YOKOGAWA CP451-10

Description

1. Detailed parameter table

YOKOGAWA CP451-10

2. Product introduction

The YOKOGAWA CP451-10 is an advanced programmable logic controller designed to meet the demands of large-scale and complex industrial automation systems. Building on the foundation of the CP401 series, it offers enhanced processing power, expanded memory, and advanced communication capabilities, making it suitable for integrated automation environments where high performance and connectivity are paramount.

This controller delivers a processing speed of 0.08μs per basic instruction, significantly faster than the CP401-10, enabling it to handle more complex control logic and larger datasets. With 4MB of program memory (expandable to 16MB), it can accommodate extensive control programs and data logging requirements. The CP451-10 supports a wide range of industrial protocols and features gigabit Ethernet for high-speed data transfer, facilitating seamless integration with enterprise systems and IoT platforms. Ideal for industries such as automotive manufacturing, semiconductor production, and large-scale water treatment plants, the YOKOGAWA CP451-10 provides a powerful and flexible control solution to drive efficiency and productivity in modern industrial operations.

3. Core advantages and technical highlights

Superior processing performance:

With a processing speed of 0.08μs per basic instruction, the CP451-10 outperforms the CP401 series, making it capable of handling complex control algorithms and real-time data processing. In semiconductor wafer fabrication, this allows the PLC to manage multiple precision robots, process thousands of sensor inputs, and adjust process parameters in microseconds, ensuring the high accuracy required for manufacturing tiny semiconductor components. The faster processing also enables more frequent data sampling, which is critical for optimizing production processes and detecting anomalies early.

Expanded memory and scalability:

The CP451-10 comes with 4MB of program memory (expandable to 16MB) and supports up to 16384 I/O points, providing ample capacity for large-scale automation systems. In a large automotive assembly plant with multiple production lines, this means the PLC can control all processes—from welding and painting to final assembly—using a single controller. The expandable memory allows for the storage of extensive historical data, which can be analyzed later to identify trends and improve production efficiency. As the plant expands, additional I/O modules can be easily added without replacing the main controller, reducing costs and minimizing downtime.

High-speed communication capabilities:

Equipped with gigabit Ethernet, the CP451-10 enables fast and reliable data transfer between the PLC and other devices in the automation system, such as HMIs, SCADA systems, and cloud platforms. In a smart factory, this high-speed communication allows for real-time monitoring of production data, remote control of equipment, and seamless integration with enterprise resource planning (ERP) systems. For example, the PLC can send production data to the ERP system in real-time, enabling managers to make informed decisions about inventory management and production scheduling. The support for MQTT protocol also makes it easy to connect to IoT platforms, facilitating predictive maintenance and other advanced industrial applications.

Enhanced reliability and environmental resistance:

The CP451-10 features a rugged design with redundant power inputs as standard, ensuring uninterrupted operation even in the event of a power supply failure. Its operating temperature range of -5°C to 70°C allows it to function reliably in harsh industrial environments, such as foundries and steel mills, where temperatures can vary significantly. The PLC also has enhanced vibration and shock resistance, making it suitable for installation in mobile equipment or areas with high levels of mechanical stress. These reliability features minimize the risk of unplanned downtime, ensuring continuous production.

YOKOGAWA CP451-10

4. Typical application scenarios

In semiconductor manufacturing, the CP451-10 controls the entire wafer fabrication process, from deposition and etching to lithography. Its high processing speed ensures precise control of robotic arms that handle wafers, with microsecond accuracy to prevent damage to the delicate components. The PLC’s large memory capacity allows for storing detailed process recipes, which can be quickly recalled and modified as needed. Through gigabit Ethernet, it communicates with inspection systems to receive real-time data on wafer quality, enabling immediate adjustments to the manufacturing process to ensure high yields.

In large-scale water treatment plants, the CP451-10 manages the complex processes of water purification, including filtration, disinfection, and distribution. It controls a large number of pumps, valves, and sensors, monitoring parameters such as pH, turbidity, and chlorine levels. The PLC’s high-speed communication capabilities allow it to send data to a central SCADA system, enabling operators to monitor the entire plant from a single location. The expandable I/O capacity means the PLC can easily accommodate additional sensors and actuators as the plant expands, ensuring efficient and reliable water treatment.

In automotive manufacturing, the CP451-10 coordinates the operation of multiple production lines, including body welding, paint shop, and final assembly. It controls robotic welding arms with high precision, ensuring strong and consistent welds. The PLC’s ability to process large amounts of data quickly allows it to monitor the performance of each piece of equipment in real-time, detecting potential faults before they cause downtime. Through integration with the factory’s ERP system, it provides accurate production data, enabling managers to optimize production schedules and reduce costs.

5. Related model recommendations

• CP401-10: A cost-effective alternative with lower processing speed and memory capacity, suitable for small to medium-sized automation systems where the advanced features of the CP451-10are not required.
• CP451-20: A higher-performance variant with a processing speed of 0.05μs per basic instruction and support for up to 32768 I/O points, ideal for extremely large-scale automation systems.
• F3PU30-0N: A high-performance HMI panel that pairs with the CP451-10, offering a large touchscreen display and advanced visualization capabilities for monitoring and controlling complex automation processes.
• AVR10D-Q22020: A servo drive that integrates seamlessly with the CP451-10for precision motion control applications, such as robotic arms and conveyor systems.
• AIP830-111: An analog input module that expands the CP451-10‘s input capabilities, allowing it to monitor a wide range of analog signals from sensors in industrial processes.
• CP451-10-R: A ruggedized version of the CP451-10with enhanced environmental resistance, designed for use in extreme conditions such as offshore platforms and mining operations.

6. Installation, commissioning and maintenance instructions

Installation preparation

Before installing the CP451-10, ensure the mounting location has adequate ventilation with a minimum clearance of 200mm around the PLC. The ambient temperature should be within -5°C to 70°C, and the area should be protected from dust, moisture, and corrosive gases. Prepare tools such as a torque screwdriver (1.0-2.0Nm), wire strippers, and a network cable tester.

Verify that the power supply meets the 100-240V AC specification and install a dedicated 3A circuit breaker for overcurrent protection. Use shielded twisted-pair cables for all communication interfaces, grounding the shield at both ends to minimize electromagnetic interference. When mounting the PLC on a DIN rail, ensure it is securely fastened to prevent vibration-induced damage. For redundant power supply configuration, follow the manufacturer’s guidelines to ensure proper wiring and operation.

Maintenance suggestions

Perform monthly visual inspections of the CP451-10 to check for loose connections, dust accumulation, or signs of overheating. Clean the ventilation slots using compressed air every two months to maintain proper cooling, especially in dusty environments. Backup the program and configuration data weekly to prevent loss in case of memory failure.

Monitor the PLC’s status indicators daily to check for error codes or abnormal operation. Use YOKOGAWA’s programming software to run diagnostic tests monthly, checking for communication errors, memory issues, and I/O module malfunctions. If a fault occurs, refer to the error code manual for troubleshooting guidance. Common issues such as communication failures may require checking network settings or cable connections.

Replace the lithium backup battery every 4 years to ensure program retention during power outages. When replacing the CP451-10, transfer the program and configuration data to the new unit using the backup function to ensure consistent operation. Use only YOKOGAWA-approved replacement parts to maintain system reliability and warranty coverage.

7. Service and guarantee commitment

YOKOGAWA provides a 5-year warranty for the CP451-10, demonstrating confidence in its quality and reliability. Each unit undergoes rigorous testing, including temperature cycling, vibration testing, and electrical performance verification, to ensure compliance with international standards.

Our global technical support team offers 24/7 assistance for programming, troubleshooting, and system optimization. On-site service is available in major industrial regions, with a response time of 24 hours for critical issues. YOKOGAWA provides comprehensive training programs on the CP451-10‘s features and programming, helping customers maximize the performance of the PLC. We also offer extended warranty options and preventive maintenance services to ensure long-term reliability and minimize downtime. This commitment to customer support ensures that users of the YOKOGAWA CP451-10 can rely on it for efficient and reliable operation in their industrial automation systems.