Omron SYSMAC C series User manual

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.