Omron C28K, C60K, C40K, C20K User Manual

Cat. No. W146-E1-5

SYSMAC

C20K/C28K/C40K/C60K

Programmable Controllers

K-type

Programmable Controllers

OPERATION MANUAL

Revised July 1999

Notice:

OMRON products are manufactured for use according to proper procedures by a qualified operator and only for the purposes described in this manual.

The following conventions are used to indicate and classify precautions in this manual. Always heed the information provided with them. Failure to heed precautions can result in injury to people or damage to property.

! DANGER Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

! WARNING Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

! Caution Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury, or property damage.

OMRON Product References

All OMRON products are capitalized in this manual. The word ªUnitº is also capitalized when it refers to an OMRON product, regardless of whether or not it appears in the proper name of the product.

The abbreviation ªCh,º which appears in some displays and on some OMRON products, often means ªwordº and is abbreviated ªWdº in documentation in this sense.

The abbreviation ªPCº means Programmable Controller and is not used as an abbreviation for anything else.

Visual Aids

The following headings appear in the left column of the manual to help you locate different types of information.

Note Indicates information of particular interest for efficient and convenient operation of the product.

1, 2, 3... 1. Indicates lists of one sort or another, such as procedures, checklists, etc.

OMRON, 1992

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form, or by any means, mechanical, electronic, photocopying, recording, or otherwise, without the prior written permission of OMRON.

No patent liability is assumed with respect to the use of the information contained herein. Moreover, because OMRON is constantly striving to improve its high-quality products, the information contained in this manual is subject to change without notice. Every precaution has been taken in the preparation of this manual. Nevertheless, OMRON assumes no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of the information contained in this publication.

ii

About this Manual:

The OMRON K-type Programmable Controllers offer an effective way to automate processing, manufacturing, assembly, packaging, and many other processes to save time and money. Distributed control systems can also be designed to allow centralized monitoring and supervision of several separate controlled systems. Monitoring and supervising can be done through a host computer, connecting the controlled system to a data bank. It is thus possible to have adjustments in system operation made automatically to compensate for requirement changes.

The K-type Units can utilize a number of additional Units including dedicated Special I/O Units that can be used for specific tasks and Link Units that can be used to build more highly integrated systems.

The K-types are equipped with large programming instruction sets, data areas, and other features to control processing directly. Programming utilizes ladder-diagram programming methods, which are described in detail for those unfamiliar with them.

This manual describes the characteristics and abilities of the K-types programming operations, instructions, and other aspects of operation and preparation that demand attention. Before attempting to operate the PC, thoroughly familiarize yourself with the information contained herein. Hardware information is provided in detail in the Installation Guide. A table of other manuals that can be used in combination with this manual is provided at the end of Section 1 Introduction.

Section 1 Introduction explains the background and some of the basic terms used in ladder-diagram programming. It also provides an overview of the process of programming and operating a PC and explains basic terminology used with OMRON PCs. Descriptions of peripheral devices used with the K-types and a table of other manuals available to use with this manual for special PC applications are also provided.

Section 2 Hardware Considerations explains basic aspects of the overall PC configuration and describes the indicators that are referred to in other sections of this manual.

Section 3 Memory Areas takes a look at the way memory is divided and allocated and explains the information provided there to aid in programming. It also explains how I/O is managed in memory and how bits in memory correspond to specific I/O points.

Section 4 Programming explains the basics of writing and inputting the ladder-diagram program, looking at the elements that make up the `ladder' part of a ladder-diagram program and explaining how execution of this program is controlled and the methods required to input it input the PC. Section 5 Instruction Set then goes on to describe individually all of the instructions used in programming, while Section 6 Program Execution Timing explains the scanning process used to execute the program and tells how to coordinate inputs and outputs so that they occur at the proper times.

Section 7 Debugging and Execution provides the Programming Console procedures used to debug the program and to monitor and control system operation.

Finally, Section 8 Troubleshooting provides information on system error indications and other means of reducing system down time. Information in this section is also necessary when debugging a program.

The Appendices provide tables of standard OMRON products available for the K-types, reference tables of instructions and Programming Console operations, and other information helpful in PC operation.

! WARNING Failure to read and understand the information provided in this manual may result in personal injury or death, damage to the product, or product failure. Please read each section in its entirety and be sure you understand the information provided in the section and related sections before attempting any of the procedures or operations given.

iii

TABLE OF CONTENTS

PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		ix
1	Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	x
2	General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	x
3	Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	x
4	Operating Environment Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	x
5	Application Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	xi

SECTION 1 ± Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		1
1-1	Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2
1-2 Relay Circuits: The Roots of PC Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		2
1-3	PC Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3
1-4	OMRON Product Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3
1-5 Overview of PC Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		4
1-6	Peripheral Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5
1-7	Available Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6

SECTION 2 ± Hardware Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . .		7
2-1	Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8
2-2	Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8
2-3	PC Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8

SECTION 3 ± Memory Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .			9
3-1	Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		10
3-2	Data Area Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		10
3-3 Internal Relay (IR) Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .			12
3-4 Special Relay (SR) Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .			21
	3-4-1	Battery Alarm Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	21
	3-4-2	Cycle Time Error Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	21
	3-4-3	High-speed Drum Counter Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	21
	3-4-4	Clock Pulse Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	21
	3-4-5	Error Flag (ER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	22
	3-4-6	Step Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	22
	3-4-7	Always OFF, Always ON Flags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	22
	3-4-8	First Cycle Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	22
	3-4-9	Arithmetic Flags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	22
3-5 Data Memory (DM) Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .			23
3-6 Holding Relay (HR) Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .			23
3-7	Timer/Counter (TC) Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		23
3-8	Temporary Relay (TR) Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		24

SECTION 4 ± Writing and Inputting the Program . . . . . . . . . . . . . . . . . . .			25
4-1	Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		26
4-2	Instruction Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		26
4-3	The Ladder Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		27
	4-3-1	Basic Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	28
	4-3-2	Mnemonic Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	28
	4-3-3	Ladder Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	30
	4-3-4	OUT and OUT NOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	32
	4-3-5	The END Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	32
	4-3-6	Logic Block Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	32
	4-3-7	Coding Multiple Right-hand Instructions . . . . . . . . . . . . . . . . . . . . . .	39
	4-3-8	Branching Instruction Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	39
	4-3-9	Jumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	43

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Table of contents

4-4	The Programming Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		44
	4-4-1	The Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	44
	4-4-2	PC Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	45
4-5	Preparation for Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		46
	4-5-1	Entering the Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	47
	4-5-2	Clearing Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	47
	4-5-3	Clearing Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	49
4-6	Inputting, Modifying, and Checking the Program . . . . . . . . . . . . . . . . . . . . . . . .		49
	4-6-1	Setting and Reading from Program Memory Address . . . . . . . . . . . .	50
	4-6-2	Inputting or Overwriting Programs . . . . . . . . . . . . . . . . . . . . . . . . . . .	51
	4-6-3	Checking the Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	53
	4-6-4	Displaying the Cycle Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	54
	4-6-5	Program Searches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	55
	4-6-6	Inserting and Deleting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . .	57
4-7	Controlling Bit Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		59
	4-7-1	DIFFERENTIATE UP and DIFFERENTIATE DOWN . . . . . . . . . . .	59
	4-7-2	KEEP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	60
	4-7-3	Self-maintaining Bits (Seal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	60
4-8	Work Bits (Internal Relays) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		61
4-9	Programming Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		63
4-10	Program Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		65

SECTION 5 ± Instruction Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .			67
5-1	Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		68
5-2	Notation	. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	68
5-3	Instruction Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		68
5-4	Data Areas, Definer Values, and Flags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		69
	5-4-1	Coding Other Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	69
5-5	Ladder Diagram Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		73
	5-5-1	LOAD, LOAD NOT, AND, AND NOT, OR, and OR NOT . . . . . . . .	73
	5-5-2	AND LOAD and OR LOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	74
5-6	Bit Control Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		75
	5-6-1	OUTPUT and OUTPUT NOT ± OUT and OUT NOT . . . . . . . . . . . .	75
	5-6-2	DIFFERENTIATE UP and DIFFERENTIATE DOWN ±
		DIFU(13) and DIFD(14) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	75
	5-6-3	KEEP ± KEEP(11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	77
5-7	INTERLOCK and INTERLOCK CLEAR ± IL(02) and ILC(03) . . . . . . . . . . . .		78
5-8	JUMP and JUMP END ± JMP(04) and JME(05) . . . . . . . . . . . . . . . . . . . . . . . . .		80
5-9	END ± END(01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		81
5-10	NO OPERATION ± NOP(00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		81
5-11	Timer and Counter Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		82
	5-11-1	TIMER ± TIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	83
	5-11-2	HIGH-SPEED TIMER ± TIMH(15) . . . . . . . . . . . . . . . . . . . . . . . . . .	86
	5-11-3	Analog Timer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	87
	5-11-4	COUNTER ± CNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	90
	5-11-5	REVERSIBLE COUNTER ± CNTR(12) . . . . . . . . . . . . . . . . . . . . . .	93
	5-11-6	HIGH-SPEED DRUM COUNTER ± HDM(61) . . . . . . . . . . . . . . . . .	94
	5-11-7	REVERSIBLE DRUM COUNTER ± RDM(60) . . . . . . . . . . . . . . . . .	103
5-12	Data Shifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		106
	5-12-1 SHIFT REGISTER ± SFT(10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		106
	5-12-2 REVERSIBLE SHIFT REGISTER ± SFTR(84) . . . . . . . . . . . . . . . . .		109
	5-12-3 WORD SHIFT ± WSFT(16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		110
5-13	Data Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		111
	5-13-1	MOVE ± MOV(21) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	111
	5-13-2 MOVE NOT ± MVN(22) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		112
5-14	DATA COMPARE ± CMP(20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		112
5-15	Data Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		115
	5-15-1	BCD-TO- BINARY ± BIN(23) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	115

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Table of contents

	5-15-2	BINARY-TO-BCD ± BCD(24) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	115
	5-15-3 4-TO-16 DECODER ± MLPX(76) . . . . . . . . . . . . . . . . . . . . . . . . . . .		116
	5-15-4 16-TO-4 ENCODER ± DMPX(77) . . . . . . . . . . . . . . . . . . . . . . . . . . .		118
5-16	BCD Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		120
	5-16-1 BCD ADD ± ADD(30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		120
	5-16-2 BCD SUBTRACT ± SUB(31) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		122
	5-16-3 BCD MULTIPLY ± MUL(32) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		123
	5-16-4 BCD DIVIDE ± DIV(33) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		124
	5-16-5 SET CARRY ± STC(40) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		125
	5-16-6	CLEAR CARRY ± CLC(41) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	125
5-17	Subroutines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		126
	5-17-1 SUBROUTINE DEFINE and SUBROUTINE RETURN
		SBN(92)/RET(93) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	126
	5-17-2	SUBROUTINE ENTRY ± SBS(91) . . . . . . . . . . . . . . . . . . . . . . . . . .	126
5-18	Step Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		128
	5-18-1 STEP DEFINE and STEP START ± STEP(08)/SNXT(09) . . . . . . . .		128
5-19	Special Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		135
	5-19-1 I/O REFRESH ± IORF(97) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		135
	5-19-2 END WAIT ± ENDW(62) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		135
	5-19-3 NOTATION INSERT ± NETW(63) . . . . . . . . . . . . . . . . . . . . . . . . . .		136

SECTION 6 ± Program Execution Timing . . . . . . . . . . . . . . . . . . . . . . . . . .			137
6-1	Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		138
6-2	Cycle Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		139
6-3	Calculating Cycle Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		141
	6-3-1	Single PC Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	141
	6-3-2	PC with Additional Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	142
6-4	Instruction Execution Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		143
6-5	I/O Response Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		145

SECTION 7 ± Program Debugging and Execution . . . . . . . . . . . . . . . . . . .			147
7-1	Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		148
7-2	Debugging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		148
7-3	Monitoring Operation and Modifying Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		149
	7-3-1	Bit/Digit Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	150
	7-3-2	Force Set/Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	153
	7-3-3	Hexadecimal/BCD Data Modification . . . . . . . . . . . . . . . . . . . . . . . .	155
	7-3-4	Changing Timer/Counter SV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	156
7-4	Program Backup and Restore Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		157
	7-4-1	Saving Program Memory Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	158
	7-4-2	Restoring or Comparing Program Memory Data . . . . . . . . . . . . . . . .	159

SECTION 8 ± Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		161
8-1	Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	162
8-2	Reading and Clearing Errors and Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	162
8-3	Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	162
8-4	Error Flags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	164

Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	165
A ± Standard Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	165
B ± Programming Instructions and Execution Times . . . . . . . . . . . . . . . . . . . . . . . . . . .	171
C ± Programming Console Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	183
D ± Error and Arithmetic Flag Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	189
E ± Binary±Hexadecimal±Decimal Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	191
F ± Word Assignment Recording Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	193
G ± Program Coding Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	199
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	201
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	215

vii

PRECAUTIONS

This section provides general precautions for using the K-type Programmable Controllers (PCs) and related devices.

The information contained in this section is important for the safe and reliable application of Programmable Controllers. You must read this section and understand the information contained before attempting to set up or operate a PC system.

1	Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	x
2	General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	x
3	Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	x
4	Operating Environment Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	x
5	Application Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	xi

ix

Application Precautions

5

1 Intended Audience

This manual is intended for the following personnel, who must also have knowledge of electrical systems (an electrical engineer or the equivalent).

•Personnel in charge of installing FA systems.

•Personnel in charge of designing FA systems.

•Personnel in charge of managing FA systems and facilities.

2 General Precautions

The user must operate the product according to the performance specifications described in the operation manuals.

Before using the product under conditions which are not described in the manual or applying the product to nuclear control systems, railroad systems, aviation systems, vehicles, combustion systems, medical equipment, amusement machines, safety equipment, and other systems, machines, and equipment that may have a serious influence on lives and property if used improperly, consult your OMRON representative.

Make sure that the ratings and performance characteristics of the product are sufficient for the systems, machines, and equipment, and be sure to provide the systems, machines, and equipment with double safety mechanisms.

This manual provides information for programming and operating the Unit. Be sure to read this manual before attempting to use the Unit and keep this manual close at hand for reference during operation.

! WARNING It is extremely important that a PC and all PC Units be used for the specified purpose and under the specified conditions, especially in applications that can directly or indirectly affect human life. You must consult with your OMRON representative before applying a PC System to the above-mentioned applications.

3Safety Precautions

!WARNING Do not attempt to take any Unit apart while the power is being supplied. Doing so

may result in electric shock.

! WARNING Do not touch any of the terminals or terminal blocks while the power is being supplied. Doing so may result in electric shock.

! WARNING Do not attempt to disassemble, repair, or modify any Units. Any attempt to do so may result in malfunction, fire, or electric shock.

4 Operating Environment Precautions

! Caution Do not operate the control system in the following locations:

•Locations subject to direct sunlight.

•Locations subject to temperatures or humidity outside the range specified in the specifications.

•Locations subject to condensation as the result of severe changes in temperature.

x

Application Precautions

5

•Locations subject to corrosive or flammable gases.

•Locations subject to dust (especially iron dust) or salts.

•Locations subject to exposure to water, oil, or chemicals.

•Locations subject to shock or vibration.

! Caution Take appropriate and sufficient countermeasures when installing systems in the following locations:

•Locations subject to static electricity or other forms of noise.

•Locations subject to strong electromagnetic fields.

•Locations subject to possible exposure to radioactivity.

•Locations close to power supplies.

! Caution The operating environment of the PC System can have a large effect on the longevity and reliability of the system. Improper operating environments can lead to malfunction, failure, and other unforeseeable problems with the PC System. Be sure that the operating environment is within the specified conditions at installation and remains within the specified conditions during the life of the system.

5 Application Precautions

Observe the following precautions when using the PC System.

! WARNING Always heed these precautions. Failure to abide by the following precautions could lead to serious or possibly fatal injury.

•Always ground the system to 100 Ω or less when installing the Units. Not connecting to a ground of 100 Ω or less may result in electric shock.

•Always turn OFF the power supply to the PC before attempting any of the following. Not turning OFF the power supply may result in malfunction or electric shock.

•Mounting or dismounting I/O Units, CPU Units, Memory Cassettes, or any other Units.

•Assembling the Units.

•Setting DIP switches or rotary switches.

•Connecting cables or wiring the system.

•Connecting or disconnecting the connectors.

! Caution Failure to abide by the following precautions could lead to faulty operation of the PC or the system, or could damage the PC or PC Units. Always heed these precautions.

•Fail-safe measures must be taken by the customer to ensure safety in the event of incorrect, missing, or abnormal signals caused by broken signal lines, momentary power interruptions, or other causes.

•Interlock circuits, limit circuits, and similar safety measures in external circuits (i.e., not in the Programmable Controller) must be provided by the customer.

•Always use the power supply voltages specified in the operation manuals. An incorrect voltage may result in malfunction or burning.

•Take appropriate measures to ensure that the specified power with the rated voltage and frequency is supplied. Be particularly careful in places where the power supply is unstable. An incorrect power supply may result in malfunction.

•Install external breakers and take other safety measures against short-circuit- ing in external wiring. Insufficient safety measures against short-circuiting may result in burning.

xi

Application Precautions

5

•Do not apply voltages to the Input Units in excess of the rated input voltage. Excess voltages may result in burning.

•Do not apply voltages or connect loads to the Output Units in excess of the maximum switching capacity. Excess voltages or loads may result in burning.

•Disconnect the functional ground terminal when performing withstand voltage tests. Not disconnecting the functional ground terminal may result in burning.

•Be sure that all the mounting screws, terminal screws, and cable connector screws are tightened to the torque specified in the relevant manuals. Incorrect tightening torque may result in malfunction.

•Leave the label attached to the Unit when wiring. Removing the label may result in malfunction if foreign matter enters the Unit.

•Remove the label after the completion of wiring to ensure proper heat dissipation. Leaving the label attached may result in malfunction.

•Use crimp terminals for wiring. Do not connect bare stranded wires directly to terminals. Connection of bare stranded wires may result in burning.

•Wire all connections correctly.

•Double-check all wiring and switch settings before turning ON the power supply. Incorrect wiring may result in burning.

•Be sure that the terminal blocks, Memory Units, expansion cables, and other items with locking devices are properly locked into place. Improper locking may result in malfunction.

•Check the user program for proper execution before actually running it on the Unit. Not checking the program may result in an unexpected operation.

•Confirm that no adverse effect will occur in the system before attempting any of the following. Not doing so may result in an unexpected operation.

•Changing the operating mode of the PC.

•Force-setting/force-resetting any bit in memory.

•Changing the present value of any word or any set value in memory.

•Resume operation only after transferring to the new CPU Unit the contents of the DM Area, HR Area, and other data required for resuming operation. Not doing so may result in an unexpected operation.

•Do not pull on the cables or bend the cables beyond their natural limit. Doing either of these may break the cables.

•Do not place objects on top of the cables or other wiring lines. Doing so may break the cables.

•When replacing parts, be sure to confirm that the rating of a new part is correct. Not doing so may result in malfunction or burning.

•Before touching a Unit, be sure to first touch a grounded metallic object in order to discharge any static built-up. Not doing so may result in malfunction or damage.

•Install the Units properly as specified in the operation manuals. Improper installation of the Units may result in malfunction.

xii

		SECTION 1
		Background
1-1	Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . 2
1-2 Relay Circuits: The Roots of PC Logic . . . . . . . . . . . . . . . . . . . . . . . .		. . . . . . . . . 2
1-3	PC Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . 3
1-4	OMRON Product Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . 3
1-5 Overview of PC Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		. . . . . . . . . 4
1-6	Peripheral Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . 5
1-7	Available Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . 6

1

Relay Circuits: The Roots of PC Logic	Section 1-2

1-1 Introduction

A Programmable Controller (PC) is basically a central processing unit (CPU) containing a program and connected to input and output (I/O) devices (I/O Devices). The program controls the PC so that when an input signal from an input device turns ON, the appropriate response is made. The response normally involves turning ON an output signal to some sort of output device. The input devices could be photoelectric sensors, pushbuttons on control panels, limit switches, or any other device that can produce a signal that can be input into the PC. The output devices could be solenoids, switches activating indicator lamps, relays turning on motors, or any other devices that can be activated by signals output from the PC.

For example, a sensor detecting a product passing by turns ON an input to the PC. The PC responds by turning ON an output that activates a pusher that pushes the product onto another conveyor for further processing. Another sensor, positioned higher than the first, turns ON a different input to indicate that the product is too tall. The PC responds by turning on another pusher positioned before the pusher mentioned above to push the too-tall product into a rejection box.

Although this example involves only two inputs and two outputs, it is typical of the type of control operation that PCs can achieve. Actually even this example is much more complex than it may at first appear because of the timing that would be required, i.e., ªHow does the PC know when to activate each pusher?º Much more complicated operations, however, are also possible. The problem is how to get the desired control signals from available inputs at appropriate times.

Desired control sequences are input to the K-type PCs using a form of PC logic called ladder-diagram programming. This manual is written to explain ladder-diagram programming and to prepare the reader to program and operate the K-type PCs.

1-2 Relay Circuits: The Roots of PC Logic

PCs historically originate in relay-based control systems. And although the integrated circuits and internal logic of the PC have taken the place of the discrete relays, timers, counters, and other such devices, actual PC operation proceeds as if those discrete devices were still in place. PC control, however, also provides computer capabilities and consistency to achieve a great deal more flexibility and reliability than is possible with relays.

The symbols and other control concepts used to describe PC operation also come from relay-based control and form the basis of the ladder-diagram programming method. Most of the terms used to describe these symbols and concepts, however, originated as computer terminology.

Relay vs. PC Terminology The terminology used throughout this manual is somewhat different from relay terminology, but the concepts are the same. The following table shows the relationship between relay terms and the PC terms used for OMRON PCs.

Relay term	PC equivalent
contact	input or condition
coil	output or work bit
NO relay	normally open condition
NC relay	normally closed condition

2

OMRON Product Terminology			Section 1-4
		Actually there is not a total equivalence between these terms, because the
		term condition is used only to describe ladder diagram programs in general
		and is specifically equivalent to one of certain basic instructions. The terms
		input and output are not used in programming per se, except in reference to
		I/O bits that are assigned to input and output signals coming into and leaving
		the PC. Normally open conditions and normally closed conditions are ex-
		plained in 4-3 The Ladder Diagram.
1-3	PC Terminology
		Although also provided in the Glossary at the back of this manual, the follow-
		ing terms are crucial to understanding PC operation and are thus explained
		here as well.
PC		When we refer to the PC, we are generally talking about the CPU and all of
		the Units directly controlled by it through the program. This does not include
		the I/O devices connected to PC inputs and outputs.
		If you are not familiar with the terms used above to describe a PC, refer to
		Section 2 Hardware Considerations for explanations.
Inputs and Outputs		A device connected to the PC that sends a signal to the PC is called an input
		device; the signal it sends is called an input signal. A signal enters the PC

through terminals or through pins on a connector on a Unit. The place where a signal enters the PC is called an input point. This input point is allocated a location in memory that reflects its status, i.e., either ON or OFF. This memory location is called an input bit. The CPU in its normal processing cycle monitors the status of all input points and turns ON and OFF corresponding input bits accordingly.

There are also output bits in memory that are allocated to output points on Units through which output signals are sent to output devices, i.e., an output bit is turned ON to send a signal to an output device through an output point. The CPU periodically turns output points ON and OFF according to the status of the output bits.

These terms are used when describing different aspects of PC operation. When programming, one is concerned with what information is held in memory, and so I/O bits are referred to. When describing the Units that connect the PC to the controlled system and the places on these Units where signals enter and leave the PC, I/O points are referred to. When wiring these I/O points, the physical counterparts of the I/O points, either terminals or connector pins, are referred to. When describing the signals that enter or leave the system, reference is made to input signals and output signals, or sometimes just inputs and outputs.

Controlled System and The Control System includes the PC and all I/O devices it uses to control an Control System external system. A sensor that provides information to achieve control is an

input device that is clearly part of the Control System. The controlled system is the external system that is being controlled by the PC program through these I/O devices. I/O devices can sometimes be considered part of the controlled system, e.g., a motor used to drive a conveyor belt.

1-4 OMRON Product Terminology

OMRON products are divided into several functional groups that have generic names. Appendix A Standard Models list products by these groups. The term Unit is used to refer to all OMRON PC products, depending on the context.

The largest group of OMRON products is I/O Units. I/O Units come in a variety of point quantities and specifications.

3

Overview of PC Operation	Section 1-5

Special I/O Units are dedicated Units that are designed to meet specific needs. These include Analog Timer Units and Analog I/O Units.

Link Units are used to create Link Systems that link more than one PC or link a single PC to remote I/O points. Link Units include I/O Link Units that are used to connect K-type PCs to Remote I/O Systems controlled by a larger PC (e.g. C1000H) and Host Link Units.

Other product groups include Programming Devices and Peripheral Devices.

1-5 Overview of PC Operation

The following are the basic steps involved in programming and operating a K-type PC. Assuming you have already purchased one or more of these PCs, you must have a reasonable idea of the required information for steps one and two, which are discussed briefly below. This manual is written to explain steps three through six, eight, and nine. The section(s) of this manual that provide relevant information are listed with each of these steps.

1, 2, 3... 1. Determine what the controlled system must do, in what order, and at what times.

2.Determine what Units will be required. Refer to the Installation Guide. If a Link System is required, refer to the required System Manual(s).

3.On paper, assign all input and output devices to I/O points on Units and determine which I/O bits will be allocated to each. If the PC includes Special I/O Units or Link Systems, refer to the individual Operation Manuals or System Manuals for details on I/O bit allocation. (Section 3 Memory Areas)

4.Using relay ladder symbols, write a program that represents the sequence of required operations and their inter-relationships. Be sure to also program appropriate responses for all possible emergency situations. (Section 4 Writing and Inputting the Program, Section 5 Instruction Set, and Section 6 Program Execution Timing)

5.Input the program and all required operating parameters into the PC. (Section 4 Writing and Inputting the Program)

6.Debug the program, first to eliminate any syntax errors and then to eliminate execution errors. (Section 4 Writing and Inputting the Program, Section 7 Program Debugging and Execution, and Section 8 Troubleshooting)

7.Wire the PC to the controlled system. This step can actually be started as soon as step 3 has been completed. Refer to the Installation Guide and to Operation Manuals and System Manuals for details on individual Units.

8.Test the program in an actual control situation and fine tune it if required. (Section 7 Program Debugging and Execution and Section 8 Troubleshooting)

9.Record two copies of the finished program on masters and store them safely in different locations. (Section 7 Program Debugging and Execution)

Control System Design Designing the Control System is the first step in automating any process. A PC can be programmed and operated only after the overall Control System is fully understood. Designing the Control System requires a thorough understanding of the system that is to be controlled. The first step in designing a Control System is thus determining the requirements of the controlled system.

4

Peripheral Devices	Section 1-6

Input/Output Requirements The first thing that must be assessed is the number of input and output points that the controlled 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 an output signal from the PC. Keep in mind that the number of I/O points available depends on the configuration of the PC. Refer to 3-3 Internal Relay (IR) Area for details on I/O capacity and assigning I/O bits to I/O points.

Sequence, Timing, and

Relationships

Unit Requirements

Next, determine the sequence in which control operations are to occur and the relative timing of the operations. Identify the physical relationships between the I/O devices as well as the kinds of responses that should occur between them.

For instance, a photoelectric switch might be functionally tied to a motor by way of a counter within the PC. When the PC receives an input from a start switch, it could start the motor. The PC could then stop the motor when the counter has received five input signals from the photoelectric switch.

Each of the related tasks must be similarly determined, throughout the entire control operation.

The actual Units that will be mounted must be determined according to the requirements of the I/O devices. This will include actual hardware specifications, such as voltage and current levels, as well as functional considerations, such as those that require Special I/O Units or Link Systems. In many cases, Special I/O Units or Link Systems can greatly reduce the programming burden. Details on these Units and Link Systems are available in individual Operation Manuals and System Manuals.

Once the entire Control System has been designed, the task of programming, debugging, and operation as described in the remaining sections of this manual can begin.

1-6 Peripheral Devices

Programming Console

Graphic Programming

Console: GPC

Ladder Support Software:

LSS

The following peripheral devices can be used in programming, either to input/ debug/monitor the PC program or to interface the PC to external devices to output the program or memory area data. Model numbers for all devices listed below are provided in Appendix A Standard Models. OMRON product names have been placed in bold when introduced in the following descriptions.

A Programming Console is the simplest form of programming device for OMRON PCs. Although a Programming Console Adapter is sometimes required, all Programming Consoles are connected directly to the CPU without requiring a separate interface. The Programming Console also functions as an interface to output programs to a standard cassette tape recorder.

Various types of Programming Console are available, including both CPU-mounting and Handheld models. Programming Console operations are described later in this manual.

A Peripheral Interface Unit is required to interface the GPC to the PC.

The GPC also functions as an interface to output programs directly to a standard cassette tape recorder. A PROM Writer, Floppy Disk Interface Unit, or

Printer Interface Unit can be directly mounted to the GPC to output programs directly to an EPROM chip, floppy disk drive, or printing device.

LSS is designed to run on IBM AT/XT compatibles to enable nearly all of the operations available on the GPC. It also offers extensive documentation capabilities.

5

Available Manuals	Section 1-7

A Host Link Unit is required to interface a computer running LSS to the PC. Using an Optical Host Link Unit also enables the use of optical fiber cable to connect the FIT to the PC. Wired Host Link Units are available when desired. (Although FIT does not have optical connectors, conversion to optical fiber cable is possible by using Converting Link Adapters.)

Factory Intelligent Terminal: The FIT is an OMRON computer with specially designed software that allows FIT you to perform all of the operations that are available with the GPC or LSS.

Programs can also be output directly to an EPROM chip, floppy disk drive, or printing device without any additional interface units. The FIT has an EPROM writer and two 3.5º floppy disk drives built in.

A Peripheral Interface Unit or Host Link Unit is required to interface the FIT to the PC. Using an Optical Host Link Unit also enables the use of optical fiber cable to connect the FIT to the PC. Wired Host Link Units are available when desired. (Although FIT does not have optical connectors, conversion to optical fiber cable is possible by using Converting Link Adapters.)

PROM Writer	Other than its applications described above, the PROM Writer can be
	mounted to the PC's CPU to write programs to EPROM chips.

Floppy Disk Interface Unit Other than its applications described above, the Floppy Disk Interface Unit can be mounted to the PC's CPU to interface a floppy disk drive and write programs onto floppy disks.

Printer Interface Unit	Other than its applications described above, the Printer Interface Unit can be
	mounted to the PC's CPU to interface a printer or X-Y plotter to print out pro-
	grams in either mnemonic or ladder-diagram form.

1-7	Available Manuals
	The following table lists other manuals that may be required to program and/
	or operate the K-type PCs. Operation Manuals and/or Operation Guides are
	also provided with individual Units and are required for wiring and other
	specifications.
	Name	Cat. No.	Contents
Installation Guide		W147	Hardware specifications
Data Access Console Operation Guide		W173	Procedures for monitoring and manipulating data.
GPC Operation Manual		W84	Programming procedures for the GPC (Graphics
			Programming Console)
FIT Operation Manual		W150	Programming procedures for using the FIT (Factory Intelligent
			Terminal
LSS Operation Manual		W237	Programming procedures for using LSS (Ladder Support
			Software)
Printer Interface Unit Operation Guide		W107	Procedures for interfacing a PC to a printer
PROM Writer Operation Guide		W155	Procedures for writing programs to EPROM chips
Floppy Disk Interface Unit Operation Guide		W119	Procedures for interfacing a PC to a floppy disk drive
Optical Remote I/O System Manual		W136	Information on building an Optical Remote I/O System to
			enable remote I/O capability
Host Link System Manual		W143	Information on building a Host Link System to manage PCs
			from a `host' computer
K-type Analog I/O Units Operation Guide		W122	Hardware and software information on using Analog I/O Units
			with the K-type PCs.

6

		SECTION 2
		Hardware Considerations
2-1	Introduction . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-2	Indicators . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-3	PC Configuration . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

7

PC Configuration Section 2-3

2-1 Introduction

This section provides information on hardware aspects of K-type PCs that are relevant to programming and software operation. These include indicators on the CPU and basic PC configuration. This information is covered in detail in the Installation Guide.

2-2	Indicators
		CPU indicators provide visual information on the general operation of the PC.
		Using the flags and other error indicators provided in the memory data areas,
		although not a substitute for proper error programming, provides ready con-
		firmation of proper operation.
CPU Indicators		CPU indicators are located on the front right hand side of the PC adjacent to
		the I/O expansion slot and are described in the following table.
		Indicator	Function
		POWER	Lights when power is supplied to the CPU.
		RUN	Lights when the CPU is operating normally.
		ERR	Lights when an error is discovered in system error diagnosis
			operations. When this indicator lights, the RUN indicator will go
			off, CPU operation will be stopped, and all outputs from the PC
			will be turned OFF.
		ALARM	Lights when an error is discovered in system error diagnosis
			operations. PC operation will continue.

2-3 PC Configuration

The system must contain a K-type CPU and may additionally contain an Expansion I/O Unit, Special I/O Units and/or I/O Link Units.

The Expansion I/O Units are not a required part of the basic system and are used to increase the number of I/O points available. Special I/O Units and I/O Link Units are used to reduce programming complexity.

8

			SECTION 3
			Memory Areas
3-1	Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		. . . . . . . . . . . . . . 10
3-2	Data Area Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		. . . . . . . . . . . . . . 10
3-3 Internal Relay (IR) Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .			. . . . . . . . . . . . . . 12
3-4 Special Relay (SR) Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .			. . . . . . . . . . . . . . 21
	3-4-1	Battery Alarm Flag . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . 21
	3-4-2	Cycle Time Error Flag . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . 21
	3-4-3	High-speed Drum Counter Reset . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . 21
	3-4-4	Clock Pulse Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . 21
	3-4-5	Error Flag (ER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . 22
	3-4-6	Step Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . 22
	3-4-7	Always OFF, Always ON Flags . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . 22
	3-4-8	First Cycle Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . 22
	3-4-9	Arithmetic Flags . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . 22
3-5 Data Memory (DM) Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .			. . . . . . . . . . . . . 23
3-6 Holding Relay (HR) Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .			. . . . . . . . . . . . . 23
3-7	Timer/Counter (TC) Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		. . . . . . . . . . . . . 23
3-8	Temporary Relay (TR) Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		. . . . . . . . . . . . . 24

9

Data Area Structure Section 3-2

3-1	Introduction
			Various types of data are required to achieve effective and correct control. To
			facilitate managing this data, the PC is provided with various memory areas
			for data, each of which performs a different function. The areas generally ac-
			cessible by the user for use in programming are classified as data areas.
			The other memory area is the Program Memory, where the user's program is
			actually stored.
			This section describes these areas individually and provides information that
			will be necessary to use them. The name, acronym, range, and function of
			each area are summarized in the following table. All but the last one of these
			are data areas. All memory areas are normally referred to by their acronyms.
	Area	Acronym		Range	Function
Internal Relay		IR	Words:	00 to 18 (bits 00 to 07)	Used to manage I/O points, control other bits,
area			Bits:	0000 to 1807	timers, and counters, to temporarily store data.
Special Relay		SR	Words:	18 (bits 08 to 15) and	Contains system clocks, flags, control bits, and
area				19 (bits 00 to 07)	status information.
			Bits:	1808 to 1907
Data Memory		DM	DM 00 to DM 63		Used for internal data storage and manipulation.
area			(words only)
Holding Relay		HR	Words:	HR 0 to HR 9	Used to store data and to retain the data values
area			Bits:	HR 000 to HR 915	when the power to the PC is turned off.
Timer/Counter		TC	TC 00 to TC 47 (TC numbers are		Used to define timers and counters and to access
area			used to access other information)		completion flags, PV, and SV for them.
Temporary Relay		TR	TR 00 to TR 07 (bits only)		Used to temporarily store execution conditions.
area
Program Memory		UM	UM: 1,194 words.		Contains the program executed by the CPU.
Work Bits and Words			When some bits and words in certain data areas are not used for their in-
			tended purpose, they can be used in programming as required to control
			other bits. Words and bits available for use in this fashion are called work bits
			and work words. Most, but not all, unused bits can be used as work bits.
			Those that can be are specified by area in the remainder of this section. Ac-
			tual application of work bits and work words is described in Section 4 Writing
			and Inputting the Program.
Flags and Control Bits			Some data areas contain flags and/or control bits. Flags are bits that are
			automatically turned ON and OFF to indicate status of one form or another.
			Although some flags can be turned ON and OFF by the user, most flags can
			be read only; they cannot be controlled directly.
			Control bits are bits turned ON and OFF by the user to control specific as-
			pects of operation. Any bit given a name using the word bit rather than the
			word flag is a control bit, e.g., Restart Bits are control bits.
3-2	Data Area Structure
			When designating a data area, the acronym for the area is always required
			for any but the IR and SR areas. Although the acronyms for the IR and SR

areas are often given for clarity, they are not required and not input when programming. Any data area designation without an acronym is assumed to be in either the IR and SR area. Because IR and SR addresses run consecutively, the word or bit addresses are sufficient to differentiate these two areas.

An actual data location within any data area but the TC area is designated by its address. The address designates the bit and/or word within the area where the desired data is located. The TR area consists of individual bits

10

Data Area Structure	Section 3-2

used to store execution conditions at branching points in ladder diagrams. The use of TR bits is described in Section 4 Writing and Inputting the Program. The TC area consists of TC numbers, each of which is used for a specific timer or counter defined in the program. Refer to 3-7 Timer/Counter (TC) Area for more details on TC numbers and to 5-11 Timer and Counter Instructions for information on actual application.

The rest of the data areas (i.e., the IR, SR, HR and DM areas) consist of words, each of which consists of 16 bits numbered 00 through 15 from right to left. IR words 00 and 01 are shown below with bit numbers. Here, the content of each word is shown as all zeros. Bit 00 is called the rightmost bit; bit 15, the leftmost bit.

Bit number	15	14	13	12	11	10	09	08	07	06	05	04	03	02	01	00
IR word 00
	0	0	0	0	0	0	0	0	0	0	0	0	0	0	0	0
IR word 01
	0	0	0	0	0	0	0	0	0	0	0	0	0	0	0	0

Note The term least significant is often used for rightmost; the term most significant, for leftmost. These terms have not been used in this manual because a single word is often split into two or more parts, with each part used for different parameters or operands, sometimes even with bits in another word. When this is done, the rightmost bits in a word may actually be the most significant bits, i.e., the leftmost bits, of a value with other bits, i.e., the least significant bits, contained in another word.

The DM area is accessible by word only; you cannot designate an individual bit within a DM word. Data in the IR, SR and HR areas is accessible either by bit or by word, depending on the instruction in which the data is being used.

To designate one of these areas by word, all that is necessary is the acronym (if required) and the one or two-digit word address. To designate an area by bit, the word address is combined with the bit number as a single threeor four-digit address. The examples in the following table should make this clear. The two rightmost digits of a bit designation must indicate a bit between 00 and 15.

The same TC number can be used to designate either a word containing the present value (PV) of the timer or counter or a bit that functions as the completion flag for the timer or counter. This is explained in more detail in 3-7 Timer/Counter (TC) Area.

Area	Word designation		Bit designation
IR	00	0015	(leftmost bit in word 00)
SR	19	1900	(rightmost bit in word 19)
DM	DM 10	Not possible
TC	TC 46 (designates PV)	TC 46 (designates completion flag)

Data Structure			Word data input as decimal values is stored in binary-coded decimal (BCD)
			code; word data input as hexadecimal is stored in binary form. Because each
			word contains 16 bits, each four bits of a word represents one digit: either a
			hexadecimal digit equivalent numerically to the binary bits or decimal. One
			word of data thus contains four digits, which are numbered from right to left.
			These digit numbers and the corresponding bit numbers for one word are
			shown below.
Digit number				3						2						1						0
Bit number
		15	14	13		12		11	10	09		08		07	06	05		04		03	02	01		00
Contents
		0	0		0	0		0	0		0	0		0	0		0	0		0	0		0	0

11

Internal Relay (IR) Area	Section 3-3

Converting Different Forms

of Data

Decimal Points

When referring to the entire word, the digit numbered 0 is called the rightmost digit; the one numbered 3, the leftmost digit.

When inputting data into data areas, it must be input in the proper form for the intended purpose. This is no problem when designating individual bits, which are merely turned ON (equivalent to a binary value of 1) or OFF (a binary value of 0). When inputting word data, however, it is important to input it either as decimal or as hexadecimal, depending on what is called for by the instruction it is to be used for. Section 5 Instruction Set specifies when a particular form of data is required for an instruction.

Binary and hexadecimal can be easily converted back and forth because each four bits of a binary number is numerically equivalent to one digit of a hexadecimal number. The binary number 0101111101011111 is converted to hexadecimal by considering each set of four bits in order from the right. Binary 1111 is hexadecimal F; binary 0101 is hexadecimal 5. The hexadecimal equivalent would thus be 5F5F, or 24,415 in decimal (163 x 5 + 162 x 15 + 16 x 5 + 15).

Decimal and BCD can also be easily converted back and forth. In this case, each BCD digit (i.e., each four BCD bits) is numerically equivalent of the corresponding decimal digit. The BCD bits 0101011101010111 are converted to decimal by considering each four bits from the right. Binary 0101 is decimal 5; binary 0111 is decimal 7. The decimal equivalent would thus be 5,757. Note that this is not the same numeric value as the hexadecimal equivalent of 0101011101010111, which would be 5,757 hexadecimal, or 22,359 in decimal (163 x 5 + 162 x 7 + 16 x 5 + 7).

Because the numeric equivalent of each four BCD binary bits must be equivalent to a decimal value, any four bit combination numerically greater then 9 cannot be used, e.g., 1011 is not allowed because it is numerically equivalent to 11, which cannot be expressed as a single digit in decimal notation. The binary bits 1011 are of course allowed in hexadecimal and they are equivalent to the hexadecimal digit C.

There are instructions provided to convert data in either direction between BCD and hexadecimal. Refer to 5-15 Data Conversion for details. Tables of binary equivalents to hexadecimal and BCD digits are provided in the appendices for reference.

Decimal points are used in timers only. The least significant digit represents tenths of a second. All arithmetic instructions operate on integers only.

3-3 Internal Relay (IR) Area

The IR area is used both to control I/O points and as work bits to manipulate and store data internally. It is accessible both by bit and by word. Those words that can be used to control I/O points are called I/O words. Bits in I/O words are called I/O bits.

The number of I/O words varies between the K-type PCs. As shown, the IR area is comprised of three main sections. These are input words, output words and work words (work bits). Work bits are used in programming to manipulate data and control other bits. IR area work bits are reset when power is interrupted or PC operation is stopped.

12

Internal Relay (IR) Area	Section 3-3

I/O Words

Input Bit Usage

Output Bit Usage

Word Allocations

The maximum number of available I/O bits is 16 (bits/word) times the number of I/O words. I/O bits are assigned to input or output points as described in

Word Allocations.

If a Unit brings inputs into the PC, the bit assigned to it is an input bit; if the Unit sends an output from the PC, the bit is an output bit. To turn on an output, the output bit assigned to it must be turned ON. When an input turns on, the input bit assigned to it also turns ON. These facts can be used in the program to access input status and control output status through I/O bits.

I/O bits that are not assigned to I/O points can be used as work bits, unless otherwise specified in Word Allocations.

Input bits can directly input external signals to the PC and can be used in any order in programming. Each input bit can also be used in as many instructions as required to achieve effective and proper control. They cannot be used in instructions that control bit status, e.g., the OUTPUT, DIFFERENTIATION UP, and KEEP instructions.

Output bits are used to output program execution results and can be used in any order in programming. Because outputs are refreshed only once during each cycle (i.e. once each time the program is executed), any output bit can be used in only one instruction that controls its status, including OUT, OUT NOT, KEEP(11), DIFU(13), DIFD(14), and SFT(10). If an output bit is used in more than one such instruction, only the status determined by the last instruction will actually be output from the PC. See 5-12-1 SHIFT REGISTER - SFT(10) for an example of an output bit controlled by two instructions.

The maximum number of words available for I/O within the IR area is 10, numbered 00 through 09. The remaining words (10 through 18) are to be used for work bits. (Note that with word 18, only the bits 00 through 07 are available for work bits although some of the remaining bits are required for special purposes when RDM is used).

The actual number of bits that can be used as I/O bits is determined by the model of the CPU and the PC configuration. There are different models of Expansion I/O Units and Special I/O Units and I/O Link Units which can be connected to any of the CPUs. Each CPU model provides a particular number of I/O bits and each Expansion I/O Unit, Special I/O Unit or I/O Link Unit provides a particular number of I/O bits. Configuration charts for the possible combinations of CPUs and Units are included later in this section. Refer to those to determine the actual available I/O bits.

Within CPUs the I/O input words are always even numbered and the output words are always odd numbered. The general rule when connecting Expansion I/O Units to CPUs is that the first available word for the Expansion I/O Unit (whether input or output or a combination) is one more than the last I/O word of the CPU. If the Expansion I/O Unit is only either input or output (and not both) then the I/O words provided by the Expansion I/O Unit are allocated consecutively and the remaining words up to word 09 may be used for work bits. If the Expansion I/O Unit provides both input and output words then the words are allocated alternatively (input words always having even numbers) until all I/O words provided by the Expansion I/O Unit are allocated. The remaining words up to word 09 may then be used for work bits. Note that when a portion of an input word is not allocated to an input point then that portion may be used for work bits.

13

Internal Relay (IR) Area	Section 3-3

I/O Bits Available in CPUs The following table shows which bits can be used as I/O bits in each of the K-type CPUs. Bits in the shaded areas can be used as work bits but not as output bits.

Model		Input bits				Output bits
	Word 00					Word 01
	00		08			00	08
	01		09			01	09
C20K	02		10			02	10
	03		11			03	11
	04					04	12
	05	Cannot				05	13
			be
	06
		used.				06	14
	07					07	15
	Word 00					Word 01
	00		08			00	08
	01		09			01	09
	02		10			02	10
C28K	03		11			03	11
	04		12			04	12
	05		13			05	13
	06		14			06	14
	07		15			07	15
	Word 00			Word 02		Word 01		Word 03
	00		08	00		00	08	00	08
	01		09	01		01	09	01	09
	02		10	02	Cannot	02	10	02	10
	03		11	03		03	11	03	11
C40K					be
	04		12	04	used.	04	12	04	12
	05		13	05		05	13	05	13
	06		14	06		06	14	06	14
	07		15	07		07	15	07	15
	Word 00			Word 02		Word 01		Word 03
	00		08	00	08	00	08	00	08
	01		09	01	09	01	09	01	09
C60K	02		10	02	10	02	10	02	10
	03		11	03	11	03	11	03	11
	04		12	04	12	04	12	04	12
	05		13	05	13	05	13	05	13
	06		14	06	14	06	14	06	14
	07		15	07	15	07	15	07	15

indicates words that cannot be used for I/O, but can be used as work bits.

14

Internal Relay (IR) Area	Section 3-3

I/O Bits Available in

Expansion I/O Units

The following table shows which bits can be used as I/O bits in each of the Expansion I/O Units. Bits in the shaded areas can be used as work bits but not as output bits. The word addresses depend on the CPU that the Expansion I/O Unit is coupled to. In all cases the first Expansion I/O Unit address for input and output words is one more than the last CPU address for input and output words. For example, the last CPU word address for a C40K CPU is 03 and hence the first input or output word address for any of the Expansion I/O Units coupled to a C40K CPU will be 04. In the tables below ªnº is the last CPU word allocated as an input or output word.

There are several models for some of the Units listed below. A blank space (_) in the model number indicates that any of the applicable model numbers could be inserted here.

	Model		Input bits		Output bits
		Word (n+1)		Word (n + 2)
		00	08	00	08
		01	09	01	09
	C20P	02	10	02	10
		03	11	03	11
		04	Cannot	04	12
		05		05	13
			be
		06	used.	06	14
		07		07	15
		Word (n+1)		Word (n + 2)
		00	08	00	08
		01	09	01	09
	C28P	02	10	02	10
		03	11	03	11
		04	12	04	12
		05	13	05	13
		06	14	06	14
		07	15	07	15

			Word (n+1)		Word (n + 3)		Word (n + 2)		Word (n + 4)
			00	08	00		00	08	00	08
			01	09	01		01	09	01	09
	C40P		02	10	02	Cannot	02	10	02	10
			03	11	03		03	11	03	11
						be
			04	12	04	used.	04	12	04	12
			05	13	05		05	13	05	13
			06	14	06		06	14	06	14
			07	15	07		07	15	07	15
			Word (n+1)		Word (n + 3)		Word (n + 2)		Word (n + 4)
			00	08	00	08	00	08	00	08
			01	09	01	09	01	09	01	09
			02	10	02	10	02	10	02	10
	C60P		03	11	03	11	03	11	03	11
			04	12	04	12	04	12	04	12
			05	13	05	13	05	13	05	13
			06	14	06	14	06	14	06	14
			07	15	07	15	07	15	07	15

indicates words that cannot be used for I/O, but can be used as work bits.

Model

Input bits Output bits

		Word (n + 1)
		00	08
		01	09
		02	10
	C16P	03	11
		04	12
	-Ij-j
		05	13
		06	14
		07	15

Word (n + 1)

		00	08
		01	09
		02	10
	C16P	03	11
	-Oj-j	04	12
		05	13
		06	14
		07	15
		Word (n + 1)
		00
		01
		02
	C4K-Ij	03
		Cannot
		be used
		Word (n + 1)
		00	08
		01	09
		02	10
	C4K-Oj	03	11
		04	12
		05	13
		06	14
		07	15

	Word (n + 1)	Word (n + 2)
00		00	08
01		01	09
02		02	10
03		03	11
C4K-TM		04	12
	Cannot
		05	13
	be used
		06	14
		07	15

15

Internal Relay (IR) Area	Section 3-3
PC Configuration	A K-type PC can be configured with a CPU Unit and one or more of the fol-
	lowing Units: Expansion I/O Units, Analog Timer Units, or an I/O Link Unit. All
	of these Units are connected in series with the CPU Unit at one end. An I/O
	Link Unit, if included, must be on the other end (meaning only one I/O Link
	Unit can be used) and an Analog Timer Unit cannot be used. The rest of the
	Units can be in any order desired.
	There is also a restriction in the number of Units which can be included. To
	compute the number of Units for this restriction, add up all of the Units count-
	ing the C40K CPU Unit, C60K CPU Unit, C40K Expansion I/O Unit and C60K
	Expansion I/O Unit as two Units each and any other Units as one Unit each.
	This total must be no more than five.
	The following table shows some of the combinations that can be used to
	achieve specific numbers of I/O points. The numbers in the table indicate the
	number of Units of that size to be used as either the CPU or Expansion I/O
	Unit; any one of the Units can be the CPU Unit. This table does not include
	the C4P or C16P Expansion I/O Units, the Analog Timer Unit, or the I/O Link
	Unit, which can be used for greater system versatility or special applications.
	Refer to the remaining tables in this section for other combinations.

I/O points			Count as 2		Count as 1
			each		each
Total	In	Out	C60j	C40j	C28j	C20j
			(32/28)	(24/16)	(16/12)	(12/8)
20	12	8	---	---	---	1
28	16	12	---	---	1	---
40	24	16	---	---	---	2
			---	1	---	---
48	28	20	---	---	1	1
56	32	24	---	---	2	---
60	32	28	1	---	---	---
	36	24	---	---	---	3
			---	1	---	1
68	40	28	---	---	1	2
			---	1	1	---
76	44	32	---	---	2	1
80	48	32	---	---	---	4
			---	1	---	2
			---	2	---	---
			1	---	---	2
84	48	36	---	---	3	---
88	48	40	1	---	1	---
	52	36	---	---	1	3
			---	1	1	1
96	56	40	---	---	2	2
			---	1	2	---
100	56	44	1	---	---	2
			1	1	---	---

I/O points			Count as 2		Count as 1
			each		each
Total	In	Out	C60j	C40j	C28j	C20j
			(32/28)	(24/16)	(16/12)	(12/8)
100	60	40	---	---	---	5
			---	1	---	3
			---	2	---	1
104	60	44	---	---	3	1
108	60	48	1	---	1	1
	64	44	---	---	1	4
			---	1	1	2
			---	2	1	---
112	64	48	---	---	4	---
116	64	52	1	---	2	---
	68	48	---	---	2	3
			---	1	2	1
120	64	56	2	---	---	---
	68	52	1	---	---	3
			1	1	---	1
124	72	52	---	---	3	2
			---	1	3	---
128	72	56	1	---	1	2
			1	1	1	---
132	76	56	---	---	4	1
136	76	60	1	---	2	1
140	76	64	2	---	---	1
	80	60	---	---	5	---
144	80	64	1	---	3	---
148	80	68	2	---	1	---

16

Internal Relay (IR) Area	Section 3-3

The tables on the following pages show the possible configurations for a K-type PC. Although the tables branch to show the various possibilities at any one point, there can be no branching in the actual PC connections. You can choose either branch at any point and go as far as required, i.e., you can break off at any point to create a smaller PC System.When implementing a system there is a physical restriction on the total cable length allowable. The sum of the lengths of all cables in the system must be limited to less than 1.2 meters.

The tables also show which words will be input words and which words will be output words. All of these are determined by the position of the Unit in the configuration except for the C4P and C16P Expansion I/O Units, in which case the model of the Unit determines whether the words are input or output.

The symbols used in the table represent the following:

C20K/C28K				C20K or C28K CPU Unit
Input		Output
		C40K/C60K				C40K or C60K CPU Unit
Input		Output		Input	Output

C4K/C16P

C4P or C16P Expansion I/O Unit

In/Output

	C20P/C28P/TU/LU,			C20P Expansion I/O Unit, C28K Expansion I/O Unit,
	Input	Output		Analog Timer Unit, or I/O Link Unit
		C40P/C60P				C40P or C60P Expansion I/O Unit
	Input	Output		Input	Output

17

Internal Relay (IR) Area

Section 3-3

IR 00

IR 01

IR 02

IR 03

IR 04

IR 05

IR 06

IR 07

IR 08

IR 09

C20K/C28K		C4K/C16P	C4K/C16P	C4K/C16P	C4K/C16P
Input	Output	In/Output	In/Output	In/Output	In/Output

C20P/C28P/TU/LU

Input Output

C20P/C28P/TU/LU		C4K/C16P
Input	Output	In/Output

C20P/C28P/TU/LU

Input Output

			C40P/C60P
		Input	Output	Input	Output
	C20P/C28P/TU/LU		C4K/C16P	C4K/C16P
	Input	Output	In/Output	In/Output
				C20P/C28P/TU/LU
				Input	Output
			C20P/C28P/TU/LU		C4K/C16P
			Input	Output	In/Output
					C20P/C28P/TU/LU
					Input	Output
				C40P/C60P
			Input	Output	Input	Output
		C40P/C60P			C4K/C16P
	Input	Output	Input	Output	In/Output
					C20P/C28P/TU/LU
					Input	Output
C20P/C28P/TU/LU		C4K/C16P	C4K/C16P	C4K/C16P
Input	Output	In/Output	In/Output	In/Output
				C20P/C28P/TU/LU
				Input	Output
			C20P/C28P/TU/LU		C4K/C16P
			Input	Output	In/Output
					C20P/C28P/TU/LU
					Input	Output

C40P/C60P

Input

Output

Input

Output

18

Internal Relay (IR) Area									Section 3-3
IR 00	IR 01	IR 02	IR 03	IR 04	IR 05	IR 06	IR 07	IR 08		IR 09

C20K/C28K		C20P/C28P/TU/LU		C20P/C28P/TU/LU		C4K/C16P	C4K/C16P
Input	Output	Input	Output	Input	Output	In/Output	In/Output

C20P/C28P/TU/LU

Input Output

C20P/C28P/TU/LU		C4K/C16P
Input	Output	In/Output

C20P/C28P/TU/LU

Input Output

					C40P/C60P
				Input	Output	Input	Output
			C40P/C60P			C4K/C16P
		Input	Output	Input	Output	In/Output
						C20P/C28P/TU/LU
						Input	Output
	C40P/C60P			C4K/C16P	C4K/C16P
Input	Output	Input	Output	In/Output	In/Output
					C20P/C28P/TU/LU
					Input	Output
				C20P/C28P/TU/LU		C4K/C16P
				Input	Output	In/Output
						C20P/C28P/TU/LU
						Input	Output

C40P/C60P

Input

Output

Input

Output

19