Sysmac Cpm1a-20car-a User manual

SYSMAC

CPM1A-20CAR-A

CPM1A-32CAR-A

ProgrammableControllers

Operation Manual

Catalog No.P12FAZ1

About thisManual:

The CPM1Aisacompact, high-speed ProgrammableController (PLC)designed forcontroloperationsin

systemsrequiring from10 to 100 I/OpointsperPLC.There arethree manualsdescribing the setup and

operation of the CPM1A: the CPM1AwithACInputsOperation Manual(P12FAZ1), the CPM1AOperation

Manual(W317)and the CQM1/CPM1/CPM1A/SRM1Programming Manual(W228).

Thismanualdescribesthe systemconfiguration and installation of the CPM1AwithACInputsand pro-

videsa basicexplanation ofoperating proceduresforthe Programming Consoles. It alsointroducesthe

capabilitiesof the SYSMACSupportSoftware(SSS).Read thismanualfirst to acquaintyourselfwiththe

CPM1AwithACInputs.

The CQM1/CPM1/CPM1A/SRM1Programming Manual(W228)providesdetailed descriptionsof the

CPM1A’sprogramming functions.The SYSMACSupportSoftwareOperation Manuals:Basics and C-se-

riesPLCs(W247 and W248)provide descriptionsofSSS operationsforthe CPM1Aand otherSYSMAC

C-seriesPLCs.The SYSMAC-CPTSupportSoftwareQuick StartGuide (W332)and UserManual

(W333)provide descriptionsofladderdiagramoperationsinthe Windowsenvironment.

Pleaseread thismanualcarefullyand be sureyou understand the information provide before attempting

toinstall and operatethe CPM1A.

Section 1givesa briefoverviewof the stepsinvolved in developing ofaCPM1A System,describesthe

possiblesystemconfigurations,and describesthe CPM1A’s specialfeaturesand functions.

Section 2providesthe technicalspecificationsof the Unitsthatgo togethertocreate a CPM1A PLCand

describesthe maincomponentsof the Units.

Section 3describeshowtoinstall and wireaCPM1A PLC.

Section 4describesSSS capabilities,howtoconnect the Programming Console,and howto performthe

variousProgramming Console operations.

Section 5describeshowto performatestrun and howto diagnose and correct the hardware and soft-

ware errorsthatcan occurduring PLCoperation.

AppendixAprovidestablesofCPM1AUnitsand related products.

AppendixBprovidesthe dimensionsofCPM1AUnits.

WARNINGFailuretoread and understand the information provided inthismanualmayresultin

personal injuryordeath,damage tothe product, orproduct failure.Pleaseread each

section initsentiretyand be sureyou understand the information provided inthe section

and related sectionsbefore attempting anyof the proceduresoroperationsgiven.

iii

Notice:

OMRONproductsaremanufactured foruse according to properproceduresbya qualified operator

and onlyforthe purposesdescribed inthismanual.

The following conventionsare used toindicate and classifyprecautionsinthismanual.Always heed

the information provided withthem.Failureto heed precautions can resultininjuryto people ordam-

age tothe product.

DANGERIndicatesinformation that, ifnotheeded,islikelytoresultinloss oflife orserious

injury.

WARNINGIndicatesinformation that, ifnotheeded,could possiblyresultinloss oflife or

seriousinjury.

Caution Indicatesinformation that, ifnotheeded,couldresultinrelatively seriousormi-

norinjury,damage tothe product, orfaultyoperation.

OMRONProductReferences

All OMRONproductsarecapitalized inthismanual.The word“Unit”isalsocapitalized when itrefers

toanOMRONproduct, regardless ofwhetherornotitappearsinthe propername of the product.

The abbreviation “Ch,”which appearsinsome displays and on someOMRONproducts,often means

“word”and isabbreviated “Wd”in documentation inthis sense.

The acronymPLCmeansProgrammableController.However,please note:withinsoftware

programming references,you will see the acronymPC(used toindicatePLC).

Forexample:PCSetup (asused withinthe software program) referstoPLCSetup.

VisualAids

The following headingsappearinthe left column of the manualto helpyou locate different typesof

information.

NoteIndicatesinformation ofparticularinterest forefficientand convenientoperation

of the product.

1,2,3... 1. Indicateslistsofone sortoranother,such asprocedures,checklists,etc.

All rightsreserved. No partofthispublication may bereproduced, storedinaretrievalsystem, ortransmitted, inany

form, orby any means,mechanical,electronic, photocopying, recording, orotherwise,without thepriorwritten permis-

sion ofOMRON.

No patent liabilityisassumedwithrespect totheuseoftheinformation contained herein. Moreover, becauseOMRON is

constantlystriving toimproveitshigh-quality products,theinformation containedinthismanual is subject tochange

withoutnotice.Every precaution hasbeentakeninthepreparation ofthismanual.Nevertheless,OMRON assumesno

responsibilityforerrorsoromissions.Neitherisany liabilityassumedfordamagesresulting from theuseoftheinforma-

tion containedinthispublication.

TABLE OFCONTENTS

PRECAUTIONSxi.................................

1IntendedAudience xii.........................................................

2GeneralPrecautionsxii........................................................

3SafetyPrecautionsxii.........................................................

4Operating EnvironmentPrecautionsxii............................................

5Application Precautionsxiii.....................................................

6ECDirectivesxvi.............................................................

SECTION1

Introduction1....................................

1-1CPM1AFeaturesand Functions2...........................................

1-1-1CPM1AFeatures2................................................

1-1-2I/OTerminaland IR Bit Allocation 3..................................

1-1-3CPM1AFunctions4...............................................

1-2SystemConfiguration 8...................................................

1-2-1CPU Unit and Expansion I/OModuleConfiguration 8.....................

1-2-2HostLink Communications9........................................

1-2-3 1-to-1CommunicationsLinks11......................................

1-2-4NT Link Communications12.........................................

1-2-5PeripheralDevice Connections12.....................................

SECTION2

UnitSpecificationsand Components15.................

2-1Specifications16.........................................................

2-1-1GeneralSpecifications16............................................

2-1-2Characteristics17..................................................

2-1-3I/OSpecifications19...............................................

2-1-4CommunicationsAdapterSpecifications23..............................

2-2Unit Components24......................................................

2-2-1CPU Unit Components24...........................................

2-2-2Expansion I/OModuleComponents26.................................

2-2-3CommunicationsAdapterComponents27...............................

SECTION3

Installationand Wiring 29...........................

3-1Design Precautions30.....................................................

3-1-1PowerSupplyWiring 30.............................................

3-1-2Interlockand Limit Circuits30.......................................

3-1-3PowerSupplyVoltage30............................................

3-1-4CPM1APower Interruptions30.......................................

3-2Selecting anInstallation Site31..............................................

3-2-1Installation SiteConditions31........................................

3-2-2Panel/CabinetInstallation 32.........................................

3-3Installing theCPM1A33...................................................

3-3-1CPM1A Orientation 33.............................................

3-3-2CPM1AInstallation 33.............................................

3-3-3Connecting anExpansion I/OModule35...............................

3-4Wiring and Connections36.................................................

3-4-1GeneralPrecautionsforWiring 36.....................................

3-4-2Ground Wiring 38.................................................

3-4-3PowerSupplyWiring 38.............................................

3-4-4InputWiring 40...................................................

3-4-5OutputWiring 43..................................................

3-4-6PeripheralDevice Connection 45......................................

3-4-7HostLink Connections45...........................................

3-4-8One-to-onePLC Connections48......................................

3-4-9NT Link Connections49............................................

SECTION4

UsingPeripheralDevices51..........................

4-1SupportSoftwareCapabilities52.............................................

4-1-1SSS SystemSetup 52...............................................

4-1-2CPM1ARestrictionsand Precautions52................................

4-1-3OfflineOperations53...............................................

4-1-4OnlineOperations55...............................................

4-1-5Offline and OnlineOperations56......................................

4-2Using aProgramming Console57............................................

4-2-1CompatibleProgramming Consoles57.................................

4-2-2Connecting theProgramming Console58...............................

4-2-3Preparation forOperation 59.........................................

4-2-4Entering thePassword 59............................................

4-2-5Changing theCPM1A’sMode60......................................

4-3Programming ConsoleOperations61..........................................

4-3-1Overview61......................................................

4-3-2Clearing Memory 62...............................................

4-3-3Reading/Clearing ErrorMessages63...................................

4-3-4BuzzerOperation 63...............................................

4-3-5Setting and Reading aProgramMemoryAddress 64.......................

4-3-6Instruction Search 64...............................................

4-3-7Bit Operand Search 65..............................................

4-3-8Inserting and Deleting Instructions65..................................

4-3-9Entering orEditing Programs67......................................

4-3-10 Checking theProgram70............................................

4-3-11 Bit,Digit,WordMonitor70..........................................

4-3-12 Differentiation Monitor72...........................................

4-3-13 BinaryMonitor73.................................................

4-3-14 3-WordMonitor73................................................

4-3-15 SignedDecimalMonitor74..........................................

4-3-16 UnsignedDecimalMonitor74........................................

4-3-17 3-WordDataModification 75.........................................

4-3-18 Changing Timer,CounterSV75.......................................

4-3-19 Hexadecimal,BCD DataModification 76...............................

4-3-20 BinaryDataModification 77.........................................

4-3-21 SignedDecimalDataModification 78..................................

4-3-22 UnsignedDecimalDataModification 78................................

4-3-23 Force Set,Reset79.................................................

4-3-24 ClearForce Set/Reset79............................................

4-3-25 Hex-ASCII DisplayChange80........................................

4-3-26 Displaying theCycleTime80........................................

4-4Programming Example81..................................................

iii

4-4-1PreparatoryOperations81...........................................

4-4-2ExampleProgram82...............................................

4-4-3Programming Procedures83..........................................

4-4-4Checking theProgram85............................................

4-4-5TestRun inMONITORMode86......................................

SECTION5

TestRunsand ErrorProcessing 87.....................

5-1InitialSystemChecksand TestRun Procedure88................................

5-1-1InitialSystemChecks88............................................

5-1-2CPM1ATestRun Procedure88.......................................

5-1-3FlashMemoryPrecautions89........................................

5-2TheCPM1ACycle90.....................................................

5-3Self-diagnosisFunctions91.................................................

5-3-1Non-fatalErrors91.................................................

5-3-2FatalErrors91....................................................

5-3-3Identifying Errors92...............................................

5-3-4User-definedErrors92..............................................

5-4Programming ConsoleOperation Errors93.....................................

5-5Programming Errors93....................................................

5-6Troubleshooting Flowcharts95..............................................

5-7Maintenance Inspections103................................................

5-8Handling Precautions104...................................................

Appendices

AStandardModels105.........................................................

BDimensions107.............................................................

Glossary 111........................................

Index 127..........................................

RevisionHistory 131.................................

PRECAUTIONS

This section provides general precautions for using the Programmable Controller (PLC) and related devices.

Theinformationcontained inthissection isimportantfor thesafeand reliableapplicationofthePLC.Youmustread

this section and understand the information contained before attempting to set up or operate a PLC system.

1 Intended Audience xii...........................................................

2 General Precautions xii..........................................................

3 Safety Precautions xii...........................................................

4 Operating Environment Precautions xii.............................................

5 Application Precautions xiii.......................................................

6 EC Directives xvi...............................................................

6EC Directives

xii

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, andbe sure to providethe

systems, machines, and equipment with double safety mechanisms.

This manual provides information for programming and operating OMRON

PLCs. Be sure to read this manual before attempting to use the software and

keep this manual close at hand for reference during operation.

WARNING It is extremely important that a PLC and all PLC 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 PLC System to the abovementioned

applications.

3 Safety Precautions

WARNING Never attempttodisassembleany Unitswhilepoweris beingsupplied. Doingso

may result in serious electrical shock or electrocution.

WARNING Never touch any of the terminals while power is being supplied. Doing so may

result in serious electrical shock or electrocution.

WARNING The PLC system is provided as “open equipment.” There are live terminals

which must be enclosed to provide the appropriate level of protection from the

risk of electric shock.

4 Operating Environment Precautions

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 theresultofsevere changesintempera-

ture.

5Application Precautions

xiii

•Locations subject to corrosive or flammable gases.

•Locations subject to dust (especially iron dust) or salts.

•Locations subject to shock or vibration.

•Locations subject to exposure to water, oil, or chemicals.

•Take appropriate and sufficient countermeasures when installing systems in

the 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 of the PLC System can have a large effect on the

longevity and reliability of the system. Improper operating environments can

lead to malfunction, failure, and other unforeseeable problems with the PLC

System. Be sure that the operating environment is within the specified condi-

tions at installation and remains within the specified conditions during the life of

the system.

5 Application Precautions

Observe the following precautions when using the PLC.

WARNING Failure to abide by the following precautions could lead to serious or possibly

fatal injury. Always heed these precautions.

•Always ground the system to 100 Ωor less when installing the system to pro-

tect against electrical shock.

•Always turn off the power supply to the PLC before attempting any of the fol-

lowing. Performing any of the following with the power supply turned on may

lead to electrical shock:

•Mounting or removing any Units.

•Assembling any Unit.

•Connecting or disconnecting any cables or wiring.

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.

Caution Tighten the screws on the terminal block of the AC Power Supply Unit to the

torque specified in this manual. The loose screws may result in short-circuit,

malfunction, or burning.

Caution Always clear memory before beginning to program the CPM1A. Although

memory is cleared before the CPU Unit is shipped (except for bits with specific

functions),AR1314, whichturnsONwhentheinternalcapacitorcannotbackup

memory, may have turned ON during shipment.

Caution If the CPM1A will be turned off for periods exceeding the data backup period of

theinternal capacitor,design thesystemso thatit willnotbe influencedif datain

the DM, HR, and CNT areas is cleared when power is turned off.

Caution EitherswitchtheCPM1AtoRUNorMONITORmode,orturnoffandonpowerto

the CPM1A after changing from a Programming Device any data that is backed

up in flash memory. This data includes the user program, read-only DM area

(DM 6144 to DM 6599), and the PC Setup (DM 6600 to DM 6655).

6EC Directives

xiv

•The user program and memory area data in the CPM1A are backed up either

by an internal capacitor or in flash memory as shown in the following table.

Backup method Data

Internal capacitor Read/write DM area (DM 0000 to DM 0999, DM 1022, and

DM 1023)

Error log area (DM 1000 to DM 1021)

HR area (HR 00 to HR 19)

Counter area (CNT 000 to CNT 127)

Flash memory User program

Read-only DM area (DM 6144 to DM 6599)

PC Setup (DM 6600 to DM 6655)

Note 1. The IR, TR, LR, and timer areas are not normally backed up when power is

turned off and all contents will be cleared the next time power is turned on.

(ThePC SetupsettinginDM6601canbeusedtobackupthisdata. Referto

details on the PC Setup later in this manual for details.)

2. The bits in the AR and SR areas have special functions and are set accord-

ing to these functions when power is turned on.

•The capacitor backup time depends on the ambient temperature, as shown in

the following graph. The backup time, however, assumes that the capacitor is

fully charged, which requires that power be supplied to the CPU Unit continu-

ously for at least 15 minutes.

Backup time (days)

Ambient temperature (_C)

125 40 80

If the power remains off for a period exceeding the data backup period,

AR 1314 will turn ON to indicate that the capacitor can no longer back up data

and the data backed up by the capacitor will be cleared. AR 1314 will remain

ON unless it is turned OFF using I/O monitor operations, using memory clear

operations, or from the user program.

If desired, the PC Setup setting in DM 6604 can be set to create a fatal error

and thus stop the system when AR 1314 goes ON.

•The data stored in flash memory will not be lost even if power remains off for a

period exceeding the data backup period, because the data stored in flash

memory will be read to the CPU Unit when the CPM1A is turned on.

•If the poweris turned off without changing the mode from PROGRAM mode to

RUNorMONITORmodeafterhavingmadechanges inthedatathatis backed

up inflash memory, thechanges will not bewritten to flash memory. Ifthe pow-

er is then left off for more than 20 days (at 25_C), the changes (i.e., the con-

tents of the RAM) will be erased and the data values will become undefined.

5Application Precautions

Caution Failure to abide by the followingprecautions could leadto faulty operation orthe

PLC or the system or could damage the PLC or PLC Units. Always heed these

precautions.

•UsetheUnitsonly withthepowersupplies andvoltages specifiedintheopera-

tion manuals.

•Take appropriate measures to ensure that the specified power with the rated

voltage and frequency is supplied, particularly inplaces where the powersup-

ply is unstable.

•Provide circuit breakers and other safety measures to provide protection

against shorts in external wiring.

•Do not apply voltages exceeding the rated input voltage to input sections.

•Do not apply voltages exceeding the maximum switching capacity to output

sections.

•Always disconnect the LG terminal when performing withstand voltage tests.

•Alwaysconnecttoaclass-3ground(to100Ωorless)wheninstallingtheUnits.

•Always turn the power supply to the PLC off before attempting any of the fol-

lowing:

•Mounting or dismounting I/O Modules, CPU Units, Memory Cassettes, or

any other Units.

•Assembling the Units.

•Setting the DIP switch or rotary switch.

•Connecting or wiring the cables.

•Connecting or disconnecting the connectors.

•Do not attempt to take any Units apart, to repair any Units, or to modify any

Units in any way.

•Be sure that all the mounting screws, terminal screws, and cable connector

screws are tightened to the torque specified in this manual.

•BesuretoattachlabelssuppliedwiththeCPM1AontotheCPM1Awhenwiring

in order to prevent wiring cuttings from entering in the Unit.

•Removethelabelsafterthecompletionofwiringtoensureproperheatdissipa-

tion.

•Use either crimp terminals or single-wire lines for wiring. Do not connect bare

stranded wires directly to terminals.

•Double-check all the wiring before turning on the power supply.

•Be sure to check polarity and directions when connecting terminal blocks or

connectors.

•Be sure that the terminal blocks, Memory Units, expansion cables, and other

items with locking devices are properly locked into place.

•Check the user program for proper execution before actually running it on the

Unit.

•Be sure to confirm that no adverse effect will occur in the equipment before

changing the operation mode of the PLC.

•Be sure to confirm that no adverse effect will occur in the equipment before

executing forced set/reset.

•Be sure to confirm that no adverse effect will occur in the equipment before

changing the set values or present values.

•Be sure to resume operation only after transferring to the replaced CPU Unit

the contents ofthe data memory or holdrelay required for resuming operation.

•Never pull on, bend to extreme angles, or place heavy objects on cables.

•Install all Units according to instructions in the operation manuals.

6EC Directives

xvi

Caution Thefollowingprecautionsarenecessarytoensurethegeneralsafetyofthesys-

tem. Always heed these precautions.

•Fail-safe measures must be taken by the customer to ensure safety in the

eventof incorrect,missing,orabnormalsignals causedby brokensignallines,

momentary power interruptions, or other causes.

•The interlock circuits, limit circuits, and similar safety measures must be pro-

vided by the customer for external circuits (i.e., not in the Programmable Con-

troller).

Caution Do not touch the Expansion I/O Module Connecting Cable while the power is

being supplied in order to prevent any malfunction due to static electricity.

6 EC Directives

•For the DC Power Supply to be used for transistor output on expansion mod-

ules, use the power supply with double insulation or reinforced insulation to

conform to the EC Directives (Low-voltage Directives).

•TheseCPM1Aunitsconformtothecommonemissionstandards(EN50081-2)

of the EMC Directives: CPM1A-jjCAR-A, CPM1A-jjCDjj-D,

CPM1A-jjEDjj, and CPM1A-MA001.

SECTION1

Introduction

ThissectiondescribestheCPM1A’sspecialfeaturesandfunctionsandshowsthepossiblesystemconfigurations.Refertothe

Programming Manual(W228) fordetailson programming actualoperation.