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Cat.

No.

W83-E1-5

-|omron|

C20

Programmable

Controller

USER'S

MANUAL

Introduction

Features

This

user's

manual!

provides

all

the

information

you

need

to

install,

operate,

and

maintain

the

OMRON

SYSMAC-C20

Programmable

Controller,

which

can

be

used

for

a

wide

range

of

industrial

applications.

The

C20

is

OMRON’s

response

to

the

demand

for

a

low-cost,

versatile

industrial

control

system

that

can

be

quickly

installed

and

easily

operated

by

technicians

with

little

or

no

experience

with

programmable

controllers.

Improved

cost

effectiveness

All

functions

for

a

small-scale

control

system

are

integrated

in

a

single

housing.

The

C20

can

be

used

in

the

place

of

conventional

relay

control

panels

and

is

ideally

suited

for

economical

control

of

manufacturing

and

other

applications

which

require

fewer

input/output

control

points.

Slim

profile

for

convenient

mounting

The

C20's

compact

design

allows

it

to

be

installed

in

locations

where

space

is

at

a

premium.

Hardly

larger

than

a

standard

text

book,

the

C20

can

easily

be

mounted

either

horizontally

or

vertically

near

the

machinery

it

operates.

Choice

of

memory

chips

Either

RAM

or

EPROM

memory

chips

can

be

installed

in

the

C20.

RAM

offers

the

convenience

of

a

read/write

memory

for

control

programs

that

are

under

development

or

subject

to

modification;

EPROM

chips

can

be

used

for

“permanent”

storage

for

rarely

changed

programs

or

when

multiple

copies

are

needed

for

programs.

Optional

optical-fiber

communication

As

with

the

other

models

of

the

SYSMAC

C-Series

programmable

controllers,

I/O

linkage

can

be

accomplished

using

a

remote

I/O

master

unit

and

optical-fiber

cables.

This

state-of-the-art

technology

enables

noise-free

communications

over

long

distances

at

ultra-high

speeds.

Detachable

terminal

block

An

easily

removable

terminal

block

greatly

facilitates

wiring

the

I/O

lines

and

makes

maintenance

more

convenient.

Upwardly

compatible

peripheral

devices

The

programming

console,

printer

interface

unit,

and

PROM

writer

can

be

shared

with

all

programmable

controllers

in

the

SYSMAC

C-Series.

Moreover,

with

the

addition

of

a

peripheral

interface,

it

is

possible

to

program

and

operate

the

PC

through

a

portable

graphic

programming

console

(either

LCD

or

CRT)

as

well

as

a

multisupport

base

unit.

Introduction

About

this

manual

This

manual

was

designed,

written,

and

illustrated

to

be

highly

useful

to

people

at

ali

levels

of

understanding

and

experience

with

program-

mable

controllers,

including

the

first-time

user.

it

has

also

been

organized

and

indexed

to

allow

easy

access

to

specific

information.

The

only

special

knowledge

you

need

is

an

understanding

of

ladder

diagrams

using

the

familiar

symbols

adopted

for

conventional

relay-

based

industrial

systems.

Here's

what

you

will

find

in

the

following

chapters

and

appendixes:

Chapter

1

Programmable

controllers

in

general

and

the

C20

in

particular

are

introduced.

Each

part

of

the

C20

is

illustrated

and

explained,

and

different

system

configurations

are

presented.

Chapter

2

What

you

need

to

know

to

install

the

C20

is

explained,

including

important

environmental,

wiring,

mounting,

and

power

supply

considerations.

Chapter

3

You're

introduced

to

programming

and

the

eight

steps

used

to

create

a

PC

control

program.

This

chapter

focuses

on

the

first

three

—

assessing

the

controlied

operation,

assigning

input/output

points,

and

writing

relay

ladder

diagrams.

Chapters

4

and5

These

two

chapters

cover

using

the

programming

console

to

write

your

application

program

and

put

it

to

work

controlling

your

equipment

or

process

through

the

C20.

Chapter

6

Examples

are

given

which

show

you

in

simplified

form

some

of

the

numerous

control

applications

that

can

be

realized

by

the

C20.

Appendixes

The

many

peripheral

devices

available

to

expand

the

C20

system

and

provide

valuable

support

services

are

introduced.

Also

covered

are

the

basic

and

special

instructions

used

in

programming,

as

well

as

product

specifications

and

other

detailed

technical

information.

A

comprehensive

index

is

included

for

easy

reference

to

this

manual.

Contents

Chapter

1

Introduction

to

the

C20

1-1

Overview

4-1

PC

Basics

1-1

input/output

section

1-2

Central

processing

unit

1-2

Programming

device

1-2

About

the

SYSMAC-C20

1-2

€20

Components

1-2

CPU

1-4

Programming

console

1-5

Basic

system

configuration

Chapter

2

Installing

the

C20

2-1

Overview

2-1

But

first...

l

2-1

Static

electricity

2-1

Memory

chips

2-2

Installing

memory

chips

2-3

Testing

the

environment

2-3

Dealing

with

problems

of

noise

2-3

Control

panel

wiring

2-3

External

wiring

2-4

Noise-suppression

measures

2-4

Power

supply

2-4

Grounding

2-5

Control

panel

mounting

2-5

Mounting

dimensions

2-6

Power

supply

2-6

Grounding

2-7

Battery

2-7

Protections

against

power

failure

,

Chapter

3

Introduction

to

programming

J

3-1

Overview

3-1

Relay

ladder

diagram

method

3-1

Eight

basic

programming

steps

3-2

Step

1—Assessing

the

controlled

operation

3-2

input/output

requirements

3-2

Sequence,

timing,

and

relationship

assessment

3-3

Step

2—Assigning

I/Os

3-3

Points

and

channels

3-3

I/O

channe!

assignment

3-3

Assigning

internal

auxiliary

relays

3-4

Assigning

numbers

to

timers

and

counters

3-4

Step

3—Writing

a

relay

ladder

diagram

3-5

Step

4—Turning

the

ladder

diagram

into

PC

code

3-6

Sample

program

for

coding

practice

Contents

Chapter

4

Using

the

programming

console

4-1

Overview

4-1

The

keyboard

4-1

Numeric

keys

4-1

CLR

key

4-2

Operation

keys

4-2

Instruction

keys

4-3

Made

switch

4-3

Console

display

4-4

PROGRAM

mode

4-4

To

erase

existing

memory

4-5

Getting

started,

summarized

4-5

Exampie

program

4-6

Step

5—Entering

the

program

in

the

CPU

4-9

Deleting

instructions

4-9

Inserting

instructions

Chapter

5

Checking

and

running

your

program

5-1

Overview

5-1

Step

6—Editing

the

program

5-1

Quick-search

editing

functions

5-1

Going

directly

to

a

known

address

5-2

Searching

for

a

specific

instruction

5-3

NO

END

INSTRUCTION

message

5-3

Searching

relay

contacts

5-4

Search

function

summary

5-4

Address

search

5-4

Specific

instruction

search

5-4

Specific

contact

search

5-5

Step

7—Testing

for

errors

5-5

Status

check

5-5

Forced

set/reset

5-6

Forced

relay

set

5-6

Forced

relay

reset

5-7

Forced

timer

set

5-7

Changing

set

value

of

timer

or

counter

5-8

Input/Output

monitor

5-9

Rapid

check

of

counter/timer

values

5-9

Rapid

check

of

relay

status

5-10

Step

8—Saving

your

program

to

cassette

tape

5-12

Loading

and

verifying

the

program

5-12

Verifying

the

program

Chapter

6

Application

examples

6-1~

Overview

6-1

Automatic

control

of

warehouse

door

6-3

Automatic

lubricating

oil

supplier

6-4

Conveyor

belt

motor

control

6-6

Automatic

car

washing

machine

6-7

Bottle

label

detection

Contents

Appendix

A

Appendix

B

Appendix

C

Appendix

D

Appendix

E

Appendix

F

Appendix

G

Appendix

H

System

expansion

and

peripherals

A-1

Overview

A-2

Expansion

1/0

unit

A-3

1/0

link

unit

A-5

1/0

link

unit

wiring

A-6

Channel

and

end

station

setting

A-14

PROM

writer

A-14

Graphic

programming

console

A-17

Multisupport

base

A-18

Printer

interface

unit

A-19

Link

adapter

Instruction

words

B-1

Overview

B-10

Special

Instructions

Scan

time

C-1

Overview

C-3

Listof

instruction

execution

times

C-4

Sean

time

calculation

examples

Assignment

of

1/0

channel

and

relay

numbers

D-1

1/0

channel

assignment

D-1

Relay

assignment

Maintenance

and

troubleshooting

E-1

Overview

E-1

Inspection

E-4

Troubleshooting

Specifications

F-{

Overview

F-1

Available

types

F-3

Ratings

F-3

Characteristics

F-5

Input/Output

specifications

F-19

10

Sink

unit

F-20

Dimensions

Mounting

kit

G-1

Overview

List

of

instructions

H-1

Basic

instruction

H-2

Applied

instructions

Chapter

1

Introduction

to

the

C20

Overview

PC

Basics

This

introductory

chapter

explains

why

programmable

controllers

have

become

such

a

valuable

part

of

modernfactories.

The

SYSMAC-C20

is

described,

including

its

basic

components

and

operating

principles.

Programmable

controllers,

or

PCs,

evolved

as

industries

sought

econo-

mical

ways

to

automate

their

production

lines,

particularly

those

involved

in

the

manufacturing

of

equipment

and

other

heavy

industry

products.

The

PCs

took

the

place

of

relay-based

control

systems

which

were

comparatively

slower,

less

reliable,

and

which

presented

formidable

wiring

and

maintenance

requirements.

PCs

operate

by

monitoring

input

signals

from

such

sources

as

pushbut-

tons,

sensors,

and

limit

switches.

When

changes

are

detected

in

the

signais,

the

controller

system

reacts,

through

user-programmed

internal

logic,

to

produce

output

signals.

These

signals

operate

the

external

loads

of

the

controlled

system,

such

as

relays,

motor

controls,

indicator

lights,

and

ajarms.

This

type

of

control

system

eliminates

much

of

the

wiring

and

rewiring

that

was

necessary

with

the

conventional

relay-based

system.

Instead,

the

programmed

logic

provides

the

“wiring

network”

which

can

be

changed

as

required

by

simply

reprogramming

the

PC.

Thus

the

automated

processes

of

a

production

line

can

be

controlled

and

modified

at

will,

for

highly

economical

adaptability

to

a

changing

manufacturing

environ-

ment.

Atypical

programmable

controller

has

three

basic

components—an

input/output

section,

a

central

processing

unit

(CPU),

and

a

programming

device.

Input/output

section

This

section

consists

of

wiring

and

interfacing

relays

that

connect

the

PC

to

the

equipment

being

controlled.

Central

processing

unit

The

CPU

contains

the

control

circuitry

as

well

as

the

memory

that

stores

the

contro!

plan

that

guides

equipment

operation.

It

is

the

heart

of

the

PC

and

organizes

ail

controller

activity

by

scanning

the

control

plan

along

with

the

status

of

the

inputs

and

executes

specified

commands

to

specified

outputs.

Introduction

to

the

C20

About

the

SYSMAC-C20

C20

Components

CPU

Programming

device

This

device

is

used

to

enter

the

control

plan

into

the

CPU's

memory.

An

operator

keys

in

the

instructions

used

to

sequentially

contro!

the

application

process.

There

are

several

programming

methods;

in

the

case

of

the

SYSMAC

C-Series,

relay

ladder

diagram

prog

ramming

is

used

because

plant

personnel

are

familiar

with

that

format

and

it

provides

for

convenient

record-keeping.

The

C20

comes

in

two

versions,

a

basic

unit

and

an

expandable

unit.

The

capabilities

of

the

basic

unit

include

up

to

1194

program

statements,

28

I/O

points,

and

136

internai

auxiliary

relays.

The

expandable

unit

is

functionally

identicai

to

the

basic

unit

except

that

it

can

be

expanded

using

expansion

/O

units

to

include

up

to

140

I/O

points.

The

C20

offers

the

flexibility

of

either

RAM-

or

EPROM-based

operation.

When

a

RAM

chip

is

installed

as

the

memory,

programs

written

by

the

user

can

be

modified

and

rewritten.

EPROM

provides

a

semi-permanent

storage

for

completed

programs.

The

programming

console

can

be

detached

and

is

upwardly

compatible

with

the

full

line

of

SYSMAC

C-Series

programmabie

controllers.

Due

to

its

compact

design,

the

C20

incorporates

the

detachable

I/O

terminals

and

microprocessor

functions

in

a

single

housing

called

the

CPU.

The

detachable

programming

console

functions

as

the

program-

ming

device.

Additionally,

various

optional

peripheral

devices

are

available

to

support

system

expansion.

The

two

main

components

are

explained

and

illustrated

in

the

next

several

pages.

Central

processing

unit

The

CPU

is

the

main

enclosure

of

the

C20

incorporating

the

micro-

processor

and

I/O

terminals.

The

controlling

program

written

using

a

programming

device

is

stored

and

executed

in

the

CPU.

1

Console

screws

These

stud

screws

are

removed

with

a

flat-bladed

screwdriver

to

open

the

cover

for

initial

setting

and

maintenance

purposes.

2

Input

terminals

These

terminals

are

used

to

connect

the

wiring

carrying

input

signals

from

the

devices

of

the

controlled

system.

3

Input/output

indicators

These

LEDs

show

the

state

of

the

signals

(by

turning

red

when

ON

and

dark

when

OFF)

for

each

of

the

input

and

output

terminals.

4

LED

indicators

(POWER,

RUN,

ERROR/ALARM)

These

LEDs

light

up

to

show

the

state

of

the

main

power

supply

(ON/OFF),

when

the

C20

is

in

the

RUN

mode,

and

if

any

error

has

occurred.

5

Power

terminals

These

terminals

connect

the

AC

or

DC

power

source

and

are

grounded

at

a

resistance

of

less

than

100Q.

6

Output

terminals

These

terminals

are

used

to

connect

the

wiring

carrying

output

signals

from

the

CPU

to

the

output

devices.

7

Connector

for

expansion

1/0

units

This

is

available

only

on

the

expandable

type

CPU

and

is

used

to

connect

to

expansion

I/O

units

to

increase

the

number

of

I/O

points.

8

Connector

for

peripheral

devices

This

connects

the

programming

console

or

another

peripheral

device.

PC

Introduction

to

the

C20

Programming

console

This

is

the

standard

programming

device

used

with

the

C20.

The

control

programs

written

by

the

programming

console

are

stored

and

run

in

the

CPU.

PROIS

PROGRAMMING

CONSOLE

9

Mounting

screws

These

two

screws

secure

the

detachable

programming

console

to

the

CPU.

10

LCD

This

displays

the

program

as

it

is

being

written

and

is

used

for

checking

and

monitoring

program

operation.

It

also

displays

error

messages.

11

Contrast

control

The

contrast

control

adjusts

contrast

level

of

display.

12

Keypad

The

color-coded

keypad

is

functionally

divided

into

the

following

areas:

White

10

keys

used

to

input

program

addresses,

timing

values,

and

other

types

of

numeric

entry

Red

One

key

used

to

clear

the

display

Yellow

12

keys

used

to

provide

editing

functions

while

writing

and

correcting

the

control

program

Gray

16

keys

used

to

input

instruction

words

used

in

the

program

The

function

of

each

key

is

detailed

in

Chapter

4.

13

Mode

selector

switch

This

three-position

switch

selects

one

of

three

operation

modes

of

the

PC:

program,

monitor,

and

run.

These

modes

are

explained

in

detail

in

Chapters

4,

and

5.

14

Jacks

for

connecting

cassette

tape

recorder

Programs

may

be

saved

to

a

standard

cassette

tape

recorder

connected

to

the

output

(MIC)

jack.

Previously

written

programs

can

also

be

supplied

to

the

CPU

via

the

input

(EAR)

jack.

These

operations

are

explained

in

Chapter

5.