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C20 User's Manual

1. 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 Th
2. 3G2C7 CPUS4 E 3G2C7 MG223 3G2C7 MC224 3G2C7 MC227 3G2C7 MC228 3G2c7 mp211_ 3G2C7 MD212 3G2C7 MC22B 3G2C7 MC22C 3G2C7 MA221 3G2C7 MA222 V O link unit AC 100 to 240V No of inputs 16 No of outputs 16 1kg max 3G2C7 LK011 1 0 connecting Cable length 5cm adig mak 3G2C7 CN501 cable Cable length 32cm gmax 3G2C7 CN311 4 For sort of piggyback arrangement of CPU and expansion O unit with ir Mounting kit 3G2C7 CN311 3G2C7 PAT02 For nonexpandable CPU Optional RAM 3G2C7 CPU13 E CPU43 E CPU23 E CPU53 E CPU83 E 50g mae j RAMS EPROM For CPU 50gmax ROM H The RAM chip is mounted in the expandable type CPU i e Type 3G2C7 CPU14 E CPU44 E CPU74 E CPU24 E CPU54 E CPU84 E as the factory set condition for shipment Specifications Programming console horizontal type For SYSMAC C series programmable controllers 3G2A6 PRO15 E Programming consoie vertical type Programming consote 50cm for C20 only 3G2C7 CN512 connecting cable 1m for C20 only 3G2C7 CN122 For SYSMAC C series programmable controllers 3G2A5 PRO13 E Cassette tape recorder connecting cable PROM writer For SYSMAC C series programmable controllers 3G2A5 PRWO04 E For SYSMAC C series programmable controllers Printer X Y plotter connecting interface and memory cassette are separately available 1 5m SCY PLGO1 P
3. Introduction to programming Step 1 Assessing the controlled operation This of course is a highly important part of setting up a PC controlled system The PC s flexibility allows a wide latitude in not just what operations can be controlled but in how they will be controlled To apply a PC to any control task the system requirements must first be determined The major part of that assessment focuses on the input output requirements Input output requirements The first thing that must be assessed is the number of I Os that your system will require This is done by identifying each device that is to send an input signal to the PC or which is to receive a PC output signal These should be totaled and it should be remembered that the C20 when not expanded has 16 input and 12 output points In terms of voltages all the signals to the C20 must be 24 V DC inputs Because the programmable controller has three independent output blocks three output voltages are available through the common terminals 24 V DC and up to 250 V AC max Sequence timing and relationship assessment Next you need to determine the sequence and timing at which these controls will occur How each of the controlled devices relates to the others should be identified such as a photoelectric switch to a motor as well as what response should occur between them For instance a photoelectric switch might be functionally tied to a motor by
4. a Reset input i 4 4 Instruction words Ladder diagram Symbol Se R Ladder diagram 0001 0002 qH LATCHING RELAY KEEP Contents of data start channel and Coding shart end channel nos Output relay internal o5 yo 17 auxiliary relay Holding relay HRO to 9 When more than 16 bit shift register is needed If a shift register should need to exceed 16 bits a shift register circuit can be configured by combining two or more stages of 16 bit shift registers Coding chart Address Instruction Data 0200 is 0000 0201 _ LD oor 0203 SFT 10 COo Td o Od mn The circuit configuration shown above is of a 32 bit shift register from 1000 to 1115 The data for the SFT instruction must be input with the upper stage SFT data which are less than or equal to the lower stage SFT data and are within the same relay area Function Acts as latching relay Remarks This instruction can be used to create a latching relay which is used in the same manner as a relay circuit The latching relay operates when the content of the result register is logical 0 and the content of the stack register is logical 1 The relay releases when the content of the result register is logical 1 Instruction words The latching relay program must be entered in the order of a set input circuit a reset input circuit and a la
5. IN3 Signal name 8 0103 VO No av Terminal Signal name V No Input power supply Input power supply S44 Sg a BERA N TA FN TA r r Ye PA N N N SR rsd eal ON TN til Nol KS OUTS 0609 com COM Power supply for external device for relay driving Load power supply Load power supply Load power supply Note The input and output channels of MC227 with 16 input points 12 output points are fixed on chan nels 1 and 6 Those of MC228 with 32 input points 24 output points are fixed on channels 1 and 2 input and 6 and 7 output F 11 Specifications Expansion I 0 unit Type Input voltage 3G2C7 MD211 DC input NPN DC 24V 10 15 Transistor output Input impedance 3kQ Input current 7mA typ DC 24V ON delay time 20ms max 1 5ms max OFF delay time 20ms max 1 5ms max Number of circuits 16 points 8 points common 12 points 8 3 1 points common ON voltage DC 16V max OFF voltage DC 5V min Max switching capacity DC 5 to 24V 0 5A max Min switching capacity DC 5V 10mA min Leakage current 100A max Saturation voltage 1 5V max External power supply 15mA point 180mA unit Service life of relay G3SD Z01P PC DC 24V 1 5K Ar o RE PETET TE n E kee D 4 OUT 00 l noi z
6. Since the CPU s input channel is fixed to channel 00 and its output channel is fixed to channel 05 the new input and output channels provided by the expansion I O unit are numbered beginning from the channel next to the CPU s input output channel That is when a 28 or 26 point expansion O unit with one input and one output channel is connected to the CPU the new input channel is assigned as channel 01 and the new output channel is assigned as channel 06 Likewise if a 56 or 52 point expansion I O unit with two input and two output channels is connected the new input channels are assigned as channels 01 and 02 and the new output channels are assigned as channels 06 and 07 in addition to the load power supply a separate power supply is required to drive the C20 s output relays 1 0 link unit System configuration example T CPU rack YSBUS optical fiber cable C500 s remote O master unit Svon ue Pe 3G2A5 RMO01 E VO link unit 3G2C7 LKO11 SYSBUS optical fiber cable 800m max f Input 16 points ve a C20 CPU cals expansion pat Te pon SYSBUS optical iber cable m max The I O link unit makes possible state of the art optical fiber communica tion within a SYSBUS system employing a higher level PC such as the C120 or C500 one or more C20s and other C Series PCs Remote data communication between the C20s and other devices is co
7. Index Programming beginning 4 1 connecting blocks B 4 connecting blocks using OR instruction B 5 eight steps 3 1 example 4 6 introduction 3 1 problem with overwriting old program 4 4 summary on how to begin 4 5 PROM writer A 12 PROM restrictions A 15 Protective cover for end station A 9 Proximity switch using with C20 6 5 Pushbutton switch using with C20 6 6 Quick search editing functions 5 1 Rapid check of counter timer values 5 9 of relay status 5 9 Ratings F 3 Relation between special auxiliary relays and instructions D 4 between control tasks 3 2 Relay assignment D 1 coils setting and resetting all at once B 12 coils using IL and ILC to set and reset B 12 contacts how to search for specific one 5 3 Relay ladder diagramming method 1 2 3 1 3 4 Relay list by number D 2 Relay status 5 5 checking rapidly 5 9 Relay forced set reset 5 6 Relay outputting to B 1 Relays 1808 to 1907 5 7 Remote data communication A 3 Replacing defective parts E 4 Replacing battery E 3 Response time caiculation example C 6 meaning C 5 Restrictions on PROM writing A 15 Right bus bar 3 4 Robot arm 6 8 RUN mode function 4 3 Index Saving program to cassette tape 5 10 flowchart 5 11 Scan time basic instructions C 3 calculation examples C 4 definition D 4 diagram C 1 flowchart C 1 variations C 2 special instructions Search function summary 5 4 Searching for duplicated timer counter 5 3 for spec
8. OMRON TATEISI ELECTRONICS CO Control Components H Q 9th FI Osaka Center Bldg 4 68 Kitakyutaro Higashiku Osaka 541 Japan Phone 06 282 2703 Fax 06 282 2754 Telex 522 2484 OMRONO J OMRON ELECTRONICS INC 1 East Commerce Drive Schaumburg IL 60173 U S A Phone 312 843 7900 Fax 312 843 8568 TWX 910 291 0426 OMRONELEC SHBU OMRON ELECTRONICS G m b H Oberrather Strasse 6 D 4000 D sseldorf 30 West Germany Phone 0211 65020 Fax 0211 6502107 Telex 8581890 OMRON ELECTRONICS H K LTD Unit 1605 6 Silvercord Tower 2 30 Canton Road Tsimshatsui Kowloon Hong Kong Phone 3 7233827 PBX Fax 3 7231475 Telex 41092 OMRON HX OMRON SINGAPORE PTE LTD 1298 Lorong 1 Toa Payoh 02 01 Singapore 1231 Phone 2556988 Fax 65 250 8245 Telex RS23403 OMRON TAIWAN ELECTRONICS INC 6th FI China Trust Bldg N 0 122 Tunhua North Road Taipei Taiwan R O C Phone 02 715 3331 Fax 02 712 6712 OMRON ELECTRONICS PTY LTD Private Box No 12 Frenchs Forest Post Office Frenchs Forest N S W 2086 Australia Phone 02 975 1511 Fax 02 975 1518 NOTE Specifications subject to change without notice Authorized distributor Printed in Japan
9. Step 3 Writing a relay ladder diagram 1 0000 0001 soo 0002 0003 0004 2 0000 0001 y 0000 0004 0002 0003 0001 H 0002 0003 0004 Assigning numbers to timers and counters The C20 can accommodate up to 48 timers or 48 counters or combinations of timers and counters not exceeding 48 How these are used is explained in Chapter 4 They must also be assigned identifying numbers in a range from 00 to 47 Note that these are not input output points but rather a way for you to identify the timer or counter you want to use There are two basic considerations when assigning counter and timer numbers Do not give counters and timers the same number For instance there cannot be a Timer 01 and a Counter 01 When you re finished assigning the input and output points internal auxiliary relays and timers counters you re ready to proceed to the next step So far we know three basic things about our operation We know which devices are to be controlled we know how they relate to each other and we know the sequence or timing at which the controlled tasks must take place Now we need to put this down in a form that is codeable that is in the form of a relay ladder diagram For this you ll use the four digit numbers you just assigned to the input and output relays and internal auxiliary relays as well as the two digit numbers you gave to the timers and counters You ll also use such relay symbols a
10. 4 9 Using the programming console Note 5 Key inthe TIM data 6 Then press WRITE to complete the insertion Steps 5 and 6 are necessary only to input the timer and counter data These are not required for insertion of other types of instructions You can check that the insertion has been correctly done by moving the program using the arrow keys CI Spend some time becoming acquainted with these editing functions by inserting and deleting various instructions In the next chapter you ll learn how to put these to use in debugging much larger programs Chapter 5 Overview Step 6 Editing the program The C20 has a number of helpful features to help you debug your program and fine tune the operation before and after it is under way This chapter covers the final three steps for programming in Step 6 we explain how the quick search editing functions make locating instructions quick and easy Also explained is how to correct the program using the C20 s debugging capabilities Once you re ready to begin a test run of the program you ll learn in Step 7 how you can monitor the operation and make any necessary modifica tions based on the actual performance of the equipment Finally Step 8 shows you how to use a standard cassette tape recorder to save and load your program Quick search editing functions The C20 programming console has three features that greatly
11. AC 60V max OFF voltage AC 20V min Max switching capacity AC 85 to 250V 0 2A max p f 1 Min switching capacity 10mA AC 100V 20mA AC 200V min Leakage current 2mA AC 100V 5mA AC 200V max Saturation voltage 1 6V max External power supply 20mA point 240mA unit Service life of relay G3S 201PL PC DC 24V Circuit configuration COM 330K 4709 0 33 IN 007 IN 064 IN 07 COM Internal circuit 330K 4709 0 33 JOUT 00 JOUT 07 COM OUT 08 l fOUT 10 COM yOUT 11 COM Internal circuit Terminal Signal name M No Terminal Signal name I O No Input power supply Input power supply suas Power supply for external device for relay driving Load power supply Load power supply Load power supply EE SN FN MeN MON HSN eae genr goya Mol ol el te nok Q SH x Note The input and output channels of MA221 with 14 input points 12 output points are fixed on chan nels 1 and 6 Detachable terminal block Specifications Expansion 1 0 unit Type 3G2C7 MA222 AC 100 to 120V input Triac output Input voltage AC 85 to 132V Input impedance 9 7kQ 50Hz 8kQ 60Hz Input current 140mA typ AC 100V ON delay time 35ms max 1 5ms max OFF delay time 55ms max 1 2 of loa
12. OUT 07 3 8 eee i com E 5 No Z 8 a Circuit configuration 1 5K P T E 2 OUT 08 COM tH OUT 10 ee COM OUT 11 COM 24VDC Eg INI 0101 a IN3 0103 Terminal Signal name 1 0 No Terminal Signal name VO No OUT3 OUTS ou 0603 oor kia Power supply for external device for relay driving Load power supply Input power i Load power supply Load power suppl Note P Rey The input and output channels of MD211 with ntl 16 input points 12 output Input power ba wu ol ol cl al al al al ol ol al ol ol iol oll ol o 1 l2 z ja s e 7 AREOSA points are fixed on chan nels 1 and 6 When connecting an inductive load connect a diode 1A 100V min in parallel with the load KOK Jay ekk BE HE if kpj 2 eS i i7 Leie 5 gt d 47 6 cmd a lente mall gs SSK ko SEERE X Ok ef To r Fo To ie iin Detachable terminal block F 12 Specifications Expansion 1 0 unit Type Input voltage 3G2C7 MD212 DC input NPN DC 24V 10 15 Transistor output Input impedance 3kQ Input current 7mA typ DC 24V ON delay time 20ms max 1 5ms max OFF delay time 20ms max 1 5ms max Number of circuits 32 points 8 points common 24 points 8 3 1 points common ON voltage DC 16V max OFF voltage OC 5V
13. Oo 0 g Note Legend Change Vacant No change 1 When special auxiliary relay 1903 is turned ON the ADD and SUB instructions are treated as NOP and the statuses of the other relays remain unchanged 2 The statuses of these special auxiliary relays are not changed by executing instructions other than those listed in the above table Appendix E Maintenance and troubleshooting Overview Power supply CPU supply voltage fluctuation measured at power terminal block using voltmeter Expansion I O unit supply voitage fluctuation measured at power terminal block using voltmeter VO link unit Link adapter Battery Environmental conditions Ambient temperature in control panel Humidity Dust Regular inspections and appropriate maintenance of the PC are essential to ensure the full life of your PC and trouble free operation of your controlled system Safety measures to protect the system and minimize system downtime in the event of PC failure must also be taken This chapter covers inspection and troubleshooting procedures for the C20 Inspection items are presented in table form in the first part of this chapter This is followed by a brief review of standard maintenance procedures The troubleshooting guide presents the actions that should be taken in the case of each type of failure in easy to follow flowchart form Finally a list of the error messages
14. Holding relays HROOO to 915 Temporary memory TRO to TR7 Timers counters 00 to 47 Constant 0000 to 9999 List of instructions Applied instructions Instruction Mnemonic gt _ Operand Function Use this instruction when an instruc tion is added in the future This instruction is also used for minute adjustment of scan time End of a program Causes all the relay coils between this instruction and the ILC instruction to be reset or not reset according to the result immediately before this instruction Clears the IL instruction Shift register operation Channel Numbers Output relay 05 to O9CH Internal auxiliary rela 15 ie 202218 0 110 to 17CH enach Start cH IN Holding relay 0 to 9CH Start CH SEND CH Start and end channel can be same channel Relay No Latching relay operation Input output relay Causes a specified relay to 0500 to 0915 Hatia operate for one scan time Internal auxiliary relay Relay No at the leading edge of the 1000 to 1807 TION UP result of a logical arithmetic Holding relay operation HROO0 to 915 Causes a specified relay to NAN oro operate for one scan time TION Eee Relay No at the trailing edge of the DOWN result of a logical arithmetic operation Timers counters 00 to 47 Timer No Performs a high speed on delay Set value down type time
15. PROM chip PROM writer By SYSMAC C20 Peripheral interface unit SYSMAG C20 interface unit The peripheral interface unit is also required for programs recorded on a cassette tape recorder Programs that have been saved to cassette tape connected to the programming console of the C20 cannot be directly read by a cassette tape player connected to the graphic programming console nor can the reverse operation be performed For this reason always use the peripheral interface unit to transfer programs between these devices SYSMAC C20 Cassette tape Cassette tape recorder g SYSMAC C20 Peripheral i SD interface unit ES Cassette 2 tape recorder Cassette tape Programming console Cassette 7 APE ttn mnaman a CRT j Peripheral az Cassette a_r E tape interface Cassettes tape recorder The features of the respective consoles are explained next System expansion and peripherals seca SYSMAC C20 Peripheral interface unit Type 3G2C7 IP002 connected to C20 CPU Cable aay Type 3G2A2 CN221 2m p SYSMAC C20 Peripheral interface unit Type 3G2C7 IP002 connected to C20 CPU Graphic programming console Type 3G2A5 CRT19 20 A 16 The GPC allows programs to be written in both ladder diagram and mnemonic form The program can be written on the GPC without the GPC having to be connected to the PC once completed the program can b
16. ink unit A maximum of 16 I O link units can be connected to a remote I O master unit However the combined number of I O points of the connected 1 0 ink units cannot exceed the 1 O point limit of the PC in which the remote O master unit is installed If the C500 is used the maximum number of O points is 512 for the C120 the maximum is 256 n addition to the I O link units remote I O slave units and optical transmitting I O units can also be connected to the remote I O master unit The remote I O siave unit and optical transmitting I O units are peripherals used with the higher level SYSMAC C Series PCs and cannot be used alone with the C20 See the user manuals of these PCs for information on those devices The network of interrelated components is governed by PC in which the remote O master unit is installed using a system of channel designation which is explained next The channels of the input and output units connected to the PC either the CPU alone or the CPU with one or two expansion I O units are automatically assigned starting from channel 00 You must assign the channel number of each of the I O link units and optical transmitting I O units however When doing this you must make sure that no channel designations overlap the same channel should not be assigned to two different devices There s a technique you can use to keep this from happening When assigning the channels for those devices start with the
17. 13 06 14 06 14 06 14 06 14 06 14 Holding relay 160 07 15 07 15 07 15 07 15 07 15 retentive relay 05CH 06CH 07CH 08CH 09CH 00 08 00 08 00 08 00 08 00 08 01 09 01 09 01 09 01 09 01 09 02 10 02 10 02 10 02 10 02 10 03 11 03 11 03 1 03 1 03 1 04 12 04 12 04 i2 04 12 04 12 05 13 05 13 05 13 05 13 05 13 06 14 06 14 06 14 06 14 06 14 07 15 07 15 07 15 07 15 07 15 D 2 Assignment of I O channel and relay numbers Timer counter numbers No of points Timer counter number TIM CNTOO to 47 Timer counter Input relays The CPU has 16 input relay points one input channel The number of input points can be increased to a maximum of 80 by the addition of expansion I O units Because one channel equals 16 points this means that a maximum of five channels from channel 00 to 04 are available The data from the SYSBUS are received by the input channel relays assigned to the I O link unit Output relays As with the input relays the CPU has one output channel consisting of 16 relay points However of these 16 points numbers 12 to 15 are internal auxiliary relays used to carry out CPU internal processes For this reason the number of output relays the CPU actually possesses is 12 When expansion I O units are connected to the CPU a maximum of 60 output relays are available for a total of five channels 05 to 09 The statuses of all the output channel rel
18. 48 points Timers Counters TIM H CNT00O to 47 Timer 0 1 to 999 9s High speed timer 0 01 to 99 99s Counter 1 to 9999 counts 8 points Relays TRO to TR7 16 points Relays 1808 to 1907 including Battery failure flag 1808 Normally OFF relays 1809 1810 1811 1812 and 1814 Normally ON relay 1813 Initial one scan time ON relay 1815 For generation of 0 1s clock 1900 For generation of 0 2s clock 1901 For generation of 1s clock 1902 Status of holding relays and present value of counters before power failure retained in memory Service life of built in battery approximately 5 years at ambient tempera ture of 25 C Battery life shortened if ambient temperature exceeds 25 C Replace battery within one week after ALARM ERROR indicator illumin ates Battery must be replaced within approximately 5 minutes after the power is turned off CPU failure watchdog timer Battery failure Memory error O bus failure PROGRAM check program execution time only END instruction missing Instruction error Specifications Input Output specifications CPU Type 38G2G7 CPU13 E RUIEN CPU43 E CPU44 E CPU73 E CPU74 E ki DC input NPN Contact output Input voltage DC 24V 10 15 Input impedance 3kQ Input current 7mA typ DC 24V ON delay time 20ms max 15ms max OFF delay time 20ms max 15ms max Number of circuits 16 points 8 points comm
19. Automatic car washing machine The C20 is used to control a car washing machine in this example Ladder diagram Explanation an As input devices a vehicle detecting device and pushbutton switches 0000 1001 are used In response to the signals from these devices the C20 opens a ae valve for the spray and starts the motor for the revolving brush 1000 0002 gt jf O 1 0 assignment 1000 Start button Vehicle detector Condition at which washing machine stops Output Spray valve Brush motor Movement of washing machine 0001 1001 0501 0501 0001 L rut Application examples Coding Chart 0000 LD 0000 0001 OR 1000 0002 AND NOT 1001 0003 OUT 1000 0004 LD 1000 0005 AND NOT 0002 0006 OUT 0502 0007 LD 1000 0008 OUT 0500 0009 LD 0001 0010 OR 0501 0011 AND NOT 1001 0012 OUT 0501 0013 LD 0501 0014 AND NOT 0001 0015 OUT 1001 Bottle Label Detection Conveyor B Operation When the start buiton input 0000 is depressed the washing machine begins operating i e the machine starts moving and at the same time the spray valve is opened The washing process continues until Internal Auxiliary Relay 1001 which can also serve as a reset input is opened Input 0000 and Internal Auxiliary Relay 1001 are ANDed and the result is internally output to nternal Auxiliary Relay 1000 This re
20. C20 basic unit 1 2 capabilities basic unit 1 2 capabilities expanded unit 1 2 channel assignment A 10 compatibility with higher level C Series 1 2 components 1 2 conveyor belt use with 6 5 counting products 6 8 detecting defective products 6 8 DIP switches 2 1 expanded unit 1 2 alarm lamp use with 6 8 limit switch use with 6 1 machinery use with 6 6 main components 1 2 memory capacity 2 1 memory chips 1 2 motors use with 6 5 peripherals A 1 photoelectric switch use with 6 1 6 8 power supply E 5 power supply 2 6 proximity switch use with 6 5 pushbutton switch use with 6 6 robot arm use with 6 8 system expansion A t ultrasonic switch use with 6 1 valve use with 6 6 versions 1 2 Index DC power diode connection 2 4 noise 2 4 Debugging program 5 1 5 4 5 10 B 10 Defective part returning to OMRON E 2 Deleting instructions 4 9 Detecting defective products 6 8 Determining cycle times C 2 Dielectric strength F 3 DIFFERENTIATION UP DIFU special instruction B 14 DIFFERIENTIATION DOWN DIFD special instruction B 15 DIP switch setting 2 1 Display light switch location and function 1 3 Distributed system A 4 DM key 4 3 Dust E 1 EAR jack tape recorder 5 10 Editing deleting from program 4 9 going straight to known address 5 1 inserting in program 4 9 keys purpose 1 4 program 5 4 quick search function 5 1 Eight steps to programming 3 1 END instruction 3 5 B 10 E 12 End station
21. Check program find and correct error reapply power RUN indicator lit wes dicator lit Correctly insert RAM EPROM chip in IC socket RAM EPROM hip correctly inserted Retum to General flowchart YES RUN indicator lit DIP switch setting correct Correct DIP switch setting RUN indicator lit Replace CPU END Maintenance and troubleshooting Failure flowchart ERROR indicator lit CPU POWER indicator lit NO Turn on CPU power supply ERROR indicator of CPU lit For I O link unit Ciear CPU error Locate transmission error DIP switch setting or repiace unit Maintenance and troubleshooting Battery flowchart For PC ERROR ALARM indicator blink Battery connector firmly connected Connect firmly Use programming console to clear BATT LOW error message ERROR indicator off Replace battery Type 3G2A9 BATO8 Use programming console to clear BATT LOW error message ERROR indicator off Repiace CPU Maintenance and troubleshooting 1 0 flowchart For PC 0000 0901 LS1 LS soll 0800 SOL1 malfunctions Use programming console to monitor the program indicator of Relay 0600 normal Use tester to check terminal voltage of Relay 0600 Use tester to check
22. K S fo Specifications CPU Type i lt pR EA 3G2C7 CPU76 E _ DC input NPN Transistor output Input voltage DC 24V 10 15 Input impedance 3kQ Input current 7mA typ DC 24V ON delay time 20ms max 1 5ms max OFF delay time 20ms max 1 5ms max Number of circuits 16 points 8 points common 12 points 8 3 1 points common ON voltage DC 16V max OFF voltage DC 5V min Max switching capacity DC 5 to 24V 0 5A max Min switching capacity T DC 5V 10mA min 7 Leakage current 100A max Saturation voltage 1 5V max External power supply Service life of relay _ G3SD YO1P PC DC 24V Power supply OC 24V Circuit configuration 5 O T c E 2 E Internal circuit 1 5K IN 08 IN 14 IN 15 Terminal Signal name 0 No Terminal Signal name I O No Bs IN 0007 B5 INIO 0010 INg 0008 OUT 0507 OuT3 0503 aa ING 008 COM Load power supply Input power supply Load power supply Input power supply Load power supply Note j The input channel is fixed E i on channel 0 and the out tists ahatia H put channel on channel 5 The terminal block can be removed When connecting an induc tive load connect a diode 1A 100V min in parallel OUT COM with t
23. Multisupport base Cassette tape A 17 SYSMAC C20 TS 3 Multisupport base Peripheral interface unit Cassette tape recorder System expansion and peripherals When the multisupport base is connected to a programmable controller in the SYSMAC C series the connected PC must be specified by the selector switch on the multisupport base When the multisupport base is connected to the C20 the setting of this selector switch is the same as when specifying the C250 The multisupport base can be connected to various peripheral devices in the SYSMAC C series Printer interface unit The printer interface unit interfaces the C20 with printers so that ladder diagrams mnemonic lists cross reference lists data memory contents and other information can be printed out for a written record This can be helpful as a diagnostic tool in correcting or modifying programs To connect the printer interface unit to a printer interface board 8145 available from Epson is required The printer interface unit can also be used with the multisupport base or graphic programming console In this case however the memory cassette of the printer interface unit must be Type 3G2A5 MP002 E When the printer interface unit is mounted to the C20 to print out programs you can stop the printer in one of two ways Either the printing can be halted at any desired point or the printer can be made to pause between each printed page A butt
24. PC in the MONITOR mode during operation Checking and running your program Locate the device you wish to check We could do this for Counter 47 in our practice program for instance by keying in which gives this display Press MONTR and the display changes to this If the PC were currently operating we would be able to watch the counter as it is decremented The same thing is also possible with timers Rapid check of counter timer values For a fast way to visually scan the set value of all timers and counters in a program go to an address where a timer or counter is located Then press MONTR and the set value of the timer counter is displayed as a four digit number Then each time you press you wili be able to see the set time of the next timer counter Rapid check of relay status You can check the status of relay contacts using the same technique To do this go to the address of a relay you want to check Then press MONTR to display the current status whether ON or OFF of the relay Then to move to the next relay press either Ea Checking and running your program Step 8 Saving your program to cassette tape At this point it s assumed that you have completed program debugging and the trial run of the equipment and are satisfied with the operation Now it s time to save the program to a cassette tape For this
25. and LG terminals must be grounded at a ground resistance of less than 1000 The following points should be kept in mind when wiring the I O link unit Be sure to perform grounding at a ground resistance of less than 1000 to safeguard against electric shock The LG terminal is a noise filter neutral terminal Normally grounding is not required However if serious noise problems exist and may cause the 1 0 link unit to malfunction ground this terminal at a resistance of less than 100Q Use twisted pair wires having a cross sectional conductor area of at least 2mm AWG14 For normal power line noise the C20 s internal noise suppressing circuit is sufficient However supplying power through a transformer with a voltage ratio of 1 1 helps to greatly reduce equipment to ground noise Installation of such a transformer is recommended Use an AC power supply with a supply voltage within the rated operating voltage range AC 85 to 264V Use solderless terminals 8 6mm max O _ semma D _ For M4 screws A 5 System expansion and peripherals Channel and end station setting Note For details on the optical fiber cable refer to the user s manual for the SYSMAC C Series optical fiber cable For the I O link unit to operate it must be designated as one of the input output channels of the PC in which the remote I O master unit is instalied This channel setting is carried out using the DIP switch in the I O
26. 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 pro
27. be free from visible abnormality 5 years 15mm min Be sure that the power is off before replacing the expansion I O or other unit Remember If a defective unit is discovered and replaced confirm the operation of the replacement unit When returning a defective unit to OMRON enclose a written description of the problem If the problem is a poor cable contact wipe the connector pins with a clean all cotton cloth moistened with industrial alcohol Make certain that there is no cloth debris remaining on the cable before plugging it in Tools and testing devices for maintenance Screwdrivers phillips and flat bladed VOM or digital voltmeter Industrial alcohol and all cotton cloth Tools and testing devices for troubleshooting Oscilloscope Pen recording oscilloscope Thermometer hygrometer Maintenance parts To ensure continuous operation in the event of failure it is recommended to keep at least one spare expansion I O unit on hand Maintenance and troubleshooting Consummabies Fuse For C20 and I O link unit 250V 1A at supply voltage of AC 100 to 120 200 to 240V 125V 3A at supply voltage of DC 24V 5 2 dia x20 For link adapter 250V 0 1A 6 35dia x31 8 Replacing the fuse awe Flet ui Y 1 Turn off the power 2 Remove the C20 s front cover 3 Replace the old fuse using a flat bladed screwdriver 4 Reattach front cover Battery Type 3G2A9 BAT08 The service li
28. be used to perform test runs of each completed circuit To do this place the END instruction at the end of each circuit in the series After testing the circuit delete the END instruction and test the next circuit in a similar manner Coding chart INTERLOCK IL and l A A Symbol Function Branches circuit to OUT instructions Ladder diagram Remarks more than one OUT instruction If the IL and ILC instructions are not used 0004 in pairs an error results during program check All relay coils between these two instructions are set or reset depending on the current status of the relays oppo ope oct CE 0902 0003 ss These two instructions are used in pairs when a circuit is branched to When the interlock flip flop ILF in the CPU is 0 the contents of the result register are fixed to 0 Consequently as long as the ILF is set to 1 the It output relay remains OFF instruction ILF ILC if instruction R Coding chart ILC 03 Instruction words The IL instruction causes the contents of the result register to be transferred to the ILF Therefore the ILF is set to 0 if the contents of the result register are 0 The ILC instruction causes the ILF to be set to 1 regardless of the contents of the result register When the IL condition is OFF for instance when 0000 or 0001 is OFF in the above example the state of each relay
29. begin at one end of the range for timers and the other end for counters That s why we gave Timer T the number 00 while Counter CC was assigned the number 47 This helps to prevent possible use of the same number for both a timer and a counter Timers and counters cannot directly produce an output but must be output by means of an output relay This relay contact can be reused as often as desired but the coil cannot be reassigned The assigned output relay plays the role of the load in this example The right bus bar does not need to be written Each logic line must be ended with a relay coil timer counter or special instruction Introduction to programming Coding must be done from left to right and from top to bottom Based on those considerations this is th coding chart we came up with Address Instruction Data This completes the first four steps In the next chapter we ll see how to actually operate the PC based on the programming code we have written Chapter 4 Using the programming console Overview The keyboard aca e a In the last chapter you learned how to perform Steps 1 4 of the eight basic programming steps This chapter focuses on Step 5 using the programming console to enter the program code in the CPU The functions of the programming console are presented step by step as we enter the
30. between the LD0002 and AND NOTO003 instructions in block D to be stored in the result register The OR LD instruction causes a logical OR operation to be performed between the result register and the stack register The result of the logical OR operation is then stored in the result register TIM timer no set value Function Performs ON delay timer operation Instruction words Ladder diagram 0000 0001 A o o TIM10 15 0s Ladder diagram 0000 1901 FA 0001 150 counts Remarks This instruction can be used as an ON delay timer in the same manner as arelay circuit The set time can be between 0 and 999 9 seconds Timer numbers can be set from 00 to 47 Do not give timers and counters the same number The timer starts when the content of the result register is logical 1 and resets when the content of the register is logical 0 A time up contact designates the timer number itself Both NO and NC contacts can be used in the number required The timer works by decrementing producing an output when the present value the time remaining becomes 0000 When input to the timer is turn d off the timer is reset and the present value returns to the preset time The timer output is transmitted externally through an output relay as shown in the circuit example Coding chart Address instruction Data a al rams 0203 tp tim 10 0204 four 050 Timer
31. counter 5 counts X2 ag O O 1 Solenoid 0000 1000 CNT47 5 counts CNT47 TIMOO i peie 1000 1000 i 2s END Now let s try a slightly more complicated program that shows how to relate Steps 1 4 to an actual application In the figure is a control circuit for a packaging machine The circuit is used to detect and count the number of products being carried on an assembly tine When it counts five products the circuit energizes a solenoid The solenoid receives electrical current for a period of two seconds and is then shut off Using Step 1 we determine that there is an input device a limit switch an output device a solenoid a control relay an internal auxiliary relay a timer and a counter To carry out Step 2 we have to assign numbers to the components constituting this circuit This is how our assignment looks Input device limit switch Input relay No 0000 Output to solenoid Output relay No 0500 Control relay X1 Internal auxiliary relay No 1000 Counter CC CNT47 Timer T TIMOO The ladder diagram that represents this circuit using the numbers we assigned looks like the one at left Next we ll encode the ladder diagram as required for Step 3 These are the key things that require attention Be sure to use the assigned input number Since the timers and counters must be assigned numbers from a range of 0 to 47 a convenient way to make this assignment is to
32. designation A 6 problem with external light A 9 protective cover A 9 Ending program B 10 Entering program meaning of LCD display 4 6 in CPU 4 6 programming console 4 4 Environmental conditions 2 3 E 1 EPROM installing 2 2 memory capacity 2 1 Erasing existing memory 4 4 Error messages E 12 Errors multiple 5 5 testing for 5 4 two levels 5 5 Index Examples coding chart 6 2 6 5 6 7 6 8 scan time caiculation C 4 I O assignment 6 2 6 3 6 5 6 6 6 8 W O link unit application A 12 I O link unit system configuration A 3 ladder diagram 3 5 ladder diagram 6 2 6 3 6 5 6 6 6 8 multistage process A 12 operation 6 5 6 7 6 8 programming 4 6 Execution time address F 3 Expanding the C 20 A 1 limits 1 5 Expansion I O unit 1 2 A 1 power supply E 1 two types A 1 Expansion of system restrictions A 2 External wiring 2 3 Fan when to use 2 5 Fatal errors 5 5 Fiber optics benefits A 4 Forced set reset 5 6 Forced timer set 5 6 Forcibly turning relay ON OFF 5 6 Forming strings substrings B 1 FUN key 4 3 Fuse E 3 Fuse power supply 2 6 Gaining access to programming console 4 1 Generating I O table A 11 Going directly to known address 5 1 Graphic programming console A 14 Grounding W O link unit A 5 requirements 2 6 sharing with other equipment 2 6 variations 2 6 High power wiring 2 3 HIGH SPEED TIMER TIMH special instruction B 15 High speed timer C 2 Holding relays channel
33. determine this by listening for the sound that marks the beginning of the program Then rewind the tape slightly so a few seconds of blank tape precedes the beginning of the program Then follow these steps 1 Press 2 Press PLAY on the tape recorder to start loading the tape into the PC 3 Press PLAY SET on the PC keyboard When you do this message appears and you ll see a blinking rectangle on the upper right portion of the display 4 Wait about 7 minutes for the program to be completely loaded 5 When the loading is complete a message appears Verifying the program It s always a good practice to check that the program was loaded correctly This is done by performing the following procedure 1 Rewind the tape until you reach the beginning Provide about 5 seconds of blank tape leader before the taped program segment begins 2 Press 3 Turn on the PLAY button of the tape recorder 4 On the C20 keyboard press VER When you do a message appears and a blinking rectangle indicates that program verification is taking place 5 Wait about 7 minutes A message will appear when verification has been successful 6 Ifa program loading error has occurred one of the messages described in Appendix E will be displayed In this case repeat the tape load operation Chapter 6 Application examples Overview Automatic control of warehouse door As amember of the SYSMAC C Series programmable co
34. has a respective bit value 16 8 4 2 and 1 permitting you to specify the channel you want by combining the values you need For instance if you wanted to set channel 5 you would turn DIP switch pins 3 and 5 ON Pin 3 has a value of 4 and pin 5 has a value of 1 thus 4 1 5 Similarly if you wished to set channel 31 you would turn all the pins ON 16 8 4 2 1 31 The remaining pin pin 6 is turned ON only when the unit is the end station 7 After you have carried out the DIP switch setting reattach the cover 8 Connect the 1 0 fink unit to the C20 with a cable Also connect the optical fiber cable for the SYSBUS to the I O link unit The I O link unit has two optical fiber cable connectors Either connector can be connected to the remote I O master unit When the I O link unit is specified as the end station be sure to cover the unused connector with a protective cover to prevent the I O link unit from malfunctioning due to external light 9 Apply power to the system The power can be applied to each unit in the system in any order However when a link adapter is employed a power application sequence must be followed The details of this are described later in the discussion on the link adapter 10 Ifyou should get a message on the display of the remote I O master unit that no end station has been designated refer to the I O table by using the programming console You can start operating the system as soon a
35. in more detail later but at this point it s important that you know how three in particular are used The first two are the arrow keys When you want to move through your program a step at atime you press the bottom down arrow key The displayed address of the program will increment once for each press To go the opposite direction press the other up key The program will decrement one step at a time until it reaches its beginning The arrow keys are normally used for moving only a small number of steps in the program Later we ll show you several ways to move right to the program step you want The third key in the yellow group you should know about now is the WRITE key During programming when you have written an instruction and its data use this key to register the instruction in the PC memory at the address desired Instruction keys Except for the SHIFT key on the upper right these gray keys are the ones you ll use to place instructions in your program The SHIFT key is similar to the shift key of a typewriter and is used to obtain the second function of those keys that have two functions Mode switch RUN MONITOR PROGRAM Each of the remaining gray keys has its function indicated by an abbreviation These are what those abbreviations mean FUN Selects a speciai function Used to key in special instructions These special instructions are realized by pressing FUN and then the appr
36. instruction execution times Servicing of commands input from peripheral devices such as programming console graphic programming console etc 1 1ms The scan time can be obtained by adding 1 2 3 and 4 in this table An adequately short period of a scan time is important to ensure an efficiently 2a error free operation This is particularly important when using the high speed timer which malfunctions if the scan time exceeds 10ms Scan time List of instruction execution times Basic instructions Instruction Execution time LOAD LOAD NOT AND AND NOT In microseconds Special instructions The channel includes the input output relay internal auxiliary relay and holding relay areas Execution time INTERLOCK INTERLOCK CLEAR SHIFT REGISTER when one channel is shifted when 13 channels are shifted LATCHING RELAY DIFFERENTIATION UP DIFFERENTIATION DOWN 57 HIGH SPEED TIMER 81 COMPARE 105 comparison of a constant with a channel 195 comparison of a timer counter with a channel MOVE 89 transfer of a constant to a channel 178 transfer of a timer counter to a channel MOVE NOT 90 transfer of a constant to a channel 179 transfer of a timer counter to a channel ADD 210 addition of two channels and then transfer of the result to achannel 334 addition of a timer count
37. more than Relay 1906 This relay turns ON if the result of the compare operation is equal to it may also turn ON if the result of an arithmetic operation is 0 Relay 1907 This relay turns ON if the result of the compare operation is lt less than Relays TRO to 7 These are temporary memory relays and may not necessarily be assigned in sequence The same coil number of these relays must not be used in duplicate within the same block of a program However the same coil number can be used in a different block When using a temporary memory relay the letters TR must be prefixed to the relay number g TRO Assignment of I O channel and relay numbers Relation between special auxiliary relays and instructions Special auxiliary relays Relay No 1907 lt 1906 1905 gt 1904 CY 1903 ER Operation Turns ON if the Turns ON ifthe Turns ON if the Turns ON if a car Turns ON if data of relay resultwhenCom resultwhenCom result when Com ryis generated as subject to BCD pareinstructionis pareinstructionis pareinstructionis aresult of an operation are not Executed __ executed is less executed is equal executed is more arithmetic opera in BCD instruction FUNNo than or 0000 than tion TIM TIMH 15 CNT CMP 20 t t t MOV 21 t MVN 22 t ADD 30 t t t SUB 31 t t t STC 40 24 CLC 41 1oy END 01 0 gr
38. number Set time value Timer output Time up output 15 0sec peze 0500 er The set value for the TIM CNT instruction cannot be set on a channel basis Memory retentive timer If a power failure occurs the timer is reset and the present value returns to the preset value Therefore if it is necessary that the current value of the timer be retained in the event of a power failure a memory retentive timer circuit must be used for the program The example circuit is configured by combining the PC s clock and the counter instruction with Special Auxiliary Relay 1901 used to generate a 0 2sec puise Coding chart instruction Data Instruction words Ladder diagram pE D ae COUNTER CNT Ladder diagram 0000 0001 0002 3 counts CNT10 Ga Consecutive OUT instruction and TIM instruction Using this circuit a LD instruction produces an output and simultaneously turns on a timer Coding chart instruction Daa counter no set value Function Performs down counter operation Remarks This instruction can be used as a preset counter in the same manner as a relay circuit The preset value can be between 0 and 9999 counts Counter numbers can be assigned from 00 to 47 Do not give counters and timers the same number The counter resets when the contents of the result register are logical 1 and starts counting when the contents of the register are logical 0 The count inp
39. of Counter 47 Do this by pressing LD He ee JL fe For address 0004 key in OR 4 to enter the OR instruction and specify the internal auxiliary relay number So that the timer acts to turn on the solenoid only 2 seconds for address 0005 key in AND This causes the contact of the timer instruction to act as an NC normally closed contact Key in Daag Now we have finished entering the timer contact The timer coil for this contact must exist somewhere in the program for the timer instruction to be executed For address 0006 to designate the relay coil key in For address 0007 key in the contact corresponding to the internal auxiliary relay coil we have just entered 4 7 Using the programming console Remember that the coil and the time value for the contact keyed in for address 0005 must stil be specified This is done by keying in poaz for address 0008 This message is displayed asking for the timer data Since the data includes a decimal point before the last digit to set a value of 2 seconds we enter C o WRITE The only thing that remains is to complete the circuit by specifying the output Do this by entering OUT e The output relay number for this output is 0500 which is automatically selected by the PC Remember that 05xx is the output channel designation while 00xx is the input channel designation The relay number is xx The final instruction in
40. starts operating Coding chart Contents of data Address Instruction Data Outputvelay __0500 0 1807 0200 LD 0000 Holding relay HRO00 to 915 0201 AND 0001 0202 DIFU 13 0500 Function Causes relay to operate at the trailing edge of input for one scan time Remarks This instruction is used to output the differentiation of an input condition to a specified relay for one scan time The instruction must be set so that the output is issued for one scan time at the trailing edge of the result register that is at the point when the register s level turns from 1 to 0 When used with the DIFFERENTIATION UP DIFU instruction the maximum number of DIFD and DIFU instructions that can be program med together is 48 The differentiation instructions perform their operations in response to changes in input after the PC starts operating Coding chart Contents of data Address Instruction Daa Outputrelay 0500to 1807 Holding relay HROOO to 915 0200 LD 0000 0201 AND 0001 0203 DIFD 14 0501 Instruction words HIGH SPEED TIMER TIMH Symbol Ladder diagram 0000 0001 TIM101 A Oo Oo Timer input 1 50s Pen Ea Time up output ee 1 50s ea COMPARE CMP Symbol CMP S1 2 Ladder diagram 0000 1907 Less 1905 gt 609 Greater 1906 3 x J s0 Equal 1907 turns ON if the S1 is les
41. sub string of relay logic is being started at the specified program address Use this instruction for each logic line that starts with an NO contact To form substrings combine this and other instructions such as AND or OR The LD instruction causes the contents ON or OFF state of the specified relay number to be stored in the result register It also causes the existing contents of the result register to be transferred to the stack register The contents of specified relay no r s Contents of data VO relay internal auxiliary relay Holding relay HR 000 to 915 Timer counter TIM CNTO0 to 47 Temporary memory telay 0000 to 1907 0500 to 1807 TROtO7 OUTPUT OUT fouT Ot j relay no Symbol Function C Outputs result of a logical operation to a specified relay or shift register Instruction words Ladder diagram 0000 Logic line Gc i T Bus bar AND Symbol Ladder diagram Tee 6 OR Symbol Remarks This instruction is used to output the result register contents the result of a logica operation to as specified relay The specified relay may be either an output relay interna auxiliary relay holding relay this is also referred to as retentive relay or temporary memory relay R Specified relay no Coding chart Address instruction Daa 0000 LD 0000 0001 OUT 0500 AND AF r
42. supply OR Load power supply Note The input channel is fixed on channel 0 and the output channe on channel 5 The terminal block can be removed Specifications CPU Type PU38 E A 3G2C7 Cl AC 100 to 120V input aa Triac output Input voltage AC 85 to 132V Input impedance 9 7kQ 50Hz 8kQ 60Hz Input current 10mA typ AC 100V ON delay time 35ms max 1 5ms max OFF delay time 55ms max 1 2 of load frequency max Number of circuits 14 points 8 6 points common 12 points 8 3 1 points common ON voltage AC 60V max OFF voltage AC 20V min Max switching capacity _ AC 85 to 250V 0 2A max Min switching capacity 10mA AC 100V 20mA AC 200V min Leakage current 2mA AC 100V 5mA AC 200V max Saturation voltage 1 6V max External power supply Service life of relay G3S 201PL PC DC 24V Power supply AC 100 to 120V Circuit configuration COM Internal circuit Internal circuit Internal circuit qOUT 10 COM OUT 11 COM Terminal Signal name VO No INS 0005 Terminal Signal name VO No BER CRRA Input power supply j amp ord Is Load power supply Load power supply Input power supply I i i divgos
43. terminal voltage of Relay 0600 Soe Disconnect external wirings check continuity External power Turn on external power supply ON supply YES Check output device SOL1 Use tester to check terminal Input indicator NO of Relay 0000 and 0001 normal voltage of Relays 0000 and 0001 YES Check terminal voltage of Relays 0000 and 0001 connect dummy Replace CPU Check input d LS1 and LS2 Maintenance and troubleshooting For PC and I O link unit Environment flowchart START Ambient temperature below 55 C noise source Ambient temperature above 0 C Humidity within range of 35 to 85 RH2 Adequate countermeasur against noise YES Atmosphere ok Maintenance and troubleshooting List of self diagnostic functions LED on CPU rack Message on POWER RUN programming console display Power failure Turn on power CPU failure Set PROGRAM mode and perform power reset Program may require correction i Check RAM ROM for correct mounting debug program After MEMORY ERR Memory failure corrective action perform failure reset operation END instruction No END instruction at end of program Write in END instruction NO END INSTR missing error and then perform failure reset operation check bus line eonnecuing the un W O units Check cable A P isconnect
44. those not carrying an object remain stationary thus conserving power Sensor 3 Application examples Ladder diagram 0002 TIMoc 0501 0001 TIMO1 0500 O T Gy se D amp 0000 TIMO1 1000 tr E Coding chart Data 0201 0501 0202 TIMOO 0203 0501 0204 0206 Explanation In this example metal plates are being transported The position of a plate is detected by a proximity switch located next to each belt segment As long as the metal plate is within the detecting range of the switch the programmable controller issues a control output that causes the motor of the next conveyor belt to work When the metal plate moves out of the detection range of the proximity switch the timer is activated and when the set time has elapsed the motor of the first conveyor belt stops V0 assignment Operation Since the metal plate is detected by sensors 3 2 and 1 in that sequence the first input signal in the ladder diagram comes from sensor 3 input j 0002 When input 0002 turns on output 0501 corresponding to motor 2 is issued by the C20 When input 0001 turns on motor 1 is started by output 0500 The operation of motor 2 only lasts 2 seconds the time required for the metal plate to travel to the next conveyor belt Thus the motors operate only when they are actually needed Application examples
45. two digits which identify the channel and the right hand two digits which identify the point within the channel For example 0000 identifies the first point of the first channel and 0104 identifies the fifth point of the second channel In the C20 the first five channels 00 to 04 are used for input and the next five 05 to 09 for output The actual number of points used by the basic C20 is 16 00 to 15 inputs and 12 00 to 11 outputs Remember that the C20 can be expanded by adding expansion I O units Up to four new channels can be added for a total of 80 5x16 input and 60 5x12 output points V0 channel assignment The assignment of I O channels is as shown on the left The total number of I O points including those of an I O link unit cannot exceed 140 Assigning internal auxiliary relays In the output channel the four points 12 to 15 that are not used to send output signals directly to output devices function as internal relays If these internal relays are to be used they must be assigned as well during Step 2 How they function is explained next These relays do not contro external devices directly Instead they are used as data memory or data process areas in controlling other relays timers and counters Functionally these internal auxiliary relays are equivalent to the internal relays used in relay control panel This is known as internal output Introduction to programming
46. way of a counter within the PC The motor would start when the PC receives an input from a switch and would be stopped by the signal output by the PC when the counter had received five input signals from the photoelectric switch Each of the related tasks would be similarly determined from the beginning of the controlled operation to the end Having made this assessment you now will be ready to go to Step 2 of programming assigning the input output devices or points Introduction to programming Step 2 Assigning I Os CPU 28 points iN OUT OCH 5CH CPU 28 points I O expansion unit 28 points CPU 28 points I O expansion unit 56 points CPU 28 points I O expansion unit 28 points VO link unit 32 points CPU 28 points 1 0 expansion unit 56 points 1 0 link unit 32 points 1CH 6CH N OUT CPU 28 points two I O expansion units 56 points When the system is configured of AC input type units the number of 1 0 points per system is decreased as follows 28 point system 26 points 56 point system 52 points Note Points and channels The programmable controllers of the SYSMAC C Series all use the concept of I O channels to identify individual I O terminals or points Each of these channels consists of 16 points The four digit number used to identify an I O point therefore can be broken down into the left hand
47. when you assign the channels of the C20s the assigned numbers will be different from those of the higher level PC but the channels themselves are the same In the example from the C20 s perspective channels 01 input and 06 output are assigned to the I O link unit connected to the C20 A These channels are the same as channels 28 and 29 of the C500 To the I O link unit connected to C20 B channels 03 input and 08 output are assigned These are the same as channels 30 and 31 of the C500 Note Generating the 1 0 table When you find it necessary to check the I O assignments of the C500 or other higher level PC and the C20 first attach the programming console to the CPU of the C500 Then set the mode selector switch on the programming console to the PROGRAM position and perform the key operations as shown below Before beginning the C500 C20 and I O link unit must be properly connected and all supplied with power To generate the I O table key in aaa in that sequence When the SHIFT and CH keys have been depressed a message appears indicating the start of O table generation Now key in SAAMA You should now start to see the I O table being generated When it is completed you can check its contents by doing the following First key in CLR Next key in rales and a message is displayed You can now make your firs
48. 6 With the DC input type CPU the number of I Os can be increased to 56 84 112 or 140 points This is accomplished by using up to two expansion of O units With the AC type the number of O points can be 52 78 104 or 130 LAMA 1 Data from to C 500 C250 C 120 via SYSBUS I ese Expansion 1 0 unit VO link unit Expandable CPU Expansion I O unit Expansion I O unit Peripheral devices connectable to C20 Programming console Peripheral interface unit horizontal type Programming console vertical type Graphic programming Graphic programming Multisupport base console GPC console CRT MSB Note Although there are several additional peripheral devices available for other PCs in the SYSMAC C Series only those shown here can be used with the C20 1 5 Chapter 2 Installing the C20 Overview But first This chapter tells you how to install the C20 You may wish to skip this section and go first to Chapter 3 Introduction to programming which provides important information on how to determine the configuration of your controlling system The following are some important points that should always be observed to ensure correct installation and operation of the C20 Static electricity in low humidity conditions static electricity may cause problems with the C20 s components Therefore before touch
49. 8 VO assignments A 11 CHG k y 4 3 CH key 4 3 CLEAR CARRY CLC special instruction B 23 Clear carry flag B 23 CLR key 1 4 4 1 CNT key 4 3 Coding about 3 5 chart examples 6 2 6 5 6 7 6 8 language elements of 3 5 direction 3 7 from ladder diagram 3 5 Common process time C 5 Communication between remote devices A 3 COMPARE CMP special instruction B 16 Compare relays D 4 Compatibility peripherals 1 5 Condensation 2 3 Conditions to avoid in C20 environment 2 3 Conducting trial run of program 5 6 Connecting program blocks B 5 OR operation B 6 Connector for peripheral devices location and function 1 3 Connector for expansion O units location and function 1 3 Consecutive OUT and TIM instructions B 8 Console display appearance 4 3 Consummables E 3 Contacts restrictions on 3 4 CONT key 4 3 Control application less than 8 input or output points A 8 Control panel mounting 2 5 wiring 2 3 Control system 1 1 Index Control task sequence timing and relationship 3 2 Conventional relay based systems 1 1 Conveyor belt motor control 6 4 6 8 Copying programs 5 10 COUNTER CNT instruction B 7 Counter forced set reset 5 7 how to change set value 5 8 monitoring during operation 5 8 monitoring during operation 5 8 number range B 8 upon power failure B 9 value range B 8 Counters and timers assigning numbers 3 4 Counters rapid check of values 5 9 Counting products 6 8 CPU failure E 6 function 1 2
50. A9 AL002 E Cable length 0 1m with connector 3G5A2 0F011 Cable length 1m with connector 3G5A2 0F 101 Cable length 2m with connector 3G5A2 0P201 Cable length 3m with connector 3G5A2 0F 301 Fiber optics cable Cable length 5m with connector 3GBA2 0F501 for indoor use i Cable length 10m with connector 3G5A2 0F111 Cable iength 20m with connector 3G5A2 0F211 Cable length 30m with connector i 3G5A2 0F311 Cable length 40m with connector 3G5A2 0F 414 Cable length 50m with connector 3G5A2 0F511 NOTE 1 The RAM and ROM for the CPU are separately available The battery set is provided to the CPU 2 The RAM G and RAM F are not compatible with each other Programming of up to 170 addresses can be performed without the RAM G 3 The RAM chip is mounted in the expandable type CPU as the factory set condition for shipment 4 Although both the vertical type and horizontal type programming consoies can be used with the SYSMAC C20 the use of the horizontal type is recommended in consideration of operability Specifications Ratings Supply voltage Operating voltage range Power consumption Insulation resistance Dieletric strength Noise immunity Vibration Shock Ambient temperature Humidity Atmosphere Degree of protection Characteristics Control system Main control element Programming system Instruction word length Number of instructions Execution t
51. 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 p
52. P Detachabale terminal block Input power supply Load power supply Input power supply Load power supply Power supply for external device for relay driving Load power supply Terminal ce ze 7 cy aT a Signal name OUTI OUT3 our ours ourio f ouTn I O No 0701 0703 0707 0708 0710 0711 Terminal Signal name OUT2 OUTS vo No 0702 0704 Specifications 1 0 link unit Ratings Supply voltage Operating voltage range Power consumption Insulation resistance Dielectric strength Noise immunitiy Vibration Shock Ambient temperature Humidity Atmosphere Degree of protection Characteristics Transmission system Communication method Transmission speed Transmission delay Transmission lines Line distance Number of I O points External output Weight AC 100 to 120 V AC 85 to 132 V 15 VA max 5MQ min at DC 500V between external terminal and outer casing AC 1 500V 50 60Hz for 1 minute between external terminal and outer casing 1 000Vp p Rise time Ins Pulse width 100ns to 1ps 16 7Hz 3mm double amplitude in X Y and Z directions respectively for 30 minutes 10G in X Y and Z directions respectively 3 times Operating 0 to 55 C Storage 20 to 65 C 35 to 85 RH without condensation Must be free from corrosive gases IP30 Time division m
53. PC and which I O unit it is Data input output time 1 04ms 0 33ms x N Since in this example we assume that the C20 is used by itself the value of constant N equals 0 Thus 1 04ms 0 33ms x 0 1 04ms Next the time required for executing all the instructions in the program must be known To do this obtain the average execution time and then multiply that time by the number of addresses in the program Because only the LD and OUT instructions are used in this example the average instruction execution time can be obtained by adding the execution times for the two types of instructions and then dividing the sum by two To find the execution times for these two instructions refer to List of instruction execution times on the preceding pages We see from this list that the execution time of the LD instruction is 12us and that of the OUT instruction is 17 5us Accordingly the average execution time is 12us 17 5yus 2 14 75us Now it is possible to obtain the total instruction execution time by multiplying 14 75us by 512 the number of program addresses Scan time Total execution time 512 addresses X 14 75us 7 55ms Adding the four parameters provides the total scan time 1 07ms 1 04ms 7 55ms 1 1ms 10 76ms Notice that if no peripheral device is connected to the PC the fourth parameter in this equation is Oms Next let s consider the scan time for a system that has a 56 point expansi
54. TION message in doing this you may have reached this display message The number 1193 here represents the total number of address locations available Normally when you see this message it means that you forgot to put an END instruction at the end of your program This is one time when you can ignore the error message though The search function has carried you into the unused region of the memory address locations 0011 to 1193 No new END statement is actually required here The quick search operation can be performed still another way If you wish to locate specific contacts this can be accomplished easily in any of the three modes with this simple operation Start from the first address of memory Then press NT Checking and running your program If you still have our sample program in the CPU memory this should be the display Then to go to the next contact with the same number again press The display now changes to the next address containing an instruction with the same contact number the four digits at the lower right of the display This continues until the end of the program is reached If you want to search for a contact having a different contact number foliow the same steps as before But this time enter the numeric value of the contact you want to locate Using our sample program if you enter 1000 and press the search key the display will show the LD instruction in addre
55. Y RELAY B 9 TIM B 6 Interblock AND operation B 4 INTERLOCK IL and INTERLOCK CLEAR ILC special instruction B 11 Internal auxiliary relay assignment 3 3 purpose D 3 channel assignment D 3 number of D 2 Internal flags 5 7 Internal operations four types C 1 Introduction to PCs 1 1 Key abbreviations 4 3 compatibility with other C Series PCs 4 3 Keys explanations on use 4 3 Ladder diagram examples 3 5 3 6 6 2 6 3 6 5 6 6 6 8 points to remember 3 6 LATCHING RELAY KEEP special instruction B 13 Latching relay B 13 LD instruction 3 5 inverting B 3 key 4 3 Left bus bar 3 4 Limit on communication distance A 3 Limit switch 6 1 Limited control application A 8 LINE IN LINE OUT jacks 5 10 Index Link adapter about A 12 power supply E 1 dimensions F 16 List of error messages E 12 List of instruction execution times C 3 List of instructions H 1 List of relay numbers D 2 LOAD LD instruction B 1 LOAD NOT LD NOT instruction B 3 Loading and verifying program 5 12 Loading program 4 6 5 12 Location of C20 2 5 Logic line beginning 3 4 B 1 with NC contact B 3 Logic line ending 3 6 Logical operation output B 1 Low humidity problems 2 1 LR key 4 3 Machinery control 6 6 Main control element Maintenance and troubleshooting E 1 Maintenance tools and testing devices E 2 Meaning of messages A 11 Memory capacity C20 2 1 Memory chip DIP switch settings 2 1 installation 2 2 introductio
56. and user program memory Checking OKed YES Inputs data from input unit to I O relays and outputs data from I O relays to output unit Initial processing on power application Common processes Resets watchdog timer and program counters Executes instructions in the user program Program execution ended Scan time of PC Instruction execution YES Resets watchdog timer Services commands from peripheral devices 3s 8 ma ot Sse Q 5 E aug fe 258 cis 2d oa OAT Scan time E a Execution time and variables Resetting of watchdog timer Checking of user program memory Checking of I O bus The required scan time differs depending on the configuration of the system the number of I O units the number of special instructions and whether peripheral devices are connected The following table shows the time required for each internal operation 1 07ms fixed Reading data input from input unit to 1 0 relays Writing data result of instruction execution to output unit from I O relays 1 04ms 0 33msxN where N 1 when a 28 point I O unit or I O link unit is used or N 2 when a 56 point I O unit is used Execution of instructions in the user program Total time for executing instructions The time required for execution differs depending on the instruction Refer to the section below List of
57. assignment D 3 Holding relays number of D 2 HR key 4 3 Humidity 2 1 2 3 E 1 E 10 Index I O assignment channel D 1 examples 6 2 6 3 6 5 6 6 6 8 V O bus failure E 11 1 0 link unit about A 3 application example A 12 detailed appearance A 4 DIP switch setting A 8 end station A 6 optical fiber cable connectors A 9 power supply E 1 restrictions A 6 system example A 10 wiring A 5 characteristics F 8 connection to remote I O master unit A 9 dimensions F 16 grounding A 5 noise suppression A 5 ratings F 6 supply voltage A 5 system configuration example A 3 O master unit A 3 system example A 10 connection to link unit O points A 4 O table generation A 11 O table messages meaning A 11 O wiring 2 3 C socket location 2 2 ndependent power sources 2 4 nput relay channel assignments D 1 nput output channels automatic designation A 1 indicators location and function 1 3 monitor 5 8 relays number of D 2 requirements 3 2 section 1 1 specifications CPU F 3 unit channel designation A 6 Inserting instructions 4 9 Inspection E 1 Installation C20 2 1 memory chip 2 2 optical fiber cables F 1 Index Instruction deletion 4 9 execution times listed C 3 insertion 4 9 keys programming console 4 2 keys purpose 1 4 word length F 4 instruction words AND B 2 AND LOAD B 5 AND NOT B 4 COUNTER B 8 LOAD B 1 LOAD NOT B 3 OR B 2 OR LOAD B 6 OR NOT B 4 OUTPUT B 1 TEMPORARY MEMOR
58. ays assigned to the I O link unit are transferred to the SYSBUS when an 1 0 link unit is employed Internal auxiliary relays The CPU has 136 internal auxiliary relays No 1000 to 1807 that constitute channels 10 to 18 Holding relays retentive relays The CPU has 160 holding relays No HROOO to 915 that constitute holding relay channels 0 to 9 The holding relay retains data during power failure Timers counters The CPU has 48 points of timers counters TIM CNTO0 to 47 that can be used for either timers or counters Timers and counters cannot be assigned the same number Assignment of I O channel and relay numbers Temporary memory relays The CPU has eight temporary memory relay points TRO to 7 Special auxiliary relays The CPU has 16 special auxiliary relays some of which operate or release according to internal conditions controlled by the hardware irrespective of the statuses of the I O devices Each of these special auxiliary relays functions as follows Relay 1808 This relay operates when a battery failure occurs An alarm signal indicating a battery failure can be output to an external device by programming a circuit incorporating the contact of this relay Relay 1809 Normally OFF Relay 1810 Normally OFF Relay 1811 Normally OFF Relay 1812 Normally OFF Relay 1813 Normally ON Relay 1814 Normally OFF Relay 1815 This relay is turned ON for one scan time at the start of program exec
59. battery has expired Replace the battery The END instruction is missing Write END instruction at end of program Clear the error message refer to step 7 Testing for errors in Chapter 5 Program exceeds the memory capacity Check the program The contents of the cassette tape and user program do not agree Check the contents of the cassette tape and user program An error exists in the cassette tape Replace the tape with a new one Appendix F Specifications Overview Available types This appendix describes the specifications for the CPU the I O link unit and the link adapter Specifications for other peripheral devices are provided in the respective user s manuals Specifications No of cPU Classification i Weight Type name Power supply Input No of Output outputs Expansion NO 3G2C7 CPU73 E NPN YES 3G2C7 CPU74 E Contact DC 24V PNP NO 3G2C7 CPU83 E YES 3G2C7 CPU84 E DC 24V NPN 16 Transistor YES 3G2C7 CPU76 E NO 3G2C7 CPU13 E banger YES 3G2C7 CPU14 E 0 J AC 100 to 120V nipe 12 NO 3G2C7 CPU23 E YES 3G2C7 CPU24 E AGAO Contact YES 3G2C7 CPU3 18 120 Triac YES 3G2C7 CPUS T NO 2kg max 3G2C7 CPU43 E YES 3G2C7 CPU44 E AC 200 to 240V Contact rea 2 ii NO 3G207 CPU53 E Expansion 1 0 unit DC 24V for output driving DC 24V AC 100 to 120V YES Contact Transistor Contact
60. before the input signal can be accepted Therefore the maximum response time is the sum of the maximum input ON delay output ON delay and two scan times The timing charts of the minimum and maximum response times required for the PC to execute the following program are shown next C 5 Scan time Response time calculation example Input Output Where the input ON delay time is 10 minimum to 20ms maximum the O scan time is 10ms and the output ON delay time is 15ms the minimum and maximum response times are Minimum response time 10ms 10ms 15ms 35ms Maximum response time 20ms 10ms x 2 15ms 55ms Scan time Data input output time Instruction execution Instruction Il Instruction execution execution ON delay time CPU reads the input signal Scan time Data input output time a Instruction execution Instruction execution Appendix D Assignment of I O channel and relay numbers 1 0 channel assignment Relay assignment The input channel of the CPU is fixed at channel 00 while the output channel is fixed at channel 05 When an expansion I O unit I O link unit or both are connected to the CPU the I O channel of the connected units are automatically assigned and registered in the CPU For example when a 28 point expansion I O unit is connected input channel 01 is automatically assigned t
61. between the IL and ILC instruction is Output relay internal auxiliary relay Timer Counter shift register holding relay Holds present state When the IL condition is ON the state of each relay is the same as that in an ordinary relay circuit when the IL ILC instructions are not used SHIFT REGISTER SFT start channel no end channel no Function Symbol Acts as a serial input shift register IN oP R ere Remarks The shift register must be programmed in the order of data input clock input reset input and an SFT instruction from the start channel to the Ladder diagram end channel 0000 0001 Data input ee nace t Each SFT instruction must be specified in units of 16 bits In the circuit example 16 bits from 1000 to 1015 are transferred 9002 Clock input i i y R ea The 16 bit contents of the shift register can be output bit by bit using the relay numbers of the specified channel 0003 F Reset input When a reset input is applied to the shift register all 16 bits are reset together TE The data are shifted at the leading edge of the input clock If the holding relay area is used the data are retained during power failure until a clock or reset input is applied Clock input ji i i I i I i H i I I i I i I Data input 1000 1001 1002 1003 1004 1005 1006 1007 1008 1009 1010 1011 1012 1013 1074 1015 i F t l i
62. can be directly mounted on the C20 It is important that when using this unit mounted on the C20 the I O cable connecting the CPU and expansion I O unit not be connected Otherwise the PROM writer may not operate As the EPROM chip use Type ROM H 2764 or the equivaient The PROM writer may not operate when mounted on the C20 if the CPU is connected by cable to an expansion I O unit Graphic programming console A 14 The graphic programming console is a quick visual way to write programs using ladder diagrams and instruction words The user presses instruction keys and other control keys on the keyboard In response the symbols appear on a screen on the portable unit The graphic programming console is available in two types One employs an LCD liquid crystal display for the screen whereas the other uses a CRT cathode ray tube The CRT type is referred to as CRT while the LCD type is referred to as GPC Both the CRT and GPC store programs onto cassette tape and load programs into the CPU memory using the peripheral interface unit Caution _PROMs that have been written by the PROM writer used with the C20 cannot be directly read by a PROM writer connected to the graphic programming console nor can the reverse operation be performed In either case the message MEMORY ERR is displayed The peripheral interface unit is required to transfer programs between these devices
63. cations of HR9 CH HR900 to HR915 If there is a carry in the result 1904 is turned ON and if the result of the addition is 0000 1906 is turned ON VO relay internal auxiliary relay Contents of HR9CH 20 HR90O HR901 HR902 HR903 HR904 HR905 eN x10 ansor J 2 3 HR908 HR903 HR910 HR911 HR912 HR913 HRg14_ 1 HR915 x10 Carry 1234 1904_ x10 Before executing an ADD instruction the carry register 1904 must always be cleared using a CLEAR CARRY instruction This is not required in multistage addition Function Performs BCD subtraction of a channel data or four digit constant S2 from a specified channel data S1 and then outputs the result to a specified channe D Remarks The SUB instruction is used to execute BCD subtraction between two specified four digit data Instruction words Ladder diagram B22 0000 Coding chart 0200 LD 0201 CLC SUB 31 Notes Contents of data Input output relay internal 00 to 19 05to 17 auxiliary relay Holding relay HR OtoS Timer counter TIM CNT00 to 47 Constant 0000 to 9999 Before executing a SUB instruction a CLC instruction must be program med to clear the carry flag 1904 When the result register is logical 1 a BCD subtraction is executed with each scan To execute it only once program a differentiating circuit for the i
64. csddes rd toh tl rol ol ol OUTS 0506 Load power supply Note The input channel is fixed on channel 0 and the out put channel on channel 5 The terminal block can be removed F 9 Specifications Expansion 1 0 unit Type 3G2C7 MC223 MC224 DC input NPN Contact output Input voltage DC 24V 10 15 input impedance 3kQ Input current 7mA typ DC 24V ON delay time 20ms max 15ms max OFF delay time 20ms max 15ms max Number of circuits 16 points 8 points common 12 points 8 3 1 points common ON voltage DC 16V max OFF voltage DC 5V min Max switching capacity AC 250V DC 24V 2A max p f 1 8 4 2A common 14A unit Min switching capacity DC 5V 10mA min Leakage current Saturation voltage External power supply 15mA point 180mA unit Service life of relay Electrically 300 000 operations Mechanical ly 50 000 000 operations G6B 1114P US M DC 24V with socket Circuit configuration Internal circuit gt 4OUT 00 4 40UT 07 COM p gt OUT 08 internal circuit Internal circuit Terminal Signal name VO No Terminal Signal name VO No Input power supply Input power supply EPERE FRFE FFER anap nynnnne OLD KOLO OMOL ORG BE Power supply for e
65. cular 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 confi
66. d frequency max Number of circuits 28 points 8 6 points common 24 points 8 3 1 points common ON voltage AC 60V max OFF voltage AC 20V min Max switching capacity AC 85 to 250V 0 2A max p f 1 Min switching capacity 10mA AC 100V 20mA AC 200V min Leakage current 2mA AC 100V 5mA AC 200V max Saturation voltage 1 6V max External power supply 20mA point 480mA unit Service life of relay G3S 201PL PC DC 24V Circuit configuration COM IN 124 IN 134 Internal circuit Internal circuit Internal circuit Internal circuit OUT 00 l OUT 07 7COM Internal circuit t OUT 08 l OUT 10 com fOUT 11 COM Internal circuit 14 pointsx2 28 points 12 pointsx2 24 points F 17 Specifications Terminal Signal name 1N12 ouT3 ouio foumi I O No 0112 0603 0510 0611 Jermina ar ignal name I O No 0609 Power supply for external device for relay drivin Note Input power supply Pry oad power phi y 9 Those of MA222 with 28 Input power supply Load power supply et panta a OuIpU Load power supply channels 1 and 2 input and 6 and 7 output ddddusas MOORA KONKON SEY 3 BN E E C A B ala Tt OA Weed oT tT 1s K7 OC
67. displayed by the programming console is given along with the corrective action Inspection items Semiconductor elements are employed as main components of the C20 Semiconductors are however subject to deterioration under severe environmental conditions and should be inspected periodically The standard inspection cycle is 6 months to 1 year The frequency of inspection should be increased if required If the C20 is found to be outside the criteria shown in the following table corrections should be made so that the criteria are met C20 rated at AC 100 to 120V AC 85 to 132V C20 rated at AC 200 to 240V AC 170 to 264V C20 rated at DC 24V DC 20 4 to 26 4V Must conform to specifications of each expansion 1 O unit AC 85 to 264V Link adapter rated at AC 100to 120V AC 85 to 132V Link adapter rated at AC 200 to 240V AC 170 to 264V Link adapter rated at AC DC 12 to 24V AC DC 10 2 to 26 4V DC 10 2 to 13 2V Oto 55 C 35 to 85 RH without condensation Must be relatively dust free Maintenance and troubleshooting Mounting CPU and expansion I O unit firmly secured Expansion I O unit cable securely inserted in connector Screws for external wiring firmly secured Any break in external wiring cables Battery service life Optical fiber cable Bending radius of the optical fiber cable Caution Mounting screws must not be loose The cable must not be loose Screws must not be loose Must
68. dress from which this program starts In this example we ll use 0000 as the starting address To this address an instruction that indicates the beginning of the program must be written For the C20 the LD LOAD instruction serves this purpose In our ladder diagram the bus bar represents the LD instruction Thus this instruction always is used any time the logic line starts from the bus bar On our coding sheet next to address 0000 we write the instruction LD Because the first contact in the AND circuit must be stored as the data of the LD instruction we write this down in the data column on our sheet In our example this data is 0005 The next element of the ladder diagram is the AND instruction which we assign to address 0001 in the program as shown The data for the AND instruction is the number assigned to the second contact in this case 0006 On our sheet we write this next to the AND instruction Next we need an OUT OUTPUT instruction to output the result of the ANDed contacts in our circuit We write this instruction in address 0002 and designate the output relay number to which we want this signal sent We ve chosen this relay to be 0500 and have written that as the next entry on the sheet We re finished except that we always have to tell the PC when a program is over So we assign an END statement to address 0003 Introduction to programming Sample program for coding practice Preset
69. e transferred to the PC s internal memory For storage purposes the program can also be transferred to a cassette tape During operation of the PC the GPC can be connected to the PC to monitor the PC s operating status A program written on the GPC can be printed out if a printer is connected to the GPC via the printer interface unit Moreover if the floppy disk unit is connected high speed transfer of the program to a floppy disk can be achieved The CRT features two registration functions label registration and user program registration A label is a four digit alphanumeric code assigned to a desired relay number making it possible for the relay numbers to be mnemonically used With the user program registration function a repeatedly used program can be registered and then easily called from memory whenever it is needed One of the other advantages of the CRT is that more peripheral devices can be connected to the CRT than is possible with the GPC Specifically as shown an X Y plotter and video printer can be connected in addition to a printer and cassette tape recorder For details refer to the User s Manual for Type 3G2A5 CRT19 20 Graphic Programming Con sole Video printer Plotter Printer Cassette tape recorder S ystem expansion and peripherals Multisupport base SYSMAC C20 Peripheral interface unit Type 3G2C7 1P002 connected to the C20 Use Type 3G2AC CN221 2m co
70. e of more than 1 200V require noise suppression For AC supplied noise sources connect a surge suppressor in parallel with the coil of each device For DC operated noise sources connect a diode in parallel with the coil of each device When mounting a CPU and I O expansion unit in a contro panel be sure to completely ground the intermediate mounting plate The mounting plate must be finished with high conductivity plating to insure noise immunity Power supply Where possible use independent power sources for the input the load and for the CPU and O units External power suppl Load power supply aes Ee Output device Input device Output device C20 CPU Expansion I O unit p i L Power supply DC 24V AC 100 to 120V AC 200 to 240V Grounding Terminal LG is a noise filter neutral terminal which does not normally require grounding When electrica noise is a problem however this terminal should be short circuited with terminal FG Installing the C20 Control panel mounting Some of the main considerations when mounting the PC in a control panel are accessibility for operation and maintenance and protection against heat These are some of the things you should consider Use M4x25 mounting screws Provide the PC with adequate space for ventilation Avoid mounting the controller directly above any heat generating source such as a heater transformer or high capacit
71. e the PC in the MONITOR mode and press Now specify the contact that you wish to force set In this case Relay 1000 is to be forced set Press A The display shows the present status of the relay which in this case is OFF Now to force set the relay to ON press PLAY SET This force sets the relay from OFF to ON Forced relay reset To force reset a relay to the OFF state press REC RESET This turns the currently ON relay to OFF Note Forced timer set To force set a timer put the PC in MONITOR mode and press The display shows the first timer Timer 00 and its preset time if the timer is not currently running Then to clear the set time for one scan time press Due to the short cycle period however you will not be able to see this clearing actually take place If the timer is currently operating depressing MONTR displays the current value of the timer If the timer has completely gone through its timing period you will see this value Depressing RESET restarts the timing operation from the set time Special auxiliary relays 1808 to 1907 cannot be forcibly set or reset These relays serve as flags that are internally raised and lowered set and reset to enable monitoring of PC operation If an attempt is made to set or reset one of these relays you ll hear a beep and no key input will be accepted by the programming console Changing set value
72. ed on channels 1 and 2 input and 6 and 7 output OUT COM When connecting an inductive load connect a 1 diode 1A 100V in Parallel with the load ST fell fon tod fot ry gt 4 t i w g i g a 4 amp bcomt cot POTEET ECE ee Detachable terminal block NEMEC K E TAERE Ca m gRr t O Ie LAN An o ji 2 3 44 5 6 7 18 19 Hol14 2413 4 15 Pe Rebetsksperoreror ere ron jas 7 no it gel otal D fea pe De 1 Bige B Dea Doe ol ol ea E 6606 4 G Q 1 Input power supply Load power supply Load power supply Input power supply Load power supply Power supply for external device for relay driving Terminal aa Signal name OUTI OUT V0 No 0701 0707 Terminal Signal name OUTS I O No 0706 Specifications Expansion 1 0 unit Type gt 3G2C7 MC22B MC22C AC 100 to 120V input Contact output Input voltage AC 85 to 132V Input impedance 9 7kQ Input current 10mA typ AC 100V ON delay time 35ms max 15ms max OFF delay time 55ms max 15ms max Number of circuits 14 points 8 6 points common 12 points 8 3 1 points common ON voltage AC 60V max OFF voltage AC 20V min _ Max switching capacity AC 250V DC 24V 2A max p f 1 Min switching capacity DC 5V 10mA min Leakage current Saturation voltage External power supply 15mA point 180mA uni
73. eferences that relay Using the PC in the RUN and MONITOR modes is explained in Chapter 5 The PROGRAM mode which is fully explained in this chapter is used during the programming operation Console display The easy to read display is your window into the workings of the PC The display format changes depending on the mode that you have selected Let s first examine the PROGRAM mode Using the programming console PROGRAM mode To erase existing memory Caution If the mode selector switch is turned to PROGRAM this is what you ll see when you apply power to the PC This is your electronic sentry that blocks unauthorized use of the PC To gain access an actual password isn t necessary just this key se quence The PC responds with a beep each time you depress a key This is what you now will see informing you of the mode you are in To clear this press CLR At this point you are ready to begin entering your program step by step using the code you wrote from your ladder diagram in Chapter 3 The display you see is the starting address of the memory This location is used in connection with the quick search editing functions Let s skip this for now because we won t need to use it until after we have input our program Although it is possible to overwrite an old program with a new one this is not recommended because it may cause confusion and lead to pr
74. elay Remarks To program a temporary memory relay the TR instruction must be used with an OUT or LD instruction The TR instruction is used when a ladder diagram cannot be program med with the interlock instructions In an output branching circuit consisting of multiple blocks temporary memory relays are used at each point These temporary relays cannot be used in duplicate within the same block but can be used within different blocks Relay numbers can be from 0 to 7 Coding chart Instruction words O ooo oil i oiz Gn Ls 03 60 0004 Ga mO pE ae or 0013 Goo 0014 Foo In addition to the instructions with their own keys additional special instructions are supplied in the C20 that are available using the FUN function key To write one of these instructions into a program press numeric key numeric key Special Instructions Symbol Function END Indicates the end of the program Ladder diagram Remarks 0000 0001 This is always the last instruction written into a program and is used to qi 4 H indicate the program s end An error message NO END INST is displayed when attempting to run or monitor the program if this instruction is missing The CPU scans the program data from address 0000 to the address with the END instruction in the sequence shown 0000 J oo Instruction words This instruction can
75. elay no Function Performs logical AND of register result i e connects two or more contacts in series with the address portion of AND instruction Remarks This instruction ANDs the result of a logical operation previously saved to the result register with the specified relay This result of the logical AND operation is then stored in the result register The contents of specified relay no IAND R h Ce Coding chart 0003 LD 0000 0004 AND 0001 0005 OUT 0501 OR s relay no Function Performs logica OR between a specified relay i e connects two or more contacts in parallel and the contents of the result register Instruction words Ladder diagram 0000 G50 0001 LOAD NOT LD NOT Symbol Ladder diagram Remarks This instruction performs the logical OR of the contents of the result register with the specified relay The result of the logical OR operation is then stored in the result register The contents of specified relay no J R N Coding chart Address Instruction Data 0006 LD 0000 0007 OR 0001 0008 OUT 0502 LD er NOT relay no Function Starts operation of each logic line with an NC contact Remarks When a logic tine starts with an NC contact this instruction is used in the place of the LD instruction The LD NOT instruction inverts the contents of the specified relay number and store
76. er and a constant and then transfer of the result to a channel SUBTRACT 217 addition of two channels and then transfer of the result to a channel 340 addition of a timer counter and a constant and then transfer of the result to a channel SET CARRY 16 RESET CARRY 16 in microseconds Scan time Scan time calculation examples When calculating the total scan time required by the PC to perform its internal operations the system configuration must be taken into consid eration This means factoring into the calculation such things as the number of input output units and specia instructions and whether peripheral devices are employed For example let s see how to calculate the scan time when the PC is used by itself and with no special instructions For the sake of simplicity it is assumed the user program consists of 512 addresses and only uses the LD and OUT instructions Of the four parameters for the calculation the times required for common processes data input output instruction execution and servicing peripheral device commands how long it takes to perform the common processes and service peripheral device commands are fixed at 1 07ms and 1 1ms respectively This leaves only the remaining two parameters to be calculated The time required for data input output can be determined by using the following equation where the variable N can be 0 1 or 2 depending on whether an V O unit is connected to the
77. ermined quantity of oil The level of the lubricating oil in the tank is monitored by a sensor that serves as an input device to the C20 If the oil level in the tank falls below a specific level the sensor detects it and inputs a signal to the C20 In response the C20 outputs a signal that illuminates an alarm indicator lamp on the C20 s control panel 1 0 assignment Position detection Lower limit oil level Output Electromagnetic valve for oil supply Oil shortage alarm indicator Application examples Coding chart Operation Instruction The signal from the sensor that detects the position of the part to be oiled LD is connected to a differentiation up circuit so that the Internal Auxiliary DIFU 13 Relay 1000 turns on for one scan time at the leading edge of the input signal input 0000 When this internal auxiliary relay turns on output 0500 turns on causing the electromagnetic valve to open supplying oil to the gear The valve stays open for 1 5 seconds as governed by Timer 00 When the oil in the tank is almost depleted a sensor assigned as input 0001 turns on and output signal 0501 is issued by the C20 to illuminate an alarm indicator on the control panel Conveyor belt motor control The C20 is used to start and stop motors of a segmented conveyor belt in this application This permits only those belt sections actually carrying an Object to be moving while
78. ese 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 Introduction to the C20 Basic system configuration The figure below shows some of control systems employing the C20 The maximum number of I O points per system is 28 if the DC input type nonexpandable CPU is used With the AC input type it is 2
79. f D 2 Test run of equipment or process B 11 Testing each circuit B 11 environment 2 3 for errors 5 4 program B 10 TIM key 4 3 TIMER TIM instruction B 5 Timer forced set reset 5 7 how to change existing value 5 1 how to change set value 5 7 monitoring during operation 5 8 number limit B 7 power failure protection B 6 rapid check of values 5 9 setting resetting B 7 value limit B 7 Timers and counters assigning numbers 3 4 Timers counters channel assignment D 3 number of D 2 restrictions 3 4 Timing of control tasks 3 2 TR key 4 3 Transformer for I O link unit A 5 rial run 5 6 roubleshooting E 1 E 4 urning ladder diagram into PC code 3 5 Index Using the programming console 4 1 Ultrasonic switch use with C20 6 1 Valve use with C20 6 6 Variations in cycle time C 2 Ventilation requirements 2 5 Verifying program 5 12 Vibration precaution against 2 3 Volume of tape recorder 5 10 Warning signal A 12 Wiring ducts use of 2 3 high power 2 3 requirements 2 5 WRITE key 4 2 Writing relay ladder diagrams 3 4 1 0 Assignment Table CODING SHEET
80. facilitate program editing and debugging One allows you to go directly to specific program addresses Another allows you to hunt for specific instructions The last lets you speedily check each contact These editing features eliminate the need for you to travel through the program a single step at time auite a tedious process when a large number of addresses are involved Going directly to a known address This is a simple way of going straight to the address you want Do this by first clearing the display by pressing Then key in the number of the address you want Let s assume that we want to change the timer value from 2 0 seconds to 3 0 seconds We first key in its address and follow that with Checking and running your program When you do this you will see that the display has gone directly to address 0008 Before you can change the timer value however you must first go to the timer s data by pressing to move the program down one step This is the display At this point you can make the change to 3 0 seconds by keying in aag Check the display It should now look like this When correcting or modifying a program this method of address locating is particularly useful to go quickly to a new part of the program Note though that you must always start at the first address in memory which is reached by pressing CLR one or more times Sea
81. fe of the battery is 5 years When the battery has been fully discharged the ERROR ALARM indicator blinks If this happens replace the battery with a new one within a week The date when the battery must first be replaced is written on the side panel of the C20 For example if it says FIRST REPLACEMENT 89 12 This means you should replace the battery by Dec 1989 Replacing the battery 1 Turn off the power If the power is not on turn it on once and then off again after waiting 10 seconds 2 Remove the C20 s front cover 3 Remove the old battery together with the connector to replace it Caution This procedure must be accomplished within 5 minutes of turning the power off 4 Reattach the front cover 5 Attach the programming console clear the BATT LOW message observing the following procedure al Maintenance and troubleshooting Troubleshooting The following flowcharts will enable you to determine the source of any abnormality occurring in the PC or I O link unit General flowcharts For PC Start POWER indicator lit YES 1 Refer to Power supply flowchart Refer to Failure flowchart RUN indicator lit YES ERROR ALARM indicator blinking Refer to Battery flowchart Refer to I O flowchart Refer to Environment flowchart YES Replace CPU For VO link unit YES YES YES NO input output sequence n
82. fied channel The MVN inverts the channel data and then performs the same function as the MOV instruction Coding chart Instruction __ Data 0200 to 0 0 MOV 21 one ae eee nee need T MVN 22 a Contents of data Input output relay internal 00 to 19 05to 17 auxiliary relay Holding relay HR Ot Timer counter TIM CNT 00 to 47 Constant 0000 to FFFF if the transferred data are all 0 special auxiliary relay 1906 turns ON When the result register is logical 1 a MOV or MVN instruction is executed at each scanning To execute it only once programa differentiating circuit for the input Instruction words Explanation Nothing is executed when the content of the result register is logical 0 When the content of the result register is logical 1 transfer of data or of inverted data is performed When the program of the circuit example is performed the 16 bit data of 10CH 1000 to 1015 is transferred to HRICH HR900 to HR915 then inverted to be further transferred to HROCH HROOO to HRO15 I O relay Holding relay Holding relay 10CH HRSCH HROCH The result of the transfer will be HR9CH 0 gt 1906 1 HRO 0 1906 0 In constant designation hexadecimal four digit binary 16 bit data is either transferred or inverted and then transferred B 19 Instruction wo
83. g 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
84. guration 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 Over
85. haracteristics 3G2A3 PS221 AC 100 110 120V AC 85 to 132V AC 200 220 240V Input voltage AC 170 to 264V 50 60Hz 7Hz AC 200V is the factory set condition Output voltage 24V 5 Output capacity 1 5A max 36W Efficiency 70 min Power failure Retains 10ms max Inrush current 5A max Fuse 2A incorporated Leakage current imA max between FG terminal and ground 560g Where possible use independent power sources for the inputs the load and for the CPU and expansion O units Grounding Attach a dedicated grounding wire with a cross sectional area of at least 2mm AWG14 to terminal FG to lessen the possibility of electrical shock Ground resistance must be less than 100Q Do not use a grounding wire longer than 20m Care must be taken because ground resistance is affected by the nature of the ground water content season and the amount of time that has elapsed since the wire was laid underground In case a large noise occurs causing the C20 to malfunction short circuit terminals LG and FG for grounding at a resistance of 100Q PC operation may be adversely affected if the grounding wire is shared with other equipment or if grounding is attempted by attaching the grounding terminal to the metal superstructure of a building Other equipment Other equipment Installing the C20 When the I O expansion unit is used with the CPU the FG terminals on both de
86. he LD instruction To do this press LD HE and you see this display The first set of four Os at left is the beginning address position and is where the LD instruction will be stored The second set of four Os at right is a numeric value representing the input point Currently the input point is 0000 Since this is the value you assigned to the input of Counter 47 you can leave it unchanged Then to WRITE this LD instruction to memory address 0000 press WRITE and this display appears Here 0001 is the address number READ means you are reading the program and NOP 00 means that no operation has yet been assigned to this address Next enter LD HE again to specify the reset input of the counter READ disappears because you are now writing to address 0001 instead of only reading its contents Now key in the the relay number and write it to the address with in the next address we want to input the counter This is done by pressing CNT Now we have to specify the coil number of the counter we want which is 47 Do this by keying in E Using the programming console This second counter display at left indicates the set value of the counter Currently it is 0000 We want to change this to 5 the number of signals that must be input by the optical sensor So key in E wate Now we have to enter the LD instruction to specify the contact of the counter that corresponds to the coil
87. he load eddies rs ret et T rs ral os dundecuada AAAA AANA Specifications CPU Type A SC 3G2C7 CPU34 E AC 100 to 120V input Contact output Input voltage AC 85 to 132V Input impedance 9 7kQ 50Hz 8kO 60Hz Input current 10mA typ AC 100V ON delay time 35ms max 15ms max OFF delay time 55ms max 15ms max Number of circuits 14 points 8 6 points common 12 points 8 3 1 points common ON voltage AC 60V max OFF voltage AC 20V min Max switching capacity AC 250V DC 24V 2A max p f 1 8 4 2A common 14A unit Min switching capacity DC 5V 10mA min Leakage current Saturation voltage External power supply Service life of relay Electrically 300 000 operations Mechanical ly 50 000 000 operations G6B 1114P US M DC 24V with socket Power supply AC 100 to 120V Circuit configuration COM IN 06 IN 07 COM Internal circuit 3 gt 4OUT 00 m o 40UT 08 l OUT 10 7COM p gt S 40UT 11 COM Internal circuit 3 2 T E 2 Terminal Signal name VO No Terminal INO i e Signal nam ey V No Ooo KokoK Nput power supply Input power supply eusiens ave Jedi tated INI3 0113 Load power supply Load power
88. highest channel number channel 31 and assign the following channels decrementing for each one Of the I O link units connected to the remote I O master unit the I O link unit which is physically the furthest from the remote I O master unit serves as the end station When you assign channel numbers and must designate the end station keep in mind that this is a physical description and is not related to the size of the channel number Channel 31 may or may not actually be the end station System expansion and peripherals System example 1 SYSBUS optical fiber cable SYSBUS optical fiber cable SYSMAC C500 CPU rack Specified as end station co SYSMAC C20 C20 VOlink unit SYSMAC C20 CPU C20 v0 Tink unit C500 remote I O master unit 8G2A5 RM001 E CPU 8G2C7 LK011 3G2C7 LKO011 channels 28 and 29 channels 30 and 31 System example 2 C500 CPU rack cee LT C120 1 0 link unit 83G2A6 LK010 16 points channel 30 6120 expansion I O rack 83G2C4 S1023 024 C20 VO link unit C20 CPU Space unit Space unit 8G207 LKO011 Remote I O master unit 32 points 16 points channels 08 channels 28 16 points channels 07 and29 is 32 points channels 05 and 06 C120 CPU rack 64 points channels 01 02 03 and 04 L416 points channel 00 SYSBUS optica
89. hion with the CPU on top and the expansion I O unit on the bottom saving mounting space The CPU can be flipped over to the right allowing you access to the indicators on the expansion I O unit for monitoring and maintenance purposes Dimensions ee nt ey ee ree we With programming console attached nN 91 3 iaie i Mounting kit pe go hossS ssSesseaesseee eso sa gt 1 i 1 L 1 L Mounting method The mounting of the CPU and expansion I O unit using this mounting kit can be performed in these three steps First attach brackets B and C two of each to the expansion I O unit and fix the brackets with four M4x25 screws j Screw Bracket yi J Screw four M4x25 W O terminal block f Bracket B The M4x25 screws are not attached Separately obtain eight binding head screws or screws with smali plain washer Second mount the CPU on the mounting plate with four M4x25 screws Note that at this time the hinge of the mounting plate must face to the right No nut is required to tighten the screws lj Screw four M4x25 i oe Mounting plate 1 0 connecting cable 32cm 3G2C7 CN311 Expansion I O unit Finally connect one end of the I O connecting cable Type 3G2C7 CN311 32cm to the left of the expansion I O unit and c
90. ific instruction 5 2 for relay contacts 5 3 Selecting the right memory chip 2 1 Semiconductor inspection E 1 Sequence of control tasks 3 2 Serial input shift register B 12 SET CARRY STC special instruction B 23 Set carry flag B 23 Setting the DIP switches 2 1 SFT key 4 3 Shared grounding 2 6 SHIFT key 4 2 SHIFT REGISTER SFT special instruction B 12 Shift register more than 16 bits B 13 outputting to B 1 Special auxiliary relays 1808 to 1907 5 7 Special auxiliary relays D 4 Special instructions ADD B 19 CLEAR CARRY B 23 COMPARE B 16 DIFFERENTIATION UP B 14 DIFFERIENTIATION DOWN B 15 END B 10 HIGH SPEED TIMER B 16 INTERLOCK IL and INTERLOCK CLEAR ILC B 1 LATCHING RELAY B 13 MOVE B 18 MOVE NOT B 18 SET CARRY B 23 SHIFT REGISTER B 12 SUBTRACT B 21 Special instructions about B 10 Specifications 2 5 F 1 Specifications power supply 2 6 Standard memory capacity expandable CPU 2 1 Starting operation of logic line B 1 Static electricity 2 1 Index Status check 5 5 5 8 Storing a program to EPROM A 15 SUBTRACT SUB special instruction B 21 Supply voltage drop 2 7 Surge suppressor when to use 2 4 SYBUS applications A 4 features A 4 System expansion A 1 Tape length 5 10 Tape recorder cable 5 10 volume 5 10 requirements 5 10 Tape standard and microcassette 5 10 Temperature 2 3 2 5 E 10 in control panel E 1 TEMPORARY MEMORY RELAY TR instruction B 9 Temporary memory relays B 9 D 3 number o
91. igits If not an error occurs special auxiliary relay 1903 turns ON and the program does not operate Function This instruction sets the carry flag CY to 1 Remarks Nothing is executed when the content of the result register is logical 0 Coding chart Address instruction Data__ 0200 ip 9000 stci4o Function Clears the carry flag CY to O Remarks Nothing is executed when the content of the result register is logical 0 Coding chart 0202 LD 0001 0203 CLC 41 B 23 Appendix C Scan time Overview up ERROR indicator Sets error flag and lights ERROR indicator lit l When a programmable controller operates that is when it executes its program to control an external system a series of operations are performed inside the PC These internal operations can be broadly classified into four categories Common processes such as resetting the watchdog timer and checking the user program memory Data input and output Instruction execution Peripheral device command servicing Scan time The total time required for a programmable controller to perform all of these internal operations is called scan time The following flowchart and diagram illustrate these internal operations Power application Clears I O and internal relays resets all timers Checks 1 0 unit connection Resets watchdog timer Checks hardware
92. ime Programming capacity Number of input output relays AC 100 to 120V AC 200 to 240V DC 24V AC 85 to 132V AC 170 to 264V DC 20 4 to 26 4V 25 VA max 20 W max 5MQ min at DC 500V between external terminal and outer casing AC 1 500V 50 60Hz for 1 minute between external terminal and outer casing 1 000Vp p Rise time Ins Pulse width 100ns to 1s 16 7Hz 3mm double amplitude in X Y and Z directions respectively for 30 minutes 10G in X Y and Z directions respectively 3 times Operating 0 to 55 C Storage 20 to 65 C 35 to 85 RH without condensation Must be free from corrosive gases IP30 Stored program system MPU CMOS LS TTL Ladder diagram 6 bytes address 27 Average 10us address Nonexpandable CPU RAM 512 addresses EPROM 1194 addresses Expandable CPU RAM 1194 addresses EPROM 1194 addresses Nonexpandable CPU Input 16 points for DC input type 14 points for AC input type output 12 points Expandable CPU Input 80 points max for DC input type 70 points max for AC input type output 60 points max with two 56 point expansion I O unit Specifications Number of internal auxiliary relays Number of holding relays Number of timers counters Number of temporary memory relays Number of auxiliary relays Memory protection against power failure Battery Diagnostic functions 136 points Relays 1000 to 1807 160 points Relays HROOO to 915
93. ing the C20 be sure to first touch a grounded metallic object to discharge any static electricity buildup Memory chips The C20 offers a choice of using either a RAM or EPROM chip for the program memory according to your application With the nonexpandabie CPU there are stiil 170 program addresses available as standard even when no RAM chip is mounted and by mounting a RAM chip the number of addresses can be increased to 512 With the expandable CPU the standard memory capacity is 1194 addresses The following table provides the necessary information as to the type of chip that can be used in the expandable and nonexpandable type CPUs as well as the DIP switch settings required for each type of chip Nonexpandable CPU Expandable CPU RAM Use Type RAM G RAM RAM not required Memory capacity 512 addresses Memory capacity 1 194 addresses DIP switch setting 7oeus 123 4 DIP switch setting LE 4 EPROM Use Type ROM H Memory capacity 1 194 addresses EPROM Use Type ROM H Memory capacity 1 194 addresses DIP switch setting TAUB 123 4 DIP switch setting TARAN 123 4 Installing the C20 Installing memory chips The procedure for installing memory chips is described below 1 Use the information given in the table above to confirm that the type of chip you have is correct 2 Remove the front pa
94. ion Coding chart Address Explanation The LD0000 and OR0001 instructions cause the result of the logical OR operation in block A to be stored in the result register The LD0002 instruction in block B causes the result of the operation in block A to be transferred to the stack register and the result of the logical operation between the LD0002 and OR NOT0003 instructions in block B to be stored in the result register The AND LD instruction causes a logical AND operation to be performed between the result register and the stack register The result of the logical AND operation is then stored in the result register Instruction words OR LOAD OR LD Ladder diagram r BlockC 7 0000 0001 I TIMER TIM Symbol ni OR LD aH HE Function Connects two blocks C and D in this example in parallel Remarks This instruction is used for interblock OR operation between two or more blocks There is no limit to the number of blocks that can be connected in parallel by the OR LD instruction D H E Coding chart 0203 AND NoT 0003 0204 oRLD 0205 out j 0500 Explanation The LD0000 and AND0001 instructions cause the result of the logical AND operation in block C to be stored in the result register The LD0002 instruction in block D causes the result of the operation in block C to be transferred to the stack register and the result of the logical operation
95. ion B 20 Adverse environmental conditions 2 3 Alarm lamp 6 8 signal A 12 ALARM ERROR indicator blinking 2 7 Ambient temperature 2 5 AND instruction B 2 instruction inverting B 4 key 4 3 AND LOAD instruction B 5 AND NOT instruction B 4 Application examples 6 1 Application trial run of 5 6 Arrow keys 4 2 Assessing the controlled operation 3 1 Assigning channel numbers A 10 D 1 internal auxiliary relays 3 3 numbers to timers and counters 3 4 relay numbers D 1 Atmosphere Automatic car washing machine 6 6 control of warehouse door 6 1 lubricating oil supplier 6 3 Auxiliary relays number of D 2 Available types F 1 Basic system configuration 1 5 Battery service life E 3 type 2 7 E 3 replacement date meaning E 3 BCD addition B 19 error alert relay D 4 subtraction B 21 Before installing 2 1 Beginning instruction on logic line 3 5 Bottle label detection 6 7 Branching a circuit to OUT instructions B 11 Bus bar left and right 3 4 Index Calculating scan times C 1 Carry flag relay D 4 Cassette tape recorder 5 10 Central processing unit 1 1 Changing set value of timer or counter 5 7 Changing timer data 5 1 Channel and end station setting A 6 Channel assignments D 1 explanation A 10 number vs channel A 10 Channel designation technique A 6 Channel numbering 1 0 link unit A 6 numbers A 1 assigning numbers manually A 10 Channels explained 3 3 Checking program 5 1 device status during operation 5
96. ion or breakage When I O link unit is used chec VO BUS ERR VO bus failure channel setting and optical fiber cable for breakage After corrective action perform failure reset operation Check battery for proper insertion into the socket Replace if BATT LOW Battery failure fully discharged After corrective action perform failure reset operation Xx denotes that the indicator illuminates denotes that the indicator goes off denotes that the indicator blinks a Fatal error i e one that causes the CPU to stop operating b Nonfatal error one that does not cause the CPU to stop operating CPU failure a The watchdog timer is a timer that is reset each time the CPU executes the END instruction This timer is used to check the execution time of the CPU when it operates in the RUN or MONITOR mode When the set time of the watchdog timer is up this indicates a failure Memory failure Sum check of the memory is performed at fixed intervals to check the memory contents and existence of any abnormal instruction END instruction missing error Checks whether the END instruction is written at the end of the program V0 bus failure The 1 O cable is checked for breakage The hardware of the I O control section of the PC is also checked Battery failure Checks the supply voltage of the memory backup battery By forming a program as shown below using special auxiliary relay 1808 a
97. ion 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
98. is more than 10msec but less than 20msec it may or may not be detected Failures longer than 20msec will cause the PC to stop operating external output relays are automatically turned off Operation automatically resumes when the supply voltage is restored to more than 85 of the rated voltage When the expansion I O unit 3G2C7 MC is used an external power supply is required to drive the relays This external power supply is not necessary when only the CPU is used External power supply for relay driving SYSMAC C20 Expansion I O unit 8G2C7 MCOO0 When a two wire sensor is used for the input the input signal may be turned ON by a leakage current exceeding 3mA To prevent this connect a bleeder resistor of 7 5kO or less as shown Power source C20 input circuit Two wire sensor Chapter 3 Introduction to programming y Overview This chapter introduces the eight steps you ll take in creating the program the PC uses to carry out its control operations You can skip this chapter if you re already familiar with PC programming using relay ladder dia grams Instead you may wish to go directly to Chapters 4 and 5 which focus on how the C20 programming console is used to install the program in the memory of the CPU Relay ladder diagram method If you re an old hand at relay based control systems you ll find a lot that s familia
99. kQ Input current 7mA typ DC 24V ON delay time 20ms max 15ms max OFF delay time 20ms max 15ms max Number of circuits 16 points 8 points common 12 points 8 3 1 points common ON voltage DC 16V max OFF voltage DC 5V min Max switching capacity AC 250V DC 24V 2A max p f 1 8 4 2A common 14A unit Min switching capacity a DC 5V 10mA min Leakage current Saturation voltage External power supply Service life of relay Power supply Circuit configuration Electrically 300 000 operations Mechanically 50 000 000 operations G6B 1114P US M DC 24V with socket DC 24V CPU83 E CPU84 E AC 100 to 120V CPU23 E CPU24 E AC 200 to 240V CPU53 E CPU54 E ee r 1 5K 3 6 40UT 00 rs 2 O 40UT 07 z 2 COM z 3 8 E 3 3 5 s touT 08 2 l 15K cOUT 10 IN 08 foom 7 gt OUT 11 IN ii 7COM IN 15 Terminal Bie B7 Signal name I 0 No OUTI 0511 Terminal Signal name VO No Input power supply las fdedudddnedes Ko od ad ola dls ja gu re fol 6 OUTS com 0509 pom Load power supply Load power supply Input power supply Load power supply Note The input channet is fixed on channel 0 and the out put channel on channel 5 The terminal block can be removed SREE
100. l fiber cable Optical transmitting O unit Optical 500 expansion I O rack Set to be an end station gt Channel 31 H 16 points channel 11 32 points channels 09 and 10 Ls Channel 31 L Remote O slave unit System expansion and peripherals Note On using optical transmitting 1 0 unit The optical transmitting t O units are used for remote control of equipment when eight or fewer input or output points are required The C20 communicates with these optical transmitting I O units through the remote I O master unit installed in the higher level PC C120 C250 or C500 Each optical transmitting I O unit has eight input or output points This means that when a channel is to be formed two of the units must be used together with one serving as the higher half of the channet and the other serving as the lower half Both halves must be assigned as either input or output You cannot mix input points and output points in creating one channel For example when you have specified a pair of optical transmitting O units as the higher and lower halves of channel 31 you should not specify the higher half as an input channel and the lower half as output Instead create a second channe using one or more other optical transmitting I O units Thus channel 31 would be used for input and channel 30 would be used for output DIP switch setting Use thi
101. min Max switching capacity DC 5 to 24V 0 5A max Min switching capacity DC 5V 10mA min Leakage current 100A max Saturation voltage 1 5V max External power supply 15mA point 360mA unit Service life of relay G3D YO1P PC DC 24V Circuit configuration N OUT 00 OUT 07 ALM R EA COM IN OG B 3 IN 07 3 cia ne E Eee 1 5K y T T OUT 08 com 5 5 H r we O H TOUT 10 sie com ouT 1 aid COM N i5 24VD0 L_ ov 1 5K r COM OUT 00 ns 1 5K x OUT 07 ee m a com IN 06 3 8 IN 074 2 15K j T g 3H 4 OUT 08 COM S 2 a H l or fOUT 10 NOs com touti te COM N is 2avo0e ov 16 points x2 32 points 12 pointsx2 24 points Specifications Terminal 5 Bio Ei CEN EE ELI HA Signal name 1 com ov oum ours outs our oure ourio our VO No 0601 0603 f 0605 0607 0608 0610 Terminal AS Aid an Ale aD als Ais ale Signal name X IN 24v outo ouT2 outa ours OUTS wo No 0500 0802 0604 0608 COM F osoo COM Input power supply Power supply for external device for relay driving Load power supply Load power supply Load power supply Input power supply Note Those of MD212 with 32 input points 24 output points are fix
102. n 2 1 selection 2 1 Memory clear operation 4 4 failure E 11 protection against power failure 2 7 retentive timer B 7 MIC jack tape recorder 5 10 Microcassette tape 5 10 Mode selector switch 1 4 4 1 4 3 MONITOR mode 4 3 Motor control 6 8 Motors starting and stopping 6 4 Mounting CPU and I O expansion unit together 2 4 Mounting E 2 Mounting dimensions 2 5 Mounting kit G 1 Mounting near high tension equipment wiring 2 3 MOVE MOV special instruction B 18 MOVE NOT MVN special instruction B 18 Moving through program 4 2 Multiple program errors 5 5 Index Multistage process example A 12 Multisupport base A 17 NC contact B 3 NO contact B 1 NO END INSTRUCTION message 5 3 No error display 5 4 Noise immunity F 3 Noise problems 2 3 A 3 Noise suppression C20 2 4 1 0 link unit A 5 Non fata errors 5 5 NOT key 4 3 Number of instructions F 3 Numeric keys 1 4 4 1 Operating voltage range F 3 Operation example 6 5 6 7 6 8 Operation checking 5 8 Operation keys 4 2 Optical transmitting 1 O unit A 8 Optical fiber cable when installing 2 5 E 2 Optical fiber cable clearance requirements 2 5 Optical fiber communication A 3 OR instruction B 2 OR instruction inverting B 4 OR key 4 3 OR LOAD OR LD instruction B 6 OR NOT instruction B 4 OUT key 4 3 OUTPUT OUT instruction B 1 Output relays channel assignment D 1 Output terminals location and function 1 3 Outputting result of logical operation B 1
103. n alarm signal can be output to an external device when there is a drop in the battery supply voltage ie Maintenance and troubleshooting List of error messages Error message In addition to the messages described on the previous page the following error messages may also be displayed on the programming console by keying in Description An address exceeding the last address of the user memory has been set Set a different address An EPROM chip is mounted as the user program Replace the EPROM with a RAM chip and then perform the intended write operation Hexadecimal data has been input as a constant where a decimal number is required Input the data as a decimal number Data exceeding the input range is input Check the limit of data each instruction can use and repeat data input There is an abnormality in the user program memory Check whether a RAM or EPROM chip is mounted in the CPU as the program memory A wrong instruction exists in the user program Check and correct the program After the corrective action clear the error message refer to step 7 Testing for errors in Chapter 5 A failure has occurred in the bus connecting the CPU and expansion I O unit Check the bus Also check the expansion I O unit for disconnection before power application Check whether the battery is correctly installed in the battery socket The service life of the
104. nel of the CPU by loosening the mouting screws with a flat bladed screwdriver You ll be able to see the CPU s circuit board Caution Before opening the CPU always be sure that the power supply to the C20 has been turned OFF Location of memory chip and DIP switch RS MMMMany 3 Insert the RAM or EPROM chip into the 28 pin IC socket on the lower left corner of the circuit board 4 Set the DIP switch to the correct setting for the type memory chip you have installed For this refer to the table on the previous page Installing the C20 Testing the environment Dealing with problems of noise Noise source C20 200mm min Grounding at a ground resistance of less than 100Q SYSMAC I O circuit SYSMAC power circuit General control circuit Power circuit When you re ready to install the C20 first give attention to the environmental conditions under which it will normally operate The PC is ruggedized for reliable use under tough conditions but you still need to avoid using it in these areas Where the ambient temperature is below 0 or above 55 C Where abrupt temperature changes may cause condensation Where relative humidity is below 35 or above 85 Where corrosive or flammable gas may occur In extremely dusty conditions or where subject to salt or iron particles Where subject to abnormal vibration or shock In direct sunlight Where it can be splattered
105. nit 1O Link Unit SYSBUS System for optical fiber data transmission Link Adapter Peripheral Interface Unit Printer Interface Unit PROM Writer Graphic Programming Console GPC CRT Multisupport Base This appendix presents an abbreviated introduction to these C20 related products many of which are upwardly compatible with other members of the C Series line of programmable controllers System expansion and peripherals Expansion 1 0 unit Type 3G2C7 MC223 227 Type 3G2C7 MC224 228 ARM EL Le om Le Ee Ree he te fe Se ett a et 36267 oun omon The basic C20 comes with 28 I O points when the DC input type CPU is used The number of I O points available from the AC input type CPU is 26 If your controlled system so requires you can increase the number of I O points of an expandable C20 by connecting either one or two expansion DC input type I O units to the DC input type CPU for a maximum of 140 I O points The maximum number of I O points is 130 when the system is configured of AC input type units The expansion I O unit can be classified by two factors the input type DC or AC and the number of I O points The DC input type comes with 28 or 56 I O points whereas the AC input type offers 26 to 52 I O points Explanation When an expansion O unit is connected to the CPU the input output channels of the expansion O unit and the CPU are automatically designated
106. nnecting cable Multisupport base Type 3G2A5 MSB01 E MSB02 E Caution SYSMAC C20 iri PROM chip Peripheral interface unit The multisupport base serves as a programming device for C series programmabie controllers The programming console is attached to the muitisupport base and used in the same way as the C20 The multisupport base also has some functions not available on the C20 The multisupport base must be connected to the C20 with a dedicated peripheral interface unit Type 3G2C7 iP002 Note that the other peripheral interface units Type 3G2A5 P001 E IPO03 E cannot be used with the C20 PROMs that have been written by a PROM writer used with the C20 cannot be directly read by a PROM writer connected to the multisupport base nor can the reverse operation be performed If either attempt is made the message MEMORY ERR is displayed The peripheral interface unit is required to transfer programs between these devices The peripheral interface unit is also required for programs recorded on a cassette tape recorder Programs that have been saved to a cassette tape connected to the programming console of the C20 cannot be directly read by a cassette tape player connected to the graphic programming console nor can the reverse operation be performed Programming console SYSMAC C20 Multisupport base Cassette tape Cassette tape recorder Programming console
107. nput Explanation Nothing is executed when the content of the result register is logical 0 When the content of the result register is logical 1 four digit BCD subtraction including a carry 1904 is executed If the result of the addition is 0000 1906 is turned ON and if there is a carry in the result 1904 is turned ON In the circuit program the 16 bit contents of HR8BCH HR800 to HR815 including a carry 1904 are subtracted in units of four BCD digits from the 16 bit contents of 10CH 1000 to 1015 and the result of the subtraction is output to the 16 bit locations of HR9CH HR900 to HR915 If there is a carry in the result 1904 is turned ON and if the result of the subtraction is 0000 1906 is turned ON VO relay Holding relay Holding relay 10CH HR8CH HROCH HR900 J gt HR901 HR902 HR903_ HR904 HRSO5 HR9O6 HR907 HR908 HRS09 ab nagio 0 HR914 HRGT2 HR913 HRS14 HR915 x10 x10 Carry 1904 eS SS 4 108 Instruction words SET CARRY STC Symbol STC Ladder diagram 0000 CLEAR CARRY CLC Symbol CLO Ladder diagram 0001 CLC Before executing a SUB instruction the carry register 1904 must always be cleared using a CLEAR CARRY CLC instruction This can be omitted in multistage subtraction The CPU checks whether the data for BCD subtraction are in four BCD d
108. ntrolled by a remote I O master unit The controlied equipment can be located as far as 800 meters from the I O master unit The network of control equipment is tied together through the SYSBUS system in which a pair of optical fiber cables transmits high speed data over long distances with high immunity to electrical noise The 1 0 link unit comes in one type 3G2C7 LKO11 System expansion and peripherals Since the remote I O master unit serves to contro the optical transmitting I O unit as well as the I O link unit it can be used to configure a system in which both types of units are used together with a remote 1 O slave unit This means a distributed system using a number of SYSMAC PCs is possible Applications For interlocking pieces of equipment or stations high speed data transmission reception improving line noise immunity reducing wiring requirements SYSBUS system Controller Remote I O master unit ess VO bus SYSBUS J Features Cea boners Long distance high speed data communication realized by an optical O unit transmission system with excellent noise immunity Because only a single 1 0 link unit etc pair of optical fiber cables is used as the communication line the amount Controller component of wiring can be significantly reduced Specifications Communication system Communication format Transmission speed Transmission system Bidirectional half duplex 1 N 187 5k bp
109. ntrollers the C20 is intended for economical control of operations that have a relatively restricted number of automated tasks Nevertheless the number and types of applications possible for equipment and process control using the C20 are practically limitless ranging from automatic door operation to many types of assembly ine applications This chapter presents examples of some of those applications In each case an explanation of the application program its ladder diagram and the coding chart are given These programs are intentionally simplified and are meant for instructional purposes only In this example the programmable controller is used to open and close an automatic door to a warehouse to allow an approaching object automobile or other vehicle to enter or leave The C20 makes it possible for two different sensing systems to be used to control the door operation Door position motor Explanation As input devices that send control input signals to the C20 an ultrasonic switch and a photoelectric switch are employed The ultrasonic switch emits an ultrasonic wave When there is an object vehicle in the way of this ultrasonic wave the wave reflects back to the ultrasonic switch which detects the object The photoelectric switch used in this example consists of two elements a light source and a receiver The light source emits a light beam that is constantly received by the receiver If a vehicle or other object interru
110. o the expansion I O unit and registered in the CPU As the output channel number of the expansion unit 06 is automatically assigned and registered The input output signals devices are connected to the input output terminals on the CPU Because the CPU uses the numbers assigned to the input output terminals when executing the program assignment and management of the input output terminal numbers are required and must be correctly performed The numbers assigned to each relay are listed in the following tables Use these to keep a record of which relays have been used Assignment of I O channel and relay numbers Relay numbers Relay number 0000 to 0415 00CH 01CH 02CH 03CH 04CH 00 08 00 08 00 08 00 08 00 08 01 09 01 09 01 09 01 09 01 09 Input relay 80 02 10 02 10 02 10 02 10 02 10 03 11 03 11 03 11 03 11 03 11 04 12 04 12 04 12 04 12 04 12 05 13 05 13 05 13 05 13 05 13 06 14 06 14 06 14 06 14 06 14 07 15 07 15 07 i 15 07 15 07 15 0500 to 0915 Output relay 05CH 06CH 07CH 08CH OCH Internal auxiliary relay HR000 to 915 O0CH 01CH 02CH 03CH 04CH 00 08 00 08 00 08 00 08 00 08 01 09 01 09 01 09 01 09 01 09 02 10 02 10 02 10 02 10 02 10 03 11 03 11 03 11 03 11 03 11 04 12 04 12 04 12 04 12 04 12 05 13 05 13 05 13 05 13 05
111. of timer or counter It s also possible to change the set value of a timer counter during program execution This is used for such purposes as slowing down or speeding up an assembly line operation without having to stop the program This operation can only be done in MONITOR mode To reset the value of a timer first key in Checking and running your program Input output monitor In our sample program the timer number is 00 Now press B to move to the timer data display The timer currently is set for 3 0 seconds To change this to 6 0 seconds press CHG and the PC display will query you about the new data 0008DATA informs you that the operation to be performed is the setting of a value for the instruction address 0008 TOO is the number of the timer 0030 is the timer s present set time and 7 asks what you want the new set time to be In response key in your new set time and write it to the PC memory Follow the same procedure to change the set value of a counter While the PC automatically controls the equipment you can keep a watchful eye over the operation using the PC s monitoring capabilities You may for instance have a particular unit of equipment that you want to check for correct operation Or you may want to keep a running check on the value of a down counter The C20 allows you to easily check the status of any device connected to it by this procedure Place the
112. ogram writing errors If the programming console has been used before and an old program currently exists in the memory carry out the procedure given next The following procedure will entirely and permanently erase any program that currently exists in the CPU memory Anytime you want to erase the memory or start over when inputting your program use this key sequence PLAY REC Using the programming console Instruction OUT END FUNO1 At this point the display will be the one shown at left to allow you to reconsider If you then press MONTR you have finished the memory clearing operation and the display will change to this Now if you press CLR you can begin writing your program Getting started summarized Putting all these steps together here s a summary on what to do to begin programming the CPU 1 Confirm whether a RAM chip is mounted and the DIP switches are set correctly 2 Apply power to PC 3 Turn mode selector switch to PROGRAM Do these key sequences 5 If you want to completely clear the old memory press PLA REC Example program For practice let s key in the program code we previously wrote This is the coding chart from Chapter 3 Using the programming console Step 5 Entering the program in the CPU The first information to be keyed in is t
113. ogrammed by the DIFD instruction described in Appendix B Instruc tion words This connection causes Interna Auxiliary Relay 1000 assigned to the DIFD instruction to turn on for only one program scan time at the falling edge of input 0001 Internal Auxiliary Relay 1000 is ANDed with a second limit switch that detects the lower limit of the door movement Consequently when Internal Auxiliary Relay 1000 turns on the AND condition is satisfied for one scan time During this period output 501 turns on This then turns on the motor which lowers the door Application examples Automatic lubricating oil supplier Ladder diagram pe 0000 DIFU 1000 1000 TIMOO 0500 In this example the C20 is used to control the supply of lubricating oil to the gears and bearings of an assembly line This automatic lubrication reduces friction and wear on the parts thus improving the efficiency of the assembly line and decreasing the amount of energy consumed by high power motors ae i 5 es shortage alarm J y Explanation When the object to be lubricated reaches a predetermined point the lubricating oil is applied in the above illustration a gear is supplied with oil A sensor detects the gear when it comes to a specific position In response to the input signal from this sensor the C20 outputs a signal that opens an electromagnetic valve This valve is opened for a set period of time supplying a predet
114. on 42 points 8 3 1 points common ON voltage DC 16V max OFF voltage DC 5V min Max switching capacity AC 250V DC 24V 2A max p f 1 8 4 2A common 14A unit Min switching capacity DC 5V 10mA min Leakage current Saturation voltage External power supply Service life of relay Electrically 300 000 operations Mechanically 50 000 000 operations G6B 1114P US M DC 24V with socket Power supply IN 06 IN 077 Circuit configuration COM CH IN 08 N14 IN 15 1 5K 1 5K 1 5K DC 24V CPU73 E CPU74 E AC 100 to 120V CPU13 E CPU14 E AC 200 to 240V CPU43 E CPU44 E Internal circuit Internal circuit internal circuit Terminal Signal name I O No OUTI 0501 Terminal Signal name 1 0 No Input power supply Input power supply aasgsgdadar SEER PERPHHI wal SES sF pe kore OUTS 0506 Load power supply Load power supply Load power supply Note The input channel is fixed on channel 0 and the out put channel on channel 5 The terminal block can be removed SPER ae 5 Ja ole F 5 Specifications CPU Type 3G2C7 CPU23 E CPU24 E CPUS53 E CPU54 E CPU83 E CPU84 E DC input PNP Contact output Input voltage DC 24V 10 15 Input impedance 3
115. on I O unit connected and the user program consists of 1194 addresses Again it is assumed that only the LD and OUT instructions are used in the program As before there are two known factors common process time and peripheral device command servicing time which are 1 07ms and 1 1ms respectively The variable N of the equation for calculating the data input output time is 2 because a 56 point expansion I O unit is used Therefore the data input output time is 1 04ms 0 33ms x 2 1 7ms Because the program has 1194 addresses and uses only the LD and OUT instructions the total instruction execution time is 1194 addresses x 14 75us 17 61ms Therefore the scan time is 1 07ms 1 7ms 17 61ms 1 1ms 21 48ms Input output response time of PC Response time means the time from when the PC receives an input signal until it outputs a control signal This response time varies If the PC receives an input signal immediately after one scan time has finished and if the input ON delay time of the PC is minimum the response time is minimized If those two factors exist the response time can be obtained by simply adding together the minimum input ON delay output ON delay and scan times of the PC However if the PC receives the input signal when one scan time has just started and the input ON delay time is the maximum value the response time is longer This is because the CPU must wait until the end of the preceding scan time
116. on makes use of the shift register SFT instruction This instruction must be programmed in the order of data input 0000 clock input 0001 and reset input 0002 Moreover the instruction data must be specified in channel units In this example channel 10 is specified as the data When a defective product a bottle bearing no label is detected input 0000 is turned on and the state is stored in point 1000 of channel 10 At the next input signal of 0001 the state of point 1000 of channel 10 is shifted to 1001 indicating detection of a defective product In response output 0500 is issued unless input 0003 is applied When output 0500 is issued the robot arm removes the defective product on conveyor A and places it on conveyor B Input 0003 is turned on when the arm of the robot after removing the defective bottle returns to its original position When relay 1001 is turned on output 0501 is also issued starting conveyor B Inputs 0000 and 0002 also serve as the count input and reset input respectively of the counter When the counter counts five count inputs five defective bottles the counter turns on output 0502 which in turn illuminates the alarm lamp Appendix A System expansion and peripherals Overview The C20 has a full line of peripherals to expand the system and provide a number of valuable support services These are the peripheral devices available for the C20 Expansion I O U
117. on on the printer is used to select between the two When the button is pressed the stop indicator on the printer interface unit blinks at intervals of 0 1 second if the printing is to be immediately stopped and at intervals of 0 4 second if printing the current page only is specified Use the memory cassette dedicated to the C20 type 3G2A5 MP009 E to attach the printer interface unit directly to the C20 Mount the printer interface unit directly on the C20 Printer available from Epson RX 80li FX 80 or equivalent Securely tighten the mounting screws Plotter available from Graphtec WX4731 MP 1000 or equivalent Use Type SCY CN201 2m connecting cable Link adapter When optical fiber transmission lines are employed in the PC system the link adapter Type 3G2A9 AL002 E may be used to prevent malfunction ing of the optical transmission path due to a power failure in one of the units of the system Appendix B Instruction words Overview This appendix describes the instructions used by the C20 The information includes the name key input sequence symbol and function of each instruction along with a ladder diagram and coding chart LOAD LD LD address HF relay no Symbol Function J Starts operation of each logic line forms substrings Remarks When a logic line starts with an NO contact this instruction indicates that a new string or
118. onnect the other end of the cable to the CPU Fix the mounting plate with the CPU on it to the four mouting brackets with four M4x5 screws Appendix H Basic instruction Instruction LOAD Mnemonic wea Operand Relay No Logical start operation LOAD NOT Relay No Logical NOT start operation AND Relay No Logical AND operation AND NOT Relay No Logical AND NOT operation oR H Relay No Logical OR operation OR NOT EEE Relay No Logical OR NOT operation Relay N input output relays 0000 to 0915 Internal auxiliary relays 1000 to 1907 Holding relays HRGOO to 915 Timers TIMOO to 47 Counters CNTOO to 47 Temporary memory relays TRO to7 Temporary memory relays can only be used with the LD instruction AND LOAD Logical AND operation with the previous condition OR LOAD Logical OR operation with the previous condition TIMER COUNTER Timer No Outputs the result of a logical operation to the specified output relay internal auxiliary relay latching relay or shift register ON delay timer operation Set time 0 to 999 9sec Down counter operation Set value 0 to 9999 Output relay 0500 0915 Internal auxiliary relays 1000 to 1807
119. opriate numerical values The special instruc tions are listed in Appendix B SFT Enters SHIFT REGISTER instruction NOT Forms NC contact AND Enters AND instruction used for ANDing two contacts OR Enters OR instruction used for ORing two contacts CNT Enters counter instruction Must be followed by counter data LD Enters LOAD instruction used for loading a specified input OUT Enters OUTPUT instruction for outputting to a specified output point TIM Enters timer instruction Must be followed by timer data TR Enters temporary memory relay instruction LR Enters link relay instruction HR Enters holding relay instruction DM Enters data memory instruction CH Specifies a channel CONT Used to search for a contact Although these functions are not available on the C20 these keys are provided to ensure programming console compatibility with other SYSMAC C Series PCs Now let s turn to the three position mode switch you will use to select the operating mode of the PC As you see there are three modes The RUN mode is the one you will use to begin PC operation When you turn on this mode the PC begins controlling the equipment using the program you have written into the PC memory The MONITOR mode allows you to visually monitor the operation in progress For instance if you want to check that a particular relay is in the correct state either ON or OFF at the proper time you can move to the address or step that r
120. ormal Environmental conditions normal Refer to Power supply flowchart Refer to Failure flowchart Refer to Environmental flowchart Maintenance and troubleshooting Power supply flowchart For PC and I O link unit POWER indicator off RUN and ERROR ALARM indicators also off Supply power Power supplied POWER indicator lit Supply voltage in rated range Supply power in rated range POWER indicator lit Replace fuse POWER indicator lit Loose screws on terminal block break Tighten loose screws replace in lead wires lead wires POWER indicator lit Return to General flowchart Maintenance and troubleshooting Failure flowchart For PC RUN indicator off ERROR indicator lit Use programming console to identify error 1 POWER indicator also on NO RUN or MONITOR mode Rewrite program in PROGRAM mode clear error message Set RUN or MONITOR mode Memory failure RUN indicator NO illuminates ERROR indicator off Set PROGRAM mode add END instruction at end of program clear error message ERROR indicator off Check cable connection of CPU and expansion O rack correct clear error message VO bus failure ERROR indicator off
121. our program is the END instruction which tells the PC that the program is complete Writing this requires the use of the FUN key and the value 01 which represents the END instruction So key in ral oe and you re finished Now check your program To check whether the program has been correctly written go back through it using the arrow keys to scan what you ve done If you see you need to make corrections just overwrite the statements that are in error Deletion and insertion of instructions is explained next Deleting instructions Let s return for a moment to Timer 00 For practice let s delete it from the program using the following procedure First go to address 0008 Then key in pall This eliminates the TIM instruction and moves the next instruction LD in this case into the 0008 address location This function is useful when you wish to modify or correct an existing program inserting instructions Inserting an instruction somewhere in a program is almost as easy Let s assume that we now realize it was a mistake to eliminate Timer 00 from the program To put it back into the program we follow this six step insert procedure 1 First key in This takes you to the first address of the memory 2 Then key in the number of the address where you wish to make the insertion Ea 3 Press 4 And then DE to move the program down one step reserving address 0008 for the TIM instruction
122. program created at the end of Chapter 3 The last part of this chapter explains how the programming console s editing functions work to make writing and modifying programs a lot more convenient In an earlier chapter the functions of the color coded keyboard were briefly mentioned Now let s take a closer look at each of these keys Numeric keys These are the white keys numbered 0 to 9 These keys are used to input numeric values used for program data For instance in our program in the last chapter these keys would be used to input the input output numbers and timer counter numbers and values These keys are also used in combination with the function key FUN for special instructions These instructions are explained in Appendix B CLR key This red key is used to clear the display It is also a key you ll use while keying in the password which is used to foil unauthorized access to the PC s program Rather than using an actual password though you gain access using this two keystroke entry When you do this on the console display you ll see written either PROGRAM MONITOR or RUN Pressing the CLR key again makes the word disappear and prepares the PC for the operation you have selected with the three position mode switch Using the programming console Operation keys These yellow keys are the ones you ll use to carry out the editing functions of the programming console These functions will be explained
123. pts the light beam the photoelectric switch detects it Application examples Ladder diagram 0000 0500 0002 0001 DIFD 1000 1000 0501 0003 Coding chart Instruction _0200_ LD OR AND NOT OUT In response to the input signals sent from these switches the C20 issues control outputs that drive the motor of the door for opening and closing The C20 also receives inputs from two additional switches one detects the upper limit of the door movement and the other detects the lower limit The following is part of a ladder diagram that might be used to perform these coordinated tasks 1 0 assignment Ultrasonic switch Photoelectric switch Switch detecting upper limit of door movement Switch detecting lower limit of door movement Output To raise door To lower door Operation As we see in the ladder diagram the input signal from the ultrasonic switch input 0000 is ANDed with a limit switch input 0002 that detects the upper limit of the door movement This switch is normally closed When input 0000 turns on the C20 outputs a signal output 0500 that starts the motor to open the door When the door moves to its upper limit input 0002 turns on This stops the output 0500 signal and that stops the motor At the same time the input signal from the photoelectric switch input 0001 is connected to a differentiation down circuit This circuit is pr
124. r in the way a PC works This is because the circuits and internal logic of the PC take the place of the relays timers counters and other formerly discrete devices The actual operation of the machinery takes place as if those discrete devices were still in place but with a great deal more flexibility and reliability But even if the actual devices are gone the symbols and other control concepts used to describe their operation still are used These are the basis of the relay ladder diagram programming method This chapter has been written on the assumption that you are already experienced with this relay symbology or have access to information that can teach you about it Eight basic programming steps In creating the control program for the PC you ll foliow these eight basic steps 1 Determine what the controlled system must do and in what order 2 Assign input and output devices that is designate the external devices that will send signals to and receive signals from the PC 3 Draw a diagram using relay ladder symbols This represents in the correct sequence all of the required functions and their relationship 4 Code the ladder symbols into a form that can be input to the CPU by the programming console 5 Transfer these written instructions to the CPU via the programming console 6 Edit the program 7 Test the program for errors 8 Save the completed program Steps 1 through 4 are the focus of this chapter
125. r operation set value Set time 00 00 to 99 99 sec Constant 0000 to 9999 List of instructions Instruction Mnemonic Function Compares a channel data or a 4 digit constant against another channel data lt 8 55 Transfers a channel data or a 4 digit constant 16 bits to a specified channel S D i amp Input output relays OOCH to 09CH Internal auxiliary relays 10CH to 19CH Holding relays HRO to 9 Timers TIMOO to 47 Counters CNTOO to 47 Constant Inverts a channel data or a 4 digit constant and transfers it to a specified channel s D 0000 to FFFF o Output relay 05 to O9CH Internal auxiliary relay 10 to 17CH Holding relay HRO to 9CH Performs BCD addition of a channel data or a 4 digit constant to a specified channel data FA A EE Performs BCD subtraction of a channel data or a 4 digit constant from a specified channel data s s2 Input output relay 00 to 19CH Holding relay HRO to 9CH TIM CNTOO to 47 Constant 0000 to 9999 0 Output relay 05 to O9CH Internal auxiliary relay 10 to 17CH Holding relay HRO to 9CH Clears the carry CY to 0 0 ov Index AC power noise 2 4 use of surge suppressor 2 4 ADD special instruct
126. rching for a specific instruction This second editing technique gives you a convenient way to locate a particular instruction for which you do not have to know the program address Assume for example that you wished to go to an unknown address containing Timer 00 To do this press CLR several times until you see the first address Then key in timer number This takes you to address 0008 which contains Timer 00 Checking and running your program K Searching relay contacts This editing feature has a wide range of uses For instance in along program you may wish to determine whether you have inadvertently used the same timer or counter number more than once This normally would be an error since a particuiar timer or counter should be used only once in a program Let s imagine for a moment that our program is actually quite large and that there s a possibility that Timer 00 has been duplicated somewhere We wouid search for the first reference to this timer by using the approach we just learned Do this by keying in eorlex m fo Pe which moves us again to address 0008 To search for any illegal timers simply press again which tells the PC to scan the rest of the program for any other mention of a times with the number 00 As can see there are no others in our program To test this further go to any address say 55 write in TIMOO and then repeat the search procedure NO END INSTRUC
127. rds ADD Function Symbol Performs BCD addition of a channel data S1 or four digit constant to a specified channel data S2 and then outputs the result to a specified channel D a Remarks This instruction is used to do addition between two specified four digit BCD data Ladder diagram Coding chart 0000 Contents of data D 00 to 19 05 to 17 Input output relay internal auxiliary relay Holding relay HROto9 TIM CNTOO to 47 0000 to 9999 Notes Before an ADD instruction is executed a CLC instruction must be programmed to clear the carry flag 1904 When the result register is logical 1 a BCD addition is executed at each scanning To execute it only one time program a differentiating circuit for the input Explanation Nothing is executed when the content of the result register is logical 0 When the content of the result register is logical 1 addition of a four digit BCD data to a four digit BCD data including a carry 1904 is executed If the result of the addition is 0000 1906 is turned ON and if there is a carry in the result 1904 is turned ON Instruction words SUBTRACT SUB Symbol In the circuit program the 16 bit contents of 10CH 1000 to 1015 are added in units of four BCD digits to the 16 bit contents of the four digit constant 1234 including a carry 1904 and the result of the addition is output to the 16 bit lo
128. rinter interface unit 3G2A5 PRTO1 E Memory cassette for printer i 5 interface unit Exclusive for SYSMAC C20 3G2A5 MP009 E Printer connecting cable 2m can be also used for X Y plotter connection SCY CN201 For connecting GPC CRT type LCD type and MSB exclusively for SYSMAC C20 Peripheral interface unit 3G2C7 1PO02 Peripheral interface unit i connecting cable For connecting GPC CRT type LCD type and MSB 3G2A2 CN221 Hee eee end conuale AC 110 120V Memory pack is separately available 3G2C5 GPC01 E Graphic programming console LCD type AC 220 240V Memory pack is separately available 3G2C5 GPCO2 E tee ee for GPC For SYSMAC C series programmable controllers C20 C120 C250 C500 3G2C5 MP301 E Graphic programming console F CRT type AC 110 120V 3G2A5 CRT19 Graphic programming console CRT type AC 220 240V 3G2A5 CRT20 AC 110V Two devices can be connected Memory cassette is separately available 3G2A5 MSB01 E Multisupport base SUPP AC 220V Two devices can be connected 3G2A5 MSB02 E Memory cassette is separately available Memory cassette for muitisupport For SYSMAC C series programmable controllers 3G2A5 MP001 amp For SYSMAC C series programmable controliers 3G2A9 BATO8 For nonexpandable type CPU eee NOTE 2 For expandable type CPU See NOTE 3 For nonexpandable type CPU For expandabie type CPU Link adapter Repeater for fiber optics AC 110 220V AC DC 12 to 24V 3G2
129. rograms 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 portabie 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 parti
130. rol panel C500 CPU rack Sto Stop input signal Channels 30 and 31 Channels 28 and 29 Processing stage Assembling stage 0001 Coating stage 0002 Warning output Warning Oil shortage 0100 display Cutting tool wear 0101 in paas mir Screw shortage 0102 O ink unit 1O link unit Shifted position 0103 Ink dirty 0104 Processing stage Assembling stage Stop Warning signal Coating stage A 12 This ladder diagram shows part of the circuit used for this control system Processing stage C500 program 29001 of Too Screw shortage Indicates screw 0001 Shortage t Stops the T Dirty ink 0002 S100 MTT Sareea ees t Indicates dirty ink te 4 on Stops the coating stage assembling stage Assembling stag C20 program 0001 0 G 4 Detects screw E i oo Shortage Stops the assembling stage 0000 Channels as viewed from C500 Channels of YO link unit connected to C20 Input channel 01 Coating stage C20 program 0100 Stops the 4 coating stage 0000 2 Channels as viewed from C500 Channels of I O link unit connected to C20 Output channel 06 1 When the screw supply is depleted during the assembling step output relay 0600 of the I O link unit is turned ON Viewed from the C500 this output relay is inpu
131. s L 7 Press the button or buttons on the tape recorder that begin the recording 8 Then within 5 seconds press REC on the programming console keyboard A blinking rectangle appears in the right corner of the display This means the program is being saved to the tape 9 Wait about 7 minutes The program is being saved from the first program address to the end of the RAM EPROM memory area The PC display increments as each address goes into the cassette recorder During this period you can halt the save operation by pressing CLR 10 When the program plus vacant memory has been completely recorded the save operation stops with this message Refer to this flowchart for the correct procedure when saving your program to the cassette recorder 1 Error takes place START Insert Cassette Tape and Rewind Recording Within 7 5 sec Recording Operation RAM ene ROM TAPE Verification Operation Cassette Recorder Operation Programming Console Operation Playing Operation Read out l TAPES RAM 4 m 20 4 g i i Error Checking and running your program Loading and verifying the program Before loading a program into the C20 determine that the tape is correctly positioned The taped program should begin to load into the PC within 5 seconds after the loading operation has been initiated You can
132. s Time division multiplexing Start stop synchronization Exclusive process cyclical control system 64 max with a transmission capacity of 8 points each Doubie core optical fiber cable crystal polymer core diameter 250um Synchronization system Transmission control process Number of stations possible V0 Link unit Transmission lines 1 RUN OUT terminals Used to monitor the operating status of the I O link unit Output signals are issued from these terminals when power is applied to the C20 CPU and to the I O link unit with the PC connected to the remote I O master unit The PC must be in RUN or MONITOR mode wr 2 LED power indicator Turns on when power is applied to the I O link unit 3 LED indicator for transmission error indication Blinks during normal transmission A steady glow indicates a transmis sion or bus error has occurred 1 0 link unit wiring Link adapter M4x8 self up M4x8 self up screw ransformer 2 pi AC power 4 Connector Connects the CPU or expansion I O unit of the C20 to the 1 0 fink unit 5 T R CONT OUT terminals Outputs a repeater signal in a system incorporating SYSBUS A link adapter is also used The repeater output turns on when power is applied to the CPU of the C20 and 1 0 link unit 6 SYSBUS connector Connects an opticai fiber cable to the I O link unit 7 Power terminals For applying AC power The FG
133. s executed at each scanning To execute it only one time program a differentiation circuit for the input Nothing is executed when the content of the result register is logical 0 Therefore the compare result area of special auxiliary relays 1905 to 1907 holds the previous status and on execution of an END instruction all of these relays are cleared to 0 When the contents of the result register are logica 1 the CMP instruction is executed In the circuit example when the program is executed the 16 bit data of 10CH 1000 to 1015 are compared with the 16 bit data of HROCH HR900 to 915 and the result is output to the result area of special auxiliary relays 1905 to 1907 nput output relay Result of comparison 10CH 1905 1906 1907 10CH gt HR9OCH 1 0 x16 40CH HRSCH o 1 10CH lt HR9CH 0 0 x16 x16 A constant iscompared with the four digit hexadecimal binary 16 bit data B 17 Instruction words MOVE MOV Symbol MOV MOVE NOT MVN Symbol MVN S D Ladder diagram 0000 Note c Function MOV instruction transfers a channel data or a four digit constant 16 bits S to a specified channel D S D MVN instruction inverts a channel data or a four digit constant and transfers it to a specified channel Remarks The MOV instruction is used to transfer 16 bit channel data or a hexadecimal four digit 16 bit binary constant to a speci
134. s it in the result register Like the LD instruction this instruction causes the existing contents of the result register to be transferred to the stack register The contents of specified relay No gt R S To form substrings combine this and other instructions such as AND or OR Coding chart B 3 Instruction words AND NOT Symbol k OR NOT Symbol AND Function Connects NC contacts in series Remarks This instruction inverts the contents of a specified relay and then carries out a logical AND operation with the contents of the result register The result is then stored in the result register The contents of specified relay no J gt and R OR relay no Function Connects NC contacts in paralle Remarks This instruction inverts the contents of a specified relay and then carries out a logical OR operation with the contents of the result register The result is then stored in the result register The contents of specified relay no BAe amt Instruction words AND LOAD AND LD Ladder diagram r Block A 1 i AND LD SE HE Function Connects two blocks A and B in this example in series Remarks This instruction is used for interblock AND operation between two blocks There is no limit to the number of blocks that can be connected in series by the AND LD instruct
135. s power is applied after you have performed the necessary settings Refer to Appendix E Mainte nance and inspection should a problem occur System expansion and peripherals nan A Rack No 0 System example 3 In this system the remote i O master unit is connected to a C500 so that this PC can transmit and receive data to from the C20 at a remote location SYSBUS optical fiber cable SYSBUS optical fiber cable E W hM JN C500 remote I O pester unit 83G2A5 RM001 A 10 F T C20 CPU i c20 VO link C20 CPU C20 expansion C20 1 0 link unit VO unit unit 8G2C7 LK011 3G207 channels 28 and 29 LKO11 channels 30 and 31 Protective cap Explanation In this example channels 0 to 27 have been automatically assigned to the C500 which has a remote I O master unit installed To establish communication between the nearest C20 via its I O link unit and the C500 channels 28 and 29 are manually assigned This assignment is from the perspective of the C500 This nearest C20 is C20 A in the figure For C20 B channels 30 and 31 are manually assigned This channel designation is also from the perspective of the C500 The distinction about perspective has been made for this reason
136. s procedure for setting the DIP switch when designating channels and the end station 1 First refer to the I O assignments of the PC or PCs connected to the remote I O master unit This is so you can determine the last input output channel number This procedure is explained ina moment 2 Decide what the channel number of the I O link unit should be When doing this be careful that no i O link unit channel number overlaps the tast assigned channel number of the PC or exceeds the allowable number of I O points of the PC If a channel number higher than the maximum number of I O points is assigned to an I O link unit an error occurs 3 Next check whether the I O link unit connected to the C20 is at the end of the SYSBUS that is the unit physically furthest from the remote 1 O master If so this I O link unit must be specified as the end station Check that no other I O link unit connected to the SYSBUS is already specified as the end station 4 Turn off the power to the I O link unit 5 Confirm that the LED power indicator on the I O link unit is not lighted Then open the front cover of the I O link unit with a flat bladed screwdriver System expansion and peripherals DIP switch setting example channel 5 6 Locate the six pin DIP switch on the upper right side of the printed circuit board inside the unit These pins represented by numbers 1 to 5 are used to specify a channel Each pin
137. s than the S2 timer no set value Function Performs high speed timer operation Remarks This instruction can be used as a high speed ON delay timer in the same manner as a relay circuit The set time can be between 00 00sec to 99 99sec in increments of 0 01sec Timer relay numbers can be set from 00 to 47 Do not give timers and counters the same number The operating conditions and contents of the operation are the same as the timer instruction lf the scan time exceeds 10msec the timing operation may be inaccurate Coding chart LD D io AND NOT 0202 TIMH 15 w0 OoOO ae 0204 LD tim 10 L_o205 our 0500 Function Compares a channel data or a four digit constant against another channel data Remarks The CMP instruction is used to compare a 16 bit channe data or a hexadecimal four digit 16 bit binary constant S1 against another 16 bit channel data S2 As a result of this comparison 1905 turns ON if the S1 is greater than the S2 1906 turns ON if the S1 is equal to the S2 Instruction words Coding chart Contents of data S1 S2 Address Instruction Data LD Input output re lay internal auxi 00 to 19 liary relay Holding relay HRO to 9 Timer counter TIM CNT00 to 47 Constant 0000 to FFFF OUT CMP 20 Note When the result register is jogical 1 a CMP instruction i
138. s the following The complete list of symbols is shown in Appendix B Hi Ah 0O Normally open contact Normally closed contact Output In writing the ladder diagram keep these things in mind Each logic line starting from the left bus bar must end with a relay coil a timer counter or a special instruction Unlike the actual circuit diagram the right bus bar need not be written into the ladder diagram The number of contacts in series or paraltel is not limited for use on a logic line within the programming capacity of the PC Therefore you can use as many contacts as you wish If this feature of the C20 is effectively used even a complicated circuit can frequently be replaced with a simpler one The bridge circuit 1 shown on the left for example could be replaced with the one shown below it 2 Introduction to programming Step 4 Turning the ladder diagram into PC code SETE D When you have finished writing your ladder diagram the next step is to encode the diagram into a language the PC can use This language consists of addresses instructions and data The addresses are locations in the memory where instructions and data are stored The instructions are used to tell the PC what to do using the data that follows each instruction For example let s consider a mini program that ANDs two contacts Here s the ladder diagram for this To code this we first need to specify the memory ad
139. ss 0001 This is how you would do it ONT A R The C20 gives you three convenient ways to search through a long Search function summary program for specific addresses instructions or contacts The key entries for these are summarized here Address search address e Specific instruction search instruction Specific contact search on contact number SRCH Step 7 Testing for errors Status check The C20 s debugging features can be used to catch many types of programming errors For this you use the FUN and MONTR keys in any of the three modes To see if the program you entered in the PC has a programming error press oona This is the display if no error is found If an error is found in the program the corresponding error message number will be displayed Refer to Appendix E Maintenance and troubleshooting and carry out the corrective action listed there If more than one error exists continue pressing to display each error message one at a time There are basically two levels of errors fatal and non fatal A fatal error such as a memory error prevents the PC from operating A non fatal error such as a battery failure allows the operation to proceed but still must be corrected In case both types of errors have occurred the error messages for the fatal error take precedence over the other and must be corrected first At times you may want to scan the
140. status whether ON or OFF of each relay contact before you start the control operation This can be an effective troubleshooting technique and is available in both the RUN and MONITOR modes You would normally perform the status check after you have carried out the debugging step above To begin go to the first address and press 5 5 Checking and running your program Forced set reset You ll see the address the instruction and the word OFF or ON displayed in the upper right hand corner of the LCD OFF or ON indicates the Current state of the relay contact Continue pressing the DOWN arrow key to check the status of each of the relays that follow During the execution of a program this operation is used to force set or reset for one scan time the operating status of each I O relay internal auxiliary relay holding relay timer or counter This operation is only meaningful while the PC is in the MONITOR mode The most common use of this function is during a trial run of the controlled system For instance if a particular task such as illuminating a heat lamp for drying would normally take 30 minutes but you simply wish to test the contact use this function to force reset the contact after a few moments of lamp operation The program could then continue to the next task in the control sequence without delay Forced relay set To do a forced set of a relay contact first plac
141. sult is then ANDed with input 0002 the condition under which the washing machine is stopped As iong as the condition of this AND circuit is satisfied output 502 is turned on causing the washing apparatus to travel the entire length of the vehicle nternal Auxiliary Relay 1000 output is also directly connected to output 0500 that causes the spray vaive to open Output 501 is issued to start operating the brush when the vehicle detector sends a signal to the C20 input 0001 unless Internal Auxiliary Relay 1001 is open This application features a system in which bottles being moved on a conveyor belt are checked by photoelectric switches for labels Alarm lamp Photoelectric Robot arm switches Conveyor A Motor to drive conveyor B Application examples Ladder diagram 0003 CNT Instruction LD NOT LD LD FUN10 OR AND NOT AND NOT QUT TIM Explanation If a defective product a bottle without a label is detected the C20 directs a robot arm to remove the bottle and place it on another conveyor line The C20 also counts the number of defective products If their number reaches a preset value the C20 causes an alarm lamp to go on 1 0 assignment Label missing detection Bottle detection Stop soe 3 Robot arm s original position detection Output Robot arm Conveyor B motor Alarm lamp Operation This applicati
142. t Service life of relay Electrically 300 000 operations Mechanical ly 50 000 000 operations G6B 1114P US M DC 24 V with sokect Circuit configuration COM IN 06 IN 07 COM IN 084 IN 12 IN 134 Internal circuit Internal circuit Terminal Signal name IN3 I O No 0103 Terminal Signal name VO No device for relay drivin input power zai i eE E elay driving Input power mt Load power supply wu al el ol al el of ol ol ofi 2 3 4 ts Je 7 guess JO sald Po oH 3 ae Ko 89 IIN ppi Load power supply BE gg BE B iS Y TT et RESESESESESESESEST Ste cojoni aiz Lele wT tw abete 1 Note The input and output channels of MC22B with 14 input points 12 output points are fixed on chan nels 1 and 6 Those of MC22C with 28 input points 24 output points are fixed on channels 1 and 2 input and 6 and 7 output Specifications Expansion I O unit Type 3G2C7 MA221 AC 100 to 120V input I Triac output Input voltage AC 85 to 132V Input impedance 9 7kQ 50Hz 8kQ 60Hz Input current 10mA typ AC 100V ON delay time 35ms max 1 5ms max OFF delay time 55ms max 1 2 of toad frequency max Number of circuits 14 points 8 6 points common 12 points 8 3 1 points common ON voltage
143. t channel assignment inquiry For example to check what kind of I O unit is connected to the fourth slot on the C500 specified as No 0 rack key in Fo Ea Jfer This causes the O unit connected at the 04 position to be displayed In this case the remote 1 0 master unit RMTO is connected to the fourth slot of No O rack A 11 System expansion and peripherals Beginning at that setting by pressing you can sequentially monitor all the channels connected to the remote I O master unit This message indicates that channel 28 specified as an output channel is connected to the remote I O master unit Another press of the key reveals that channel 29 is also connected and is specified as an input channel Channel 30 is specified as an output channel Channel 31 is specified as an input channel Application example A control system employing I O link units is shown below This system controls three manufacturing stages processing assembling and coating objects The dual role of the O link units is to transmit a specific quantity of information such as stop and warning signals and to interlock equipment and stations in the system If a warning signal is generated during one of the stages it is received by the central contro panel and displayed The control panel reacts with a return stop signal which shuts off the operation SYSBUS Central cont
144. t relay 2900 of the C500 which is connected to the remote I O master unit Since the I O link unit is using channels 28 and 29 the I O link unit must be set as channel 28 with its DIP switch Therefore the signal indicating the screw shortage that is output from relay 0600 of the I O link unit is input to relay 2900 in the processing stage In response relay 0102 on the central control panel is turned ON issuing the alarm signal 2 By connecting the RUN output of the I O link unit to input relay 0000 of the C20 in the coating stage the other two stages processing and assembling can be stopped in case a failure occurs in the I O link unit in the coating stage A 13 System expansion and peripherals PROM writer Mount PROM writer directly on CPU Securely tighten the mounting screws The PROM writer provides C20 users a means of storing their programs on microchip as opposed to cassette tape This way the program can be permanently saved or easily duplicated for use elsewhere The EPROM erasable programmable read only memory chip can be written and then later erased by ultraviolet light The PROM writer has functions to write the contents of the CPU memory to an EPROM chip and vice versa and also to verify the contents of the EPROM against the CPU memory However these functions of the PROM writer work in normal write mode but not high speed write mode The PROM writer
145. tching relay coil When both a set input and a reset input are applied at the same time the reset input takes precedence Set input z Reset input El Latching relay output 0500 If the holding relay is used as a latching relay data in the memory are retained during power failure until a set or reset input is applied Coding chart Address Instruction Data 0200 LD 0002 0201 AND 0002 0202 LD 0203 AND Contents of data Output relay in 0500 to 1807 ternal auxiliary relay Holding relay HRO00 to 915 DIFFERENTIATION UP DIFU relay no Symbol Function Causes relay to operate at leading edge of the input for one scan time aa Remarks Ladder diagram This instruction is used to output the differentiation of an input condition to 0000 0001 a specified relay for one scan time HH 4 0500 The instruction must be set so that the output is issued for one scan time at the leading edge of the result register that is at the point when the register s level turns from 0 to 1 When used with the DIFFERENTIATION DOWN DIFD instruction the maximum number of DIFU and DIFD instructions that can be program med together is 48 Instruction words DIFFERIENTIATION DOWN DIFD Symbol ny Ladder diagram 0000 met 0001 0501 The differentiation instructions perform their operations in response to changes in input after the PC
146. to relay B 1 Overwriting programs 4 4 1s clock generation D 4 Password 4 1 PC basic components 1 1 Peripherals A 1 appearence 1 5 compatibility with other C Series PCs 1 5 device command servicing time C 5 introduction 1 5 Permanent program storage A 14 Photoelectric switch use with C20 6 1 6 8 Points I O 3 3 Index Power cables connection to equipment 2 3 conservation 6 4 failure protections 2 7 B 6 failure backup battery 2 7 failure counter status B 8 failure momentary 2 7 line routing 2 3 problems E 5 sequence circuit 2 7 Power supply 2 4 C20 E 1 expansion I O unit E 1 1 0 link unit E 1 link adapter E 1 output relays A 2 required levels 2 6 specifications 2 6 Power terminals location and function 1 3 Printer interface unit A 18 Process trial run 5 6 Program capacity 2 1 copying 5 10 debugging 5 1 editing 4 2 end designation B 10 errors testing for 5 4 loading 4 6 testing using END instruction B 11 trial run 5 6 when multiple copies are needed A 18 when rarely modified A 14 PROGRAM mode function 4 3 Program save operation 5 10 Program saving on cassette tape restrictions A 15 Program storage 5 10 alternative A 15 Program writing errors 4 4 END instruction B 10 Programming console appearance and function 1 3 arrow keys 4 2 entering programs 4 4 gaining access 4 1 instruction keys 4 2 introduction 1 2 mode switch 4 1 operation keys 4 2
147. ultiplexing cyclic system Half duplex 187 5k bps Ams 32 points Polymer clad quartz core optical fiber 800m max 32 16 input and 16 output points RUN Contact output 2A max SPST NO Model G6B REPEATER Contact output SPST NO Model G6B for repeater signal 1kg max Specifications Dimensions CPU 28 point expansion 0 unit 250 jl A 59 5 18 Mounting hole Mounting hole 4 M4 5 25 4 M4 5 25 230 F 20 Specifications 1 0 link unit Type 3G2C7 LK011 Mounting hole 5 25 Link adapter Type 3G2A9 AL002 E Mounting hole 2 Optical fiber cable connector Reception ferrule Optical fiber cable Halflock connector Protective sheath Transmission ferrule F 21 Appendix G Mounting kit Overview To save mounting space at the installation site Type 3G2C7 PAT02 mounting kit is optionally available This kit includes four mounting screws two pairs of mounting brackets and one mounting plate Screw A M4x5 x4 Bracket B x2 Bracket C x2 Mounting plate x1 1 0 connecting cable 8G2C7 CN311 32cm option With this mounting kit the CPU and one expansion I O unit can be mounted in a sort of piggyback fas
148. ut is provided from the stack register A count up contact designates the counter number NO and NC contacts can be used in combination and in any quantity The counter decrements producing an output when the count value becomes 0000 The present value of the counter returns to the preset value when a reset input is applied The counter output is transmitted to an externa device through an output relay as shown in the ladder diagram After the preset count is finished any additional counts are ignored The program for a counter must be entered in the order of a count input circuit a reset input circuit and a counter coil Coding chart AND NOT LD CNT LD OUT Instruction words Leading edge Count input TEMPORARY MEMORY RELAY TR Ladder diagram nt 0002 Q 0003 0004 aie ie D 0006 At the leading edge from OFF to ON of a count input signal the counter decrements by a value of 1 When a count input and a reset input are simultaneously applied the reset input takes precedence No counting will be performed after that even if the reset input is removed If a power failure occurs the current count value the number of counts remaining is retained in memory and the counter is not reset The set value for the TIM CNT instruction cannot be set on a channel basis OH TR TR TR rr relay number or Hr relay number Function Serves as temporary memory r
149. ution A scan timeis the time required for the PC to execute the user program once starting from address 0000 to the program s end instruction Start of program execution One scan time Relay 1900 This relay is used to generate a 0 1s clock When used in conjunction with a counter it functions as a timer that can retain its present value during power failure Assignment of I O channel and relay numbers Note The ON time of a 0 1s clock is 50ms If a longer time is required for program execution the CPU may fail to read the clock Relay 1901 This relay is used to generate a 0 2s clock When used in conjunction with a counter it functions as a long time timer that can retain its present value during power failure Relay 1902 This relay is used to generate a ts clock When used in conjunction with a counter it functions as a long time timer that can retain its present value during power failure The relay output can be also used as a flicker signal Relay 1903 This relay turns ON when the result of an arithmetic operation is not output in BCD form Relay 1904 This relay serves as a carry flag and operates or releases according to the result of an arithmetic operation It can be forcibly turned ON by the SET CARRY STC instruction and turned OFF by the CLEAR CARRY CLC instruction Relay 1905 This relay turns ON if the result of the COMPARE CMP instruction is gt
150. vices are used for grounding Battery The CPU has a built in battery to back up the memory in case of power failure This backup battery is required regardless of whether a RAM or EPROM chip is used as the program memory The battery s service life is about five years when the PC is used at a temperature of 25 C and is somewhat shortened in temperatures higher than this or where humidity is unusually high These factors should also be kept in mind when storing the PC When the battery is almost completely discharged the ALARM ERROR indicator on the CPU blinks You then have one week to change the battery before memory loss occurs A fresh battery must be installed within 3 minutes after the old one has been removed from its connector Protections against power failure A power sequence circuit is incorporated in the PC to prevent malfunctioning because of a momentary power failure or a drop in the supply voltage If the voltage drops below 85 the PC stops operating and the external output relays are automatically turned off AC P oS Momentary power failure PF power failure detection time detection signal 5 jo 5Ve GRE power reset co 4 Approx H Relay output 10msec Approx 1sec k f 2 7 Installing the C20 The PC ignores all momentary power failures when the interruption tasts no longer than 10msec If the interruption
151. view 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 execut
152. with water oil or chemical substances One of the most important considerations when installing and wiring the C20 is the problem of noise The C20 should be mounted at least 200mm from high tension equipment or wiring Control panel wiring Wherever possible always use wiring ducts to contain and protect the wiring for the I O units I O wires should not be placed in the same duct with a power line or other wiring External wiring Use standard wiring conduits for routing I O and power lines to the C20 However be sure to use separate conduits for the 1 0 wiring The following points are important when the controlled system requires the laying of 400V 10A max or 220V 20A max power lines A minimum distance of 300mm must be provided between the I O lines and power cables when their conduits are run parallel to each other lf the cables must be placed in the same duct at the point of connection to the equipment be sure to screen them with a grounded metal plate Metal iron plate Z a 200mm min Grounding at a ground resistance of less than 1000 2 3 Installing the C20 Surge suppressor AC power source DC power source Input power supply Input device Noise suppression measures Be sure to take appropriate noise suppression measures when any electrical device likely to produce noise is employed as a PC output load For example electromagnetic relays and valves generating nois
153. xternal device for relay driving Load power supply Load power supply Load power supply Note The input and output channels of MC223 with 16 input points 12 output points are fixed on chan nels 1 and 6 Those of MC224 with 32 input points 24 output points are fixed on channels 1 and 2 input and 6 and 7 output Specifications Expansion 1 0 unit Type 7 3G2C7 MC227 MC228 DC input PNP Contact output Input voltage DC 24V 10 15 _ Input impedance 3kQ Input current 7mA typ DC 24V ON delay time 20ms max 15ms max OFF delay time 20ms max 15ms max Number of circuits 16 points 8 points common 12 points 8 3 1 points common ON voltage DC 16V max OFF voltage DC 5V min Max switching capacity AC 250V DC 24V 2A max p f 1 8 4 2A common 14A unit Min switching capacity DC 5V 10mA min Leakage current Saturation voltage f External power supply 15mA point 180mMA unit Service life of relay Electrically 300 000 operations Mechanical ly 50 000 000 operations G6B 1114P US M DC 24V with socket 1 5K COM 5S OUT 00 7 4 l E ens Ts 33 fouT 07 f i x g Lcon 3 g 3 5 5 Circuit configuration g g E P m H ouT 08 S S E 4 7 2S 40UT 10 COM po SOUT 11 00M 24v00 ov Terminal
154. y resistor If the ambient temperature is above 55 C within the panel you must install a fan for forced air ventilation Avoid mounting the PC in a panel in which high tension wiring or equipment is also installed Use wire with a cross sectional area of at least 2mm AGW14 to prevent pesado aa possible voltage drop Use twisted pair cables for the wiring l l T 1 tI i CPU rie igg Mounting dimensions i When the CPU and I O unit are mounted together in the control panel a ithe distance of about 30mm should be maintained between the two units tf a This means that the holes for the CPU mounting screws and those for the ES a 2 27 VO unit mounting screws should be separated by about 40mm Although the CPU is actually 59 5mm thick measured at the I O terminal block be sure to leave enough room in front of the unit to allow for instailation of optional peripheral devices such as the programming console When the programming console is attached to the PC the total depth increases to 68mm eM ge wv th a Pict yerery Pipi eee ee 2 ere ef Peripheral device CERTiageuee ee ra CERST CTEE Installing the C20 Power supply Use a commercially available DC 24V AC 100 to 120V or AC 200 to 240V power supply for the C20 As the DC 24V power supply Type 3G2A3 PS221 is available Here are the electrical specifications Power supply unit C
155. you can use any reliable cassette tape recorder This provides a way to save your programs for later use The same tape can also be used to program other C20s that control identical operations Multiple copies of the tape can be made using a conventional tape copier at either normal or high speed Store only one program to a tape or side of a tape The reason for this is that there is no way to identify individual programs if more than one have been stored on the same side of a cassette The only requirement is that the tape be at least 7 minutes long Either a standard or microcassette tape can be used First you ll learn how to save the program you have in the PC s memory Then you ll see how to load it back into the PC and verify that it was loaded correctly To save the program carry out this procedure 1 Plug one end of a Type SCY PLGO1 cable into the MIC jack of the PC and the other into the MIC jack of the tape recorder 2 Plug a second cable into the EAR jacks of both devices 3 Turn the volume and tone controls of the tape recorder to their maximum levels 4 Switch the PC to the PROGRAM mode 5 Press 6 Press A message is displayed to ask you to start the save operation On some tape recorders this may correspond to the LINE IN jack On some tape recorders this may correspond to the LINE OUT jack Checking and running your program Confirm the error content

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