CONTENTS PAGE

1. Introduction

What is a Control System ------------------------------------ 1-1

The Role of the Programmable Controllers
Input and Output Devices
What is a Programmable Controller
Conventional Control Panel and it's difficulties
Disadvantages of Conventional Control Panel
PLC Panel and their advantages
Conversion of Conventional Control Circuit to PLC
A Systematic Approach of control system Design
Programmable Controller Application
Consider A Simple Project
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2. System Configuration

CPM1A CPU Components ------------------------------------ 2-1

CPM2A CPU Components ------------------------------------ 2-3
Expansion I/O Units Components ------------------------------------ 2-6
CPU and Expansion I/O Unit Configuration ------------------------------------ 2-9
CPM1A- Communications
- Host Link Communication ------------------------------------ 2-11
- Multi-drop Communications to Computer ------------------------------------ 2-12
- 1 to 1 PLC Communication Links ------------------------------------ 2-14
- NT Link Communication ------------------------------------ 2-15
- Programming Example of 1:1 PLC Link Between 2 CPM1A Units ------------------------------------ 2-15
CPM2A- Communications
- Host Link Communication ------------------------------------ 2-16
- Multi-drop Communications to Computer ------------------------------------ 2-17
- No-Protocol Communication (RS-232C Communication) ------------------------------------ 2-18
- NT Link Communication ------------------------------------ 2-19
- 1 to 1 PLC Communication Links ------------------------------------ 2-19
- CompoBus/S I/O Link Connections ------------------------------------ 2-20
Peripheral Devices ------------------------------------ 2-21
Programming Console ------------------------------------ 2-21
Sysmac Window Based Support software ------------------------------------ 2-22
Training Kit Configuration ------------------------------------ 2-24
PLC Electrical Wiring I/O Connection ------------------------------------ 2-25

3. Features and Functions

CPM1A General ------------------------------------ 3-1

- Analog Setting Function ------------------------------------ 3-2
- Input Interrupt ------------------------------------ 3-3
- Quick Response Inputs Function ------------------------------------ 3-4
- Interval Timer Function ------------------------------------ 3-4
- High Speed Counter ------------------------------------ 3-5
CPM2A General ------------------------------------ 3-6
- Interrupt Functions ------------------------------------ 3-7
- Interrupt Inputs ------------------------------------ 3-8
- Interval Timer Interrupts ------------------------------------ 3-8
- High Speed Counter ------------------------------------ 3-9
- Interrupt Inputs (Counter Mode) ------------------------------------ 3-10
- Interrupt by High Speed Counter Inputs
(Count-check Interrupts) ------------------------------------ 3-10

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-Example of Input Interrupt in Counter Mode ------------------------------------ 3-11

- High Speed Counter ------------------------------------ 3-12
-Example of using High Speed Counter ------------------------------------ 3-12
- Pulse Output Function ------------------------------------ 3-13
- Synchronized Pulse Control ------------------------------------ 3-14
- Analog Controls ------------------------------------ 3-15
- Quick Response Inputs Function ------------------------------------ 3-15
- Marco Function ------------------------------------ 3-16

4. Unit Specifications and Components

CPM1A
General Specifications ------------------------------------ 4-1
Characteristics ------------------------------------ 4-2
Structure of Memory Area ------------------------------------ 4-3
I/O Terminal - IR Bit Allocation ------------------------------------ 4-4
CPM2A
General Specifications ------------------------------------ 4-5
Characteristics ------------------------------------ 4-6
Structure of Memory Area ------------------------------------ 4-8
I/O Terminal - IR Bit Allocation ------------------------------------ 4-9
Expansion Unit for CPM1A and CPM2A ------------------------------------ 4-9
Example of I/O Allocation for CPM2A ------------------------------------ 4-10
Programming Console ------------------------------------ 4-12
Password Input ------------------------------------ 4-14
Clearing all Program ------------------------------------ 4-15

5. Window Based Programming Software-SYSWIN

Programming of CPM1A and CPM2A ------------------------------------ 5-1

Programming Using SYSWIN Version 3.3
- Connection to the PC ------------------------------------ 5-1
- RS232C Connector Configuration ------------------------------------ 5-1
- Installing SYSWIN Program ------------------------------------ 5-2
- SYSWIN Window ------------------------------------ 5-3
- Start Up with SYSWIN ------------------------------------ 5-3
- Programming with SYSWIN ------------------------------------ 5-4
- Saving the Project ------------------------------------ 5-7
- Transfer Program to PLC ------------------------------------ 5-8

6. Application Examples of Basic Commands

Overview of Instructions ------------------------------------ 6-1

Application #1 : Self Holding Circuit ------------------------------------ 6-2
Application #2 : On Delay Circuit ------------------------------------ 6-19
Application #3 : Control Circuit for Packaging Machine ------------------------------------ 6-31
Application #4 : Drilling Control Operation ------------------------------------ 6-33
Application #5 : Filling/Draining Control Operation ------------------------------------ 6-37
Application #6 : Overhead Crane Control of Degreasing Operation ------------------------------------ 6-41
Application #7 : Parts Sorting ------------------------------------ 6-45
Application #8 : Robot Movement Control ------------------------------------ 6-47
Application #9 : A Simple Sequence Control Concept ------------------------------------ 6-51
Application #10: Automatic Control of Warehouse Door ------------------------------------ 6-58
Application #11: Automatic Lubrication of Gear ------------------------------------ 6-60
Application #12: Conveyor Belt Motor Control ------------------------------------ 6-62

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Application #13: Display Error Code of Machine to Aid ------------------------------------ 6-66

In The Tracing Source of The Problem
Application #14: Measuring the Life of a Cutting Knife ------------------------------------ 6-78
Application #15: Car Park Control ------------------------------------ 6-81

7. Useful Ladder Circuitry

1-Cycle Differentiation Circuit ------------------------------------ 7-1

Flicker Circuit ------------------------------------ 7-3
Single-shot Circuit ------------------------------------ 7-4
Long-time Timer Circuit ------------------------------------ 7-5
ON/OFF - Delay Circuit ------------------------------------ 7-6
Push-on/Push-off Circuit (Binary Circuit) ------------------------------------ 7-7
Scanning Counter ------------------------------------ 7-8
Concept of IL Instruction and JMP Instruction ------------------------------------ 7-9
First-in Priority Circuit ------------------------------------ 7-11
Last-in Input Priority Circuit ------------------------------------ 7-14
Non-Lock-in Annunciator ------------------------------------ 7-16
Lock-in Annunciator ------------------------------------ 7-19

8. Installation and Wiring Considerations

PLC Power Interruptions ------------------------------------ 8-1

Installation Site Considerations
Panel/Cabinet Installation Guide
General Precautions for Wiring
Power Supply Wiring
Countermeasures For Inductive Load
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9. Maintenance and Troubleshooting

The PLC Cycle ------------------------------------ 9-1
Self-diagnosis Functions ------------------------------------ 9-2
Non-fatal Errors ------------------------------------ 9-2
Fatal Errors ------------------------------------ 9-2
User-defined Errors ------------------------------------ 9-3
Programming Errors ------------------------------------ 9-4
Troubleshooting Flowcharts ------------------------------------ 9-6
Preventive Maintenance ------------------------------------ 9-7

10. Appendices (A-E)

Appendix A ------------------------------------ A-1

Appendix B ------------------------------------ B-1
Appendix C ------------------------------------ C-1
Appendix D ------------------------------------ D-1
Appendix E ------------------------------------ E-1