Omron CPM2C User manual

CPM2C Programmable Controllers
Operation Manual
Produced June 1999

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
About this Manual:
The CPM2C is a compact, high-speed Programmable Controller (PC) designed for control operations in
systems requiring from 10 to 120 I/O points per PC. There are two manuals describing the setup and
operation of the CPM2C: The
CPM2C Operation Manual (this manual) and the CPM1/CPM1A/CPM2A/
CPM2C/SRM1(-V2) Programming Manual
(W353). (The CPM1/CPM1A/CPM2A/CPM2C/SRM1(-V2)
Programming Manual
is referred to as simply the Programming Manual in this manual.)
This manual describes the system configuration and installation of the CPM2C and provides a basic
explanation of operating procedures for the Programming Consoles. It also introduces the capabilities of
the SYSMAC Support Software (SSS) and SYSMAC-CPT Support Software. Read this manual first to
acquaint yourself with the CPM2C.
The
Programming Manual (W353) provides detailed descriptions of the CPM2C’s programming func-
tions. The
SYSMAC Support Software Operation Manuals: Basics and C-series PCs (W247 and W248)
providedescriptionsofSSSoperations for theCPM2CandotherSYSMACC-series PCs.The
SYSMAC-
CPTSupportSoftwareQuickStartGuide
(W332)and UserManual (W333)providedescriptionsofladder
diagram operations in the Windows environment.
Pleasereadthismanualcarefullyandbesureyouunderstandtheinformationprovidedbeforeattempting
to install and operate the CPM2C.
Section 1
gives a brief overview of the steps involved in developing of a CPM2C System, describes the
possible system configurations, and describes the CPM2C’s special features and functions.
Section 2
provides the technical specifications of the Units that go together to create a CPM2C PC and
describes the main components of the Units.
Section 3
describes how to install and wire a CPM2C PC.
Section4
describesSYSMACandSYSMAC-CPTSupportSoftwarecapabilities,howtoconnectthePro-
gramming Console, and how to perform the various programming operations.
Section 5
describes how to perform a test run and how to diagnose and correct the hardware and soft-
ware errors that can occur during PC operation.
Appendix A
provides tables of CPM2C Units and related products.
Appendix B
provides the dimensions of CPM2C Units.
WARNING Failure to read and understand the information provided in this manual may result in
personal injury or death, damage to the product, or product failure. Please read each
section in its entirety and be sure you understand the informationprovided inthe section
and related sections before attempting any of the procedures or operations given.
!

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3
 

1 Intended Audience
This manual is intended for the following personnel, who must also have knowl-
edge of electrical systems (an electrical engineer or the equivalent).
•Personnel in charge of installing FA systems.
•Personnel in charge of designing FA systems.
•Personnel in charge of managing FA systems and facilities.
2 General Precautions
The user must operate the product according to the performance specifications
described in the operation manuals.
Beforeusingtheproductunderconditionswhicharenotdescribedinthemanual
or applying the product to nuclear control systems, railroad systems, aviation
systems, vehicles, combustion systems, medical equipment, amusement ma-
chines, safety equipment, and other systems, machines, and equipment that
may have a serious influence on lives and property if used improperly, consult
your OMRON representative.
Make sure that the ratings and performance characteristics of the product are
sufficient for the systems,machines, and equipment, and be sureto provide the
systems, machines, and equipment with double safety mechanisms.
This manual provides information for programming and operating the Unit. Be
sure to read this manual before attempting to use the Unit and keep this manual
close at hand for reference during operation.
WARNING It is extremely important that a PC and all PC Units be used for the specified
purpose and under the specified conditions, especially in applications that can
directly or indirectly affect human life. You must consult with your OMRON
representative before applying a PC System to the above-mentioned
applications.
3 Safety Precautions
WARNING Donotattemptto takeany Unitapartwhilethepowerisbeingsupplied.Doingso
may result in electric shock.
WARNING Do not touch any of the terminals or terminal blocks while the power is being
supplied. Doing so may result in electric shock.
WARNING Do not attempt todisassemble, repair, or modify any Units. Any attempt to do so
may result in malfunction, fire, or electric shock.
WARNING Provide safety measures in external circuits (i.e., not in the Programmable
Controller), including the followingitems, inorder to ensure safety in the system
if an abnormality occurs due to malfunction of the PC or another external factor
affecting the PC operation. Not doing so may result in serious accidents.
•Emergency stop circuits, interlock circuits, limit circuits, and similar safety
measures must be provided in external control circuits.
•The PC will turn OFF all outputs when its self-diagnosis function detects any
erroror whena severefailurealarm (FALS)instructionisexecuted.Asacoun-
termeasure for such errors, external safety measures must be provided to en-
sure safety in the system.

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5
 

•The PC outputs may remain ON or OFF due to deposition or burning of the
output relays or destruction of the output transistors. As a countermeasure for
suchproblems,externalsafety measuresmustbeprovidedtoensuresafetyin
the system.
WARNING When handling the Memory Backup Battery, never drop, disassemble, distort,
short-circuit, recharge, heat to a temperature exceeding 100°C, or throw into
fire. Otherwise the Battery may explode, catch fire, or leak fluid.
WARNING When transferring programs to other nodes, or when making changes to I/O
memory, confirm the safety of thedestination node before transfer.Not doing so
may result in injury.
Caution Execute online edit only after confirming that no adverse effects will be caused
by extending the cycle time. Otherwise, the input signals may not be readable.
4 Operating Environment Precautions
Caution Do not operate the control system in the following places:
•Locations subject to direct sunlight.
•Locations subject to temperatures or humidity outside the range specified in
the specifications.
•Locationssubjecttocondensationas theresultofseverechangesintempera-
ture.
•Locations subject to corrosive or flammable gases.
•Locations subject to dust (especially iron dust) or salts.
•Locations subject to exposure to water, oil, or chemicals.
•Locations subject to shock or vibration.
Caution Takeappropriateandsufficientcountermeasures when installingsystemsinthe
following locations:
•Locations subject to static electricity or other forms of noise.
•Locations subject to strong electromagnetic fields.
•Locations subject to possible exposure to radioactivity.
•Locations close to power supplies.
Caution The operating environment ofthe PC System can have a large effect on the lon-
gevityandreliabilityof thesystem.Improperoperatingenvironments canleadto
malfunction, failure, and other unforeseeable problems with the PC System. Be
sure that the operating environment is within the specified conditions at installa-
tion and remains within the specified conditions during the life of the system.
5 Application Precautions
Observe the following precautions when using the PC System.
WARNING Always heed these precautions. Failure to abide by the following precautions
could lead to serious or possibly fatal injury.
•Always connect to a ground such that the grounding resistance does not ex-
ceed 100 Ωwhen installing the Units. Not connecting to the correct ground
may result in electric shock.

!
5
 

•Always turn OFF the power supply to the PC before attempting any of the fol-
lowing. Not turning OFF the power supply may result in malfunction or electric
shock.
•Assembling the Units.
•Connecting or disconnecting the Expansion I/O Units
•Connecting or wiring the cables.
•Connecting or disconnecting the connectors.
•Setting DIP switches.
•Replacing the battery
Caution Failure to abide by thefollowing precautions could lead to faulty operation of the
PC or thesystem, or could damagethe PC or PC Units. Always heed thesepre-
cautions.
•Fail-safe measures must be taken by the customer to ensure safety in the
eventofincorrect,missing, or abnormalsignals causedbybroken signallines,
momentary power interruptions, or other causes.
•Emergency stop circuits, interlock circuits, limit circuits, and similar safety
measures must be provided in external control circuits.
•Construct a control circuit so that power supply for the I/O circuits does not
come ON before power supply for the Unit. If power supply for the I/O circuits
comes ON before power supply for the Unit, normal operation may be tempo-
rarily interrupted.
•IftheoperatingmodeischangedfromRUNorMONITORmodetoPROGRAM
mode, with the IOM Hold Bit ON, the output will hold the most recent status. In
such a case, ensure that the external load does not exceed specifications. (If
operation is stopped because of an operation error (including FALS instruc-
tions), the values in the internal memory of the CPU Unit will be saved, but the
outputs will all turn OFF.)
•For models with only the super-capacitor installed, the contents of the READ/
WRITE enable area of the DM area, HR area, AR area, and CNT data area
may be damaged if the power is turned OFF for a long time. To prevent such
damage, provide ladder program that will check AR 1314 in order to ensure
proper operation of the system.
•The life of relays largely varies depending on switching conditions. Be sure to
testoperatingconditionsusingactualUnitsandusetheproductwithinthespe-
cifiednumberofswitchingssoasnottocauseanyperformance problems.Us-
ing the product with performance problems may result in defective insulation
between circuits or burning of the relays.
•Install the Units properly so that they will not fall off.
•Be sure that all the mounting screws, terminal screws, and cable connector
screws are tightened to the torque specified in therelevant manuals. Incorrect
tightening torque may result in malfunction.
•Be sure that the terminal blocks, Memory Units, expansion cables, and other
items with locking devices are properly locked into place. Improper locking
may result in malfunction.
•Be sure that terminal blocks and connectors are connected in the specified di-
rection with the correct polarity. Not doing so may result in malfunction.
•Use the Unit with the battery housing cover in place to prevent dust or foreign
matter from entering inside the Unit. Not doing so may result in malfunction.
•Install the Expansion I/O Unit connector cover to thelast Expansion I/O Unitto
prevent dust or foreign matter from entering inside the Unit. Not doing so may
result in malfunction.

5 

•Be sure to attach the labels supplied with the CPM2C or provide other protec-
tivecoverswhenwiringinordertopreventdustorwiringcuttingsfromentering
the Unit.
•Remove the label after the completion of wiring to ensure proper heat dissipa-
tion. Leaving the label attached may result in malfunction.
•Be sure to perform wiring in accordance with the CPM2C Operation Manual.
Incorrect wiring may result in burning.
•Use specified connectors and wiring materials (connector models:
C500-CE241/C500-CE242/C500-CE243; terminal block models: AWG24-12
with stripped length of 7 mm).
•Donotapplyvoltagestotheinputterminalsinexcessoftheratedinputvoltage.
Excess voltages may result in burning.
•Do not apply voltages or connect loads to the output terminals in excess of the
maximum switching capacity. Excess voltage or loads may result in burning.
•Install external breakers and take other safety measures against short-circuit-
inginexternalwiring.Insufficientsafetymeasures againstshort-circuitingmay
result in burning.
•Always use the power supply voltage specified in the operation manuals. An
incorrect voltage may result in malfunction or burning.
•Check the user program for proper execution before actually running it on the
Unit. Not checking the program may result in an unexpected operation.
•Double-check all wiring and switch settings before turning ON the power sup-
ply. Incorrect wiring or switch settings may result in burning.
•Confirmthatnoadverseeffectwilloccurinthesystembeforeattemptinganyof
the following. Not doing so may result in an unexpected operation.
•Changing the operating mode of the PC.
•Force-setting/force-resetting any bit in memory.
•Changing the present value of any word or any set value in memory.
•Before touching the Unit, be sure to first touch a grounded metallic object in
ordertodischargeanystatic built-up.Not doingsomayresultinmalfunctionor
damage.
•Do not pull on the cables or bend the cables beyond their natural limit. Doing
either of these may break the cables.
•Do not apply forces exceeding 50 N  m to connector sections.
•Do not place objects on top of the cables. Doing so may break the cables.
•Resume operation only after transferring to the new CPU Unit the contents of
theDMandHRAreasrequiredforresumingoperation.Notdoingsomayresult
in an unexpected operation.
•InstalltheUnitproperlyasspecifiedintheoperationmanual.Improperinstalla-
tion of the Unit may result in malfunction.
•When transporting the Units, use special packing boxes. Be careful not to ap-
plyexcessivevibrationorshockduringtransportationandnottodroptheprod-
uct.
•Store the Units within the following temperature and humidity ranges:
Storage temperature: --20°Cto75°C, storage humidity: 10 to 90% (with no ic-
ing or condensation)

6 

6 EC Directives
6-1 Applicable Directives
•EMC Directives
•Low Voltage Directive
6-2 Concepts
EMC Directives
OMRON devices that comply with EC Directives also conform to the related
EMC standards so that they can be more easily built into other devices or the
overall machine. Theactual products have been checked for conformity to EMC
standards (see the following note). Whether the products conform to the stan-
dards in the system used by the customer, however, must be checked by the
customer.
EMC-related performance of the OMRON devices that comply with EC Direc-
tives will vary dependingon theconfiguration, wiring, and otherconditions of the
equipmentorcontrolpanelonwhichtheOMRONdevicesareinstalled.Thecus-
tomer must, therefore, perform the final check to confirm that devices and the
overall machine conform to EMC standards.
Note Applicable EMC (Electromagnetic Compatibility) standards are as follows:
EMS (Electromagnetic Susceptibility): EN61131-2
EMI (Electromagnetic Interference): EN50081-2
(Radiated emission: 10-m regulations)
Low Voltage Directive
Always ensure that devices operating at voltages of 50 to 1,000 VAC and 75 to
1,500 VDC meet the required safety standards for the PC (EN61131-2).
6-3 Conformance to EC Directives
The CPM2C PCs comply with EC Directives. To ensure that the machine or de-
vice in which the CPM2C PC is used complies with EC Directives, the PC must
be installed as follows:
1, 2, 3... 1. The CPM2C PC must be installed within a control panel.
2. Reinforced insulation or double insulation must be used for the DC power
supplies used for the communications and I/O power supplies.
3. CPM2C PCs complying with EC Directives also conform to the Common
Emission Standard (EN50081-2). Radiated emission characteristics (10-m
regulations) may vary depending on the configuration of the control panel
used, other devices connected to the control panel, wiring, and other condi-
tions. You must therefore confirm that the overall machine or equipment
complies with EC Directives.
6-4 Relay Output Noise Reduction Methods
The CPM2C PCs conform to the Common Emission Standards (EN50081-2) of
the EMCDirectives. However,the noise generated whenthe PC is switched ON
or OFF using the relay output may not satisfy these standards. In such a case, a
noise filter mustbe connectedto theload sideorother appropriatecountermea-
sures must be provided external to the PC.
Countermeasures taken to satisfy the standards vary depending on the devices
on the load side, wiring, configuration of machines, etc. Following are examples
of countermeasures for reducing the generated noise.

6 

Countermeasures (Refer to EN50081-2 for more details.)
Countermeasures are not required if the frequency of load switching for the
whole system with the PC included is less than 5 times per minute.
Countermeasures are required if the frequency of load switching for the whole
system with the PC included is 5 times or more per minute.
Countermeasure Examples
Whenswitchinganinductiveload,connectasurgeprotector,diodes,etc.,inpar-
allel with the load or contact as shown below.
Circuit Current Characteristic Required element
AC DC
CR method
Power
supply
Inductive load
Yes Yes If the load is a relay or solenoid, there
is a time lag between the moment the
circuit is opened and the moment the
load is reset.
If the supply voltage is 24 to 48 V,
insert the surge protector in parallel
with the load. If the supply voltage is
100 to 200 V, insert the surge
protector between the contacts.
The capacitance of the capacitor must
be1to0.5µF per contact current of
1 A and resistance of the resistor must
be 0.5 to 1 Ωper contact voltage of
1 V. These values, however, vary with
the load and the characteristics of the
relay. Decide these values from
experiments, and take into
consideration that the capacitance
suppresses spark discharge when the
contacts are separated and the
resistance limits the current that flows
into the load when the circuit is closed
again.
The dielectric strength of the capacitor
must be 200 to 300 V. If the circuit is
an AC circuit, use a capacitor with no
polarity.
Diode method
Power
supply
Inductive load
No Yes The diode connected in parallel with
the load changes energy accumulated
by the coil into a current, which then
flows into the coil so that the current
will be converted into Joule heat by
the resistance of the inductive load.
This time lag, between the moment
the circuit is opened and the moment
the load is reset, caused by this
method is longer than that caused by
the CR method.
The reversed dielectric strength value
of the diode must be at least 10 times
as large as the circuit voltage value.
The forward current of the diode must
be the same as or larger than the load
current.
The reversed dielectric strength value
of the diode may be two to three times
larger than the supply voltage if the
surge protector is applied to electronic
circuits with low circuit voltages.
Varistor method
Power
supply
Inductive load
Yes Yes The varistor method prevents the
imposition of high voltage between the
contacts by using the constant voltage
characteristic of the varistor. There is
time lag between the moment the
circuit is opened and the moment the
load is reset.
If the supply voltage is 24 to 48 V,
insert the varistor in parallel with the
load. If the supply voltage is 100 to
200 V, insert the varistor between the
contacts.
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1-1Section   
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1-1 CPM2C Features and Functions
1-1-1 CPM2C Features
The CPM2C PCs incorporate a variety of features in a compact Unit, including
synchronizedpulsecontrol,interruptinputs,pulse outputs,anda clockfunction.
The CPM2C CPU Unit is a stand-alone Unit that can handle a broad range of
machine control applications and it is small enough to be incorporated as the
control unit in almost any free-standing machine.
The full complement ofcommunications functions provide communications with
personal computers, other OMRON PCs, and OMRON Programmable Termi-
nals.Thesecommunicationscapabilitiesallowtheusertodesignalow-costdis-
tributed production system.
The two communications ports (peripheral and
RS-232C) can be used simultaneously.
The peripheral port supports Programming Devices,
Host Link, and no-protocol communications.
The RS-232C port supports Host Link, no-protocol
(serial), 1:1 Link, and 1:1 NT Link communications.
CPU Units with 10 I/O points (relay or transistor
outputs) or 20 I/O points (transistor outputs only)
are available. Expansion I/O Units can be con-
nected to increase capacity to 140 I/O points.
Basic Functions
TheCPM2CPCsareone-piecePCswith10or 20I/OpointsinI/O terminalsora
connector port. in the built-in connectors. There are 3 types of outputs available
(relay outputs, sinking transistor outputs, and sourcing transistor outputs). All
CPM2C PCs require a 24-VDC power supply.
Up to 5 Expansion I/O Units can be connected to the CPU Unit to increase the
PC’s I/O capacity to a maximum of 140 I/O points. There are 2 types of Expan-
sion I/O Units available: one with 24 I/O points and the other with 10 I/O points.
The maximum I/O capacity of 140 I/O points is achieved by connecting five
24-point Expansion I/O Units to a CPU Unit with 20 built-in I/O points.
The same Programming Devices, such as Programming Consoles and Support
Software, can be used for the C200H, C200HS, C200HX/HG/HE, CQM1,
CPM1, CPM1A, CPM2A, and SRM1(-V2) PCs, so existing ladder program re-
sources can be used effectively.
CPU Unit Variations
Expansion I/O Units
Share Programming
Devices

1-1Section   

Built-in Motor Control Capability
Synchronized pulse control provides an easy way to synchronize the operation
of a peripheral piece of equipment with the main equipment. The output pulse
frequency can be controlled as some multiple of the input pulse frequency, al-
lowingthespeedofaperipheralpieceofequipment(suchas asupplyconveyor)
to be synchronized with the speed of the main piece of equipment.
Encoder
CPM2C
Motor driver Motor
Pulses are output as a fixed multiple of the input frequency.
The CPM2C has a two kinds of high-speed counter inputs. The high-speed
counter input hasa response frequency of 20kHz/5 kHz andthe interrupt inputs
(in counter mode) have a response frequency of 2 kHz.
The single high-speed counter can be used in any one of the four input modes:
differential phase mode (5 kHz), pulse plus direction input mode (20 kHz), up/
down pulse mode (20 kHz), or increment mode (20 kHz). Interrupts can be trig-
gered when the count matches a set value or falls within a specified range.
The interrupt inputs (counter mode) can be used for incrementing counters or
decrementing counters (2 kHz) and trigger an interrupt (executing the interrupt
program) when the count matches the target value. Four interrupt inputs can be
used in the 20-point CPU Units and two interrupt inputs can be used in the
10-point CPU Units.
CPM2C PCs with transistor outputs have two outputs that can produce 10 Hz to
10 kHz pulses (single-phase outputs).
When used as single-phase pulse outputs, there can be two outputs with a fre-
quency range of 10 Hz to 10 kHz with a fixed duty ratio or 0.1 to 999.9Hz with a
variable duty ratio (0 to 100% duty ratio).
When used as pulse plus direction or up/down pulse outputs, there can be just
one output with a frequency range of 10 Hz to 10 kHz.
High-speed Input Capabilities for Machine Control
The 20-point CPU Units have 4 inputs that can be used as interrupt inputs and
the10-pointCPUUnitshave2inputsthatcanbeused asinterruptinputs.These
inputs are shared with quick-response inputs and interrupt inputs in counter
mode and have a minimum input signal width of 50 µs and response time of
0.3 ms. When an interrupt input goes ON, the main program is stopped and the
interrupt program is executed.
Regardless of the cycle time, the 20-point CPU Units have 4 inputs that can be
used as quick-response inputs and the 10-point CPU Units have 2 inputs that
can be used as quick-response inputs. These inputs are shared with interrupt
inputs and interrupt inputs in counter mode; they can reliably read input signals
with a signal width as short as 50 µs.
The input time constant for all inputs can be set to 1 ms, 2 ms, 3 ms, 5 ms,
10 ms,20 ms,40 ms,or 80 ms.The effects ofchatteringandexternalnoisecan
be reduced by increasing the input time constant.
Other Functions Theintervaltimercanbesetbetween0.5and319,968msandcanbesettogen-
erate just one interrupt (one-shot mode) or periodic interrupts (scheduled inter-
rupt mode).
Synchronized Pulse
Control
(Transistor Outputs Only)
High-speed Counters and
Interrupts
Easy Position Control
with Pulse Outputs
(Transistor Outputs Only)
High-speed Interrupt
Input Function
Quick-response Input
Function
Stabilizing Input Filter
Function
Interval Timer Interrupts

1-1Section   

InCPUUnitswithabuilt-inclock,theclock(accuracywithin1minute/month)can
bereadfromthe programtoshow thecurrentyear, month,day,dayof theweek,
andtime.Theclockcan besetfromaProgrammingDevice (suchasaProgram-
mingConsole)orthetimecanbeadjustedbyroundingupordowntothenearest
minute.
TIML(----) is a long-term timer that accommodates set values up to 99,990 sec-
onds (27 hours, 46 minutes, 30 seconds). When combined with the SECONDS
TO HOURS conversion instruction (HMS(----)), the long-term timer provides an
easy way to control equipment scheduling.
Complete Communications Capabilities
A Host Link connection can be made through the PC’s RS-232C port or Periph-
eral port. A personal computer or Programmable Terminal connected in Host
Link mode can be used for operations such as reading/writing data in the PC’s
I/O memory or reading/changing the PC’s operating mode.
1:1 Host Link Communications
CPM2C
1:N Host Link Communications
B500-AL004
Link Adapter
CPM2C
(Up to 32 PCs can be connected.)
NT-AL001
Commands
Responses
Commands
Responses
The TXD(48) and RXD(47) instructions can be used in no-protocol mode toex-
change data with standard serial devices. For example, data can be received
from a bar code reader or transmitted to a serial printer. The serial devices can
be connected to the RS-232C port or Peripheral port.
Inputting data from
a bar code reader
Bar code
reader
Outputting data to
a serial printer
Serial
printer
CPM2C CPM2C
In a 1:1 NT Link, an OMRON Programmable Terminal (PT) can be connected
directlytotheCPM2C.ThePTmustbeconnectedtotheRS-232Cport;itcannot
be connected to the Peripheral port.
OMRON PT CPM2C
Calendar/Clock
Long-term Timer
Host Link
No-protocol
Communications
High-speed 1:1 NT Link
Communications