Relay Terminal 8 40
temperature
scaling instructions, are provided. X4EYR C block
[Built-in RUN/STOP switch] Vibration Frequency Acceleration Half amplitude Sweep
HCA8C-4E 4 24VD 4 Transistor Terminal 8 40
The PLC can be started and stopped with the built-in switch. resistance (Hz) (m/s2) (mm) Count
X4EYT C block
RUN and STOP commands can be given to the PLC through a general-purpose input terminal When 10 to 57 -- 0.035 for X, Y, Z:
HCA8C-8E 8 24VD -- -- Terminal 8 25 10
or peripheral device. installed 57 to 150 4.9 --
X C block
[Writing during RUN] on DIN rail times (80
HCA8C-8E -- -- 8 Relay Terminal 8 30 min. in
The programming software for personal computer enables you to modify the program while When -- 0.075
YR block each
the PLC is running. installed 9.8 -- Input signal 24V DC +20% -15% Ripple Voltage (p-p) 5% or less
HCA8C-8E -- -- 8 Transistor Terminal 8 30 directly direction)
[Built-in clock function] YT block voltage
2
The PLC has a clock function to control the time. Shock (147m/s Acceleration, Action time: 11ms, 3 times by half-sine pulse in each Input impedance Main unit X000 ~ X005 3.9kΩ
HCA8C-8E 8 24VD 8 Relay Terminal 16 60
[Programming tool] resistance direction X, Y, and Z X006, X007 3.3kΩ 4.3kΩ
X8EYR C block
Use a version of HCP-WORKS applicable to HCA2C. Noise resistance By noise simulator at noise voltage of 10,000Vp-p, noise width of 1µs, rise time of
[Remote debugging of program]
HCA8C-8E 8 24VD 8 Transistor Terminal 16 60 1ns and period of 30 to 100Hz HCA2C extension blocks 4.3kΩ
X8EYT C block Input signal Main unit X000 ~ X005 6mA/24V DC 5mA/24V DC
Programming software enables you to remotely transfer the program and monitor the PLC Dielectric 500V AC for one minute
HCA8C-16 16 24VD -- -- Terminal 16 30 current X006, X007 7mA/24V DC
operation through a modem connected to the RS-232C expansion board or RS-232C withstand
EX C block
communication special adapter. voltage HCA2C extension blocks 5mA/24V DC
1.2 Input/output high-speed processing function of main unit HCA8C-16 -- -- 16 Relay Terminal 16 50
Insulation 5MΩor more by 500V DC megger Input ON Main unit X000 ~ X005 3.5mA or 3.5mA or more
EYR block
[High-speed counter function] resistance sensitiv more
HCA8C-16 -- -- 16 Transistor Terminal 16 50
- 1-phase 60 kHz x 2 points, 10 kHz x 4 points Grounding Class D grounding (grounding resistance: 100Ωor less) <Common grounding with ity X006, X007 4.5mA or
- 2-phase 30 kHz x 2 points, 5 kHz x 1 point EYT block
a heavy electrical system is not allowed.> current more
[Pulse catch function] HCA8C-16 16 24VD -- -- Connector 16 30
Working Free from corrosive or flammable gas and excessive conductive dusts HCA2C extension blocks 3.5mA or
Signals with short ON width or OFF width can be captured without a complicated program. EX-C C
atmosphere more
Input terminal Signal ON/OFF width HCA8C-16 -- -- 16 Transistor Connector 16 50
Working altitude <2000m OFF 1.5mA or less 1.5mA or less
X000 to X001 5µs EYT-C
2.3 Terminal layout 3.2 Safety precautions Input response Approx. 10ms Approx. 10ms
X002, X005 50µs time
[Input interruption function (with delay function)] Main unit
Design Precautions Input signal form Sink input: No-voltage contact input/NPN open collector transistor
Interruption routines can be processed preferentially by external signals with a minimum ON Source input: No-voltage contact input/PNP open collector transistor
• Make sure to have the following safety circuits outside of the PLC to ensure safe system operation
or OFF width of 10 µs (X000, X001).
even during external power supply problems or PLC failure. Circuit insulation Photocoupler insulation
[Pulse output function]
Otherwise, malfunctions may cause serious accidents. Input operation Main unit Turning on the input will light the LED
Pulses of up to 100kHz, 2points can be output simultaneously (Y000-Y003).
1) Most importantly, have the following: an emergency stop circuit, a protection circuit, an interlock display HCA2C extension indicator lamp
Program can be easily created using the following instructions.
circuit for opposite movements (such as normal vs. reverse rotation), and an interlock circuit (to blocks
Instruction Description prevent damage to the equipment at the upper and lower positioning limits).
DSZR Mechanical zero return instruction with DOG search function 3.3.1 Input terminals
2) Note that when the PLC CPU detects an error, such as a watchdog timer error, during There are two optional connection methods (sink input/ source input) between input terminals
ABS Instruction to read the current value from a servo amplifier with self-diagnosis, all outputs are turned off. Also, when an error that cannot be detected by the PLC CPU and S/S terminal.
absolute position (ABS) detecting function occurs in an input/output control block, output control may be disabled. Instructions for connecting input devices:
DRVI Positioning (relative positioning) to specify the movement from the External circuits and mechanisms should be designed to ensure safe machinery operation in such a 1) In the case of no-voltage contact:
current position case. The input current of this PLC is 5 to 7 mA/24V DC. Use input devices applicable to this minute
DRVA Positioning (absolute positioning) to specify the target position 3) Note that when an error occurs in a relay, triac or transistor output device, the output could be held current.
based on an absolute value 0 either on or off.
2) In the case of input device with built-in series diode:
When lead switches with a series LED are used, up to two switches can be connected in
DPLSV Instruction to change the pulse train output frequency For output signals that may lead to serious accidents, external circuits and mechanisms should be series.
DVIT Positioning for fixed-feed interruption drive designed to ensure safe machinery operation in such a case.
1.3 Communication and network functions
An expansion board, special adapter or special function block for each communication
function can be connected. Design Precautions
[Kinds of communication functions]
• Do not bundle the control line together with or lay it close to the main circuit or power line. As a
• Programming communication through RS485C, RS422
guideline, lay the control line at least 100mm (3.94") or more away from the main circuit or power line.
• Parallel link
Noise may cause malfunctions.
• Computer link Power supply terminal RS485
• Install module so that excessive force will not be applied to peripheral device connectors, power
• No-protocol communication through RS-232C/ RS485
connectors or input/output connectors.
• Inverter communication
Failure to do so may result in wire damage/breakage or PLC failure.
1.4 Analog functions
[Types of analog functions]
• Voltage/current input
• Voltage/current output Wiring Precautions
• Temperature sensor input (thermocouple, Pt100, Pt1000) •Make sure to cut off all phases of the power supply externally before attempting installation 3.3.2 Input circuit
• Temperature control or wiring work. The primary and secondary circuits for input are insulated with a photocoupler, and the
1.5 Interpretation of model names (Main unit, I/O extension blocks) Failure to do so may cause electric shock or damage to the product. second circuit is provided with a C-R filter.
• Make sure to attach the terminal cover, offered as an accessory, before turning on the The C-R filter is designed to prevent malfunctions caused by chattering of the input contact
power or initiating operation after installation or wiring work. and noise from the input line.
2.4 Part names
Failure to do so may cause electric shock. X000 to X007 have digital filters, and the filter time can be changed in increments of 1ms in
• Make sure to properly wire theHCA2C Series extension equipment in accordance with the the range from 0 to 60ms through applied instructions. When 0 is specified for the time, the
following precautions. input filter values are set as shown in the following table.
Failure to do so may cause electric shock, a short-circuit, wire breakage, or damage to the Input number Input filter value when 0 is specified
product. X000 to X001 5 µs*1
- The disposal size of the cable end should follow the dimensions described in this manual.
X002, X007 50 µs
- Tightening torque should be between 0.5 and 0.8 N•m.
*1 When setting the input filter to 5µs or capturing pulses of a response frequency of 50 to
• Make sure to properly wire to the European terminal board in accordance with the following
100kHz with a high-speed counter, wire the terminals as stated below.
precautions.
- The wiring length should be 5m or less.
Failure to do so may cause electric shock, a short-circuit, wire breakage, or damage to the
2. List of products - Connect a bleeder resistance of 1.5kΩ(1W or more) to the input terminal, so that the sum of
product.
the load current of the open collector transistor output on the mating device and the input
1
current of the main body is 20mA or more. is turned on (or off) is 5 µs or less. Output circuit diagram can be driven directly.
3.3.3 Input sensitivity (1) Output terminals 4. Troubleshooting with LEDs
When trouble occurs, check the LEDs on the PLC to identify the problem with the PLC.
The Main units input current and input sensitivity are shown in the following table. 4 or 8 transistor output points are covered by one common terminal.
4.1 POW LED [on/flashing/off]
When DC diodes or resistors are provided at input contacts or when parallel resistors or Two COM terminals connected each other inside the PLC are provided for sink outputs in the
State of State of PLC Remedies
leakage current are present at input contacts, perform wiring in accordance with this user’s HCA2C-8X8YT main unit, transistor output type extension blocks for output. HCA2C. For
LED
manual. external wiring, connect two COM terminals outside the PLC so that the load applied on each
COM terminal becomes smaller. On Power of the specified voltage The power supply is normal.
Items X000 to X001 X002, X007
is being correctly supplied to
Input voltage 24V DC +20% -15% Ripple Voltage (p-p) 5% or less
External power supply 30V DC or less or 250V AC or less the power supply terminal.
Input current 6mA 7mA
Resistance HCA8C-16EYT 2A/1 point Make sure that the total load current Flashing One of the following problems • Check the supply voltage.
Input sensitivity ON 3.5mA or more 4.5mA or more may have occurred. • After disconnecting the cables
current OFF 1.5mA or less 1.5mA or less load of 16 resistance load points is 8A or
less • Power of the specified other than the power cable, reapply
3.4 Output specification voltage and current is not power to the PLC, and check for
• Transistor output specification being supplied to the power changes in the state. If no
Items Specification supply terminal. improvement is obtained, consult
Output circuit configuration • External wiring is incorrect. your local HCFA distributor.

Max. load
HCA8C-8ER 2A/1 point The total resistance load current per • Internal error of PLC
HCA8C-16EYR common should be as follows:
Off One of the following problems • If the power is not off, check the
4 output points/common: 8A
may have occurred. power supply and the power supply
(2) External power supply 8 output points/common: 8A
• The power supply is off. route.
For driving the load, use a smoothing power supply of 5 to30V DC that can output current two • External wiring is incorrect. If power is being supplied correctly,
or more times the rated current of the fuse connected to the load circuit.
• Power of the specified consult your local
(3) Circuit insulation Inductive HCA8C-16EYT 80VA For the product life, refer to this
The internal circuit of the PLC and the output transistor are insulated with a photocoupler. voltage is not being supplied to HCFA distributor.
External power supply 5 to 30V DC load HCA8C-8ER manual. the power supply terminal.
The common blocks are separated from one another.
Resistance Main Y000 to 0.3A/1 Make sure that the total load current (4) Display of operation HCA8C-16EYR • The power cable is broken.
load unit Y001 point of 16 resistance load points is 1.6A or The main unit does not have operation indicator LEDs, but the operation can be monitored Minimum load 5V DC, 2mA (reference values)
Y002 to 0.1A/1 less with the display module. Operation indicator LEDs are built into the output extension blocks,
4.2 ERR LED [on/flashing/off]
Open circuit leakage current --
Y007 point and turn ON when photocouplers are actuated. State State of PLC Remedies
Response time OFF→ON Approx. 10 ms
HCA8C-16EYT, 0.1A/1 point (5) Response time of
The time from when the PLC drives (or shuts down) the photocoupler until the transistor is ON→OFF Approx. 10 ms
HCA8C-32EYT LED
turned on (or off) is shown in the following table. Circuit insulation Mechanical insulation On A watchdog 1) Stop the PLC, and re-apply power.
HCA8C-16EYT-C 0.3A/1 point Make sure that the total load Display of output operation Supplying power to the relay coil will light the LED
Classification Response Load current timer error may If ERR LED goes off, a watchdog timer error may have
current of 16 resistance load indicator lamp on panel.
time have occurred, occurred. Take any of the following measures.
points is 1.6A or less. (1) Product life of relay contacts
Main Y000~Y001 5 µs or less 5 to 24V DC When using an instruction or the hardware - Review the program
HCA8C-8EYT 0.5A/1 point The total load current of The standard life of contacts used for Inductive loads, such as contactors and solenoid valves,
unit Y002~Y007 10mA or related to pulse train output of the PLC may The maximum value (D8012) of the scan time should not
HCA8C-16EYT resistance loads per common is 500,000 operations at 20VA.
more or positioning, make sure to The following table shows the approximate life of a relay based on the results of an operation be damaged. exceed the setting (D8000) of the watchdog timer.
HCA8C-16EYR terminal should be the following
set the load current to 10 to life test. - Check that the input used for input interruption or pulse
value.
100mA (5 to 24V DC) Test condition: 1 sec. ON/1 sec. OFF catch is not being abnormally turned on and off in one
4points/common: 0.8A
Extension blocks 0.2 ms or less 24V DC 100mA *1 Load capacity Contact life scan.
8points/common: 1.6A
*1 The transistor OFF time is longer under lighter loads. For example, under a load of 24V DC 20 VA 0.2A/100V AC 3,000,000 times - Check that the frequency of the pulse (duty of 50%) input
HCA8C-8EYTR 1A/1 point Make sure that the total load 40mA, the response time is approx. 0.3ms. When response performance is required under
current of 4 resistance load 0.1A/200V AC to the high-speed counter does not exceed the specified
light loads, provide a dummy resistor as shown below to increase the load current. range.
points is 2A or less. 35 VA 0.35A/100V AC 1,000,000 times
0.17A/200V AC - Add the WDT instructions.
Inductive Main Y000 to 7.2W/1 point Make sure that the total load of
Max. load

80 VA 0.8A/100V AC 200,000 times Add some WDT instructions to the program, and reset the
load unit Y001 (24V DC) 16 inductive load points is
watchdog timer several times in one scan.
Y002 to 2.4W/1 point 38.4W/24V DC or less. 0.4A/200V AC
(2) Output terminals - Change the setting of the watchdog timer.
Y007 (24V DC)
One common terminal is used for 4 or 8 relay output points. The common terminal blocks can Change the watchdog timer setting (D8000) in the
HCA8C-16EYT, 2.4W/1 point (24V DC)
drive loads of different circuit voltage systems. Use an external power supply of 30V DC or program so that the setting is larger than the maximum
HCA8C-32EYT less or 250VAC or less for loads. value of the scan time (D8012).
HCA8C-16EYT-C 7.2W/1 point (24V DC) When power is applied to the output relay coil, the LED is lit, and the output contact is turned 2) Remove the PLC and supply power to it from another
HCA8C-8EYT, 12W/1 point (24V DC) on. The response time of the output relay from when the power is applied to the coil until the power supply on a desk.
HCA8C-16EYT, output contact is turned on and from when the coil is shut off until the output contact is turned
(6) Output current If the ERR LED goes off, noise may have affected the
HCA8C-16EYR off is approx. 10ms.
The ON voltage of the output transistor is approx. 1.5V. When an inductive load is switched, connect a diode (for commutation) or a surge absorber in PLC.
HCA8C-8EYT-H 24W/1 point (24V DC) When driving a semiconductor element, carefully check the input voltage characteristics of Take the following measures.
parallel with this load.
Lamp load Main Y000 to 0.9W/1 point Make sure that the total load of the applied element. - Check the ground wiring, and reexamine the wiring route
unit Y001 (24V DC) 16 lamp load points is 4.8W/24V Model Output Limitation and installation location.
Y002 to 0.3W/1 point DC or less. current - Fit a noise filter onto the power supply line.
Y007 (24V DC) Main unit Y000 to Y001 0.3A/1 Make sure that the total load current of 3) If the ERR LED does not go off even after the
HCA8C-16EYT, 0.3W/1 point (24V DC) point*1 resistance loads per common terminal measures stated in (1) and (2) are taken, consult your
HCA8C-32EYT Y002 to Y007 0.1A/1 point (16points/common) is 1.6A so that local HCFA distributor.
HCA8C-16EYT-C 1W/1 point (24V DC) temperature rise is restrained Flash One of the Perform PLC diagnosis and program check with the
HCA8C-8EYT, 1.5W/1 point (24V DC) Extension HCA8C-16EYT 0.1A/1 point ing following errors programming tool.
HCA8C-16EYT, blocks HCA8C-32EYT has occurred in For the remedies, refer to Section "Judgment by Error
HCA8C-16EYR HCA8C-16EYT- 0.3A/1 point Make sure that the total load current of 16 the PLC. Codes and Representation of Error Codes".
HCA8C-8EYTR 3W/1 point (24V DC) C resistance load points is 1.6A or less • Parameter
Open circuit leakage current 0.1mA or less/30V DC HCA8C-8EYT 0.5A/1 point The total load current of resistance loads error
ON voltage 1.5V HCA8C-16EYT per common terminal should be the • Syntax error
OFF→ON Main Y000 to 5µs or less/10mA or more (5 to 24V DC) following value. • Ladder error
unit Y001 4points/common: 0.8A Off No errors that If the operations of the PLC are abnormal, perform PLC
(3) External power supply
Y002 to 0.2ms or less/100mA (24V DC) 8points/common: 1.6A stop the PLC diagnosis and program check with the programming tool.
Use an external power supply of 30V DC or less or 250VAC or less for loads.
Y007 HCA8C-8EYT- 1A/1 point Make sure that the total load current of 4 (4) Circuit insulation have occurred. An I/O error, Comms. error or Runtime error may have
Extension blocks H resistance load points is 2A or less. The PLC internal circuit and external load circuits are electrically insulated between the output occurred.
Response time

ON→OFF Main Y000 to 5µs or less/10mA or more (5 to 24V DC) *1. When using an instruction related to pulse train output or positioning, make sure to set the relay coil and contact. The common terminal blocks are separated from one another.
load current to 10 to 100mA (5 to 24V DC). (5) Display of operation
unit Y001 4.3 RUN LED
(7) Open circuit leakage current When power is applied to the output relay coil, the LED is lit, and the output contact is turned
Y002 to 0.2ms or less/100mA (24V DC) 0.1mA or less on.
Y007 When the RUN LED is on, Data link is being executed; When off, Data link is stopped.
(6) Response time
Extension blocks The response time of the output relay from when the power is applied to the coil until the
Circuit insulation Photocoupler insulation output contact is turned on and from when the coil is shut off until the output contact is turned
off is approx. 10ms. 5. RS-485 communication
Output operation Main unit Monitored by the display module • Relay output specification (7) Output current
display 1> Wiring
Extension blocks LED on panel lights when photocoupler is driven. Items Relay output specification At a circuit voltage of 250V AC or less, a resistance load of 2A per point or an inductive load of
4 or 8 transistor output points are covered by one common terminal. For driving the load, use 80VA or less (100V AC or 200V AC) or the lamp load of 100W or less (100V AC or 200V AC) HCFA’s new product, HCA2C has built-in RS-485 on one channel (half-duplex, two-pair
a smoothing power supply of 5 to 30V DC that can output current two or more times the rated can be driven. wiring).
current of the fuse connected to the load circuit. When an inductive load is switched, connect a diode (for commutation) or a surge absorber in
The internal circuit of the PLC and the output transistor are insulated with a photocoupler. The parallel with this load. 2> Non-Protocol Communication
common blocks are separated from one another. Operation indicator LEDs are built into the DC Circuit Diode (for commutation) Non-programming Communication function contains N:N network, Parallel Link, Computer
main unit and output extension blocks, and turn ON when photocouplers are actuated. The AC Circuit Surge absorber
(8) Open circuit leakage current Link, Non-Protocol Communication (RS, RS2 instruction) and MODBUS master-slave
response time from when the PLC drives (or shuts down) the photocoupler until the transistor
Because there is no leakage current even while output contacts are OFF, the neon ball, etc. protocol.
2
Make sure if the devices of communication format (D8120, D8400, D8420), N:N network
(D8176~D8180) and parallel link (M8070, M8071) are used in the sequence control program.
If the devices are used, communication cannot be executed normally.
3> Communication setting in the sequence program
Set the communication format using a sequence program. The tables below show the setting
details.
•Communication format setting by RS instruction
.
D8120 (communication format)
This device can set the data length, parity, baud rate, etc.
The table below shows the contents of the communication format setting.

Bit Name Contents

No. 0 (bit = OFF) 1 (bit = ON)
b0 Data length 7-bit 8-bit
b1 Parity b2, b1
b2 (0, 0): Not provided
(0, 1): Odd
(1, 1): Even
b3 Stop bit 1-bit 2-bit
b4 Baud rate b7, b6, b5, b4 b7, b6, b5, b4 b7, b6, b5, b4
b5 (bps) (0, 0, 1, 1): 300 (0, 1, 1, 1): 4800 (1, 0, 1, 1): 57600
b6 (0, 1, 0, 0): 600 (1, 0, 0, 0): 9600 (1, 1, 0, 0): 115200
b7 (0, 1, 0, 1): 1200 (1, 0, 0, 1): 19200
(0, 1, 1, 0): 2400 (1, 0, 1, 0): 38400*1

b8 Header Not provided Provided (D8124) Initial value: STX (02H)

b9 Terminator Not provided Provided (D8125) Initial value: ETX (03H)
b10 Control line Non-protocol b11, b10
b11 (0, 0): Not provided <RS-232C interface>
(0, 1): Standard mode <RS-232C interface>
(1, 0): Interlink mode <RS-232C interface>
(1, 1): Modem mode
<RS-232C interface, RS-485/RS-422
interface*3>
Computer link b11, b10
(0, 0): RS-485/RS-422 interface
(1, 0): RS-232C interface
b12 Not applicable
b13*2 Sum check Not added Added
b14*2 Protocol Not used Used
b15*2 Control Format 1 Format 4
procedure

*1 Make sure to set as "0" when using non-protocol communication.

*2 When using the RS-485/RS-422 interface, only HCA8 and HCA8C PLCs are applicable.
Communication settings are shown below.

Data length 7-bit

Parity Even
Stop bit 1-bit
Baud rate (bps) 9600bps
Protocol Non-protocol
Header Not provided
Terminator Not provided
Control line Modem mode

4> If 485 communication is needed between the PLC and computer, unscrew the back and
make the jumper change from DE to GND.

6. Reverse voltage absorption function in output

HCA2C-8X8YT is equipped with the reverse voltage absorption function in the output. If you
want to use it, connect the power supply line to ‘24V-P’ point, then to ‘Y’ point.

Manual number:
DOC-HCFA-HCA
2C
Manual version: V1.0
Date: Apr.1st, 2015