Sysmac CPM1A-20CAR-A User manual

SYSMAC
CPM1A-20CAR-A
CPM1A-32CAR-A
ProgrammableControllers
Operation Manual
Catalog No.P12FAZ1

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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.
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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.
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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.

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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...............................

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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..................................................

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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.................................

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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...............................................................