Omron SYSMAC C500 Installation Manual
Cat. No. W132-E1-4
SYSMAC
C500
Programmable Controller
C500 Programmable Controller
Installation Guide
Revised May 2000
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 the product.
DANGER Indicates information that, if not heeded, is likely to result in loss of life or serious injury.
!
WARNING Indicates information that, if not heeded, could possibly result in loss of life or serious injury .
!
Caution Indicates information that, if not heeded, could result in relatively serious or minor injury, dam-
!
age to the product, or faulty operation.
OMRON Product References
All OMRON products are capitalized in this manual. The word “Unit” 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 “Ch,” which appears in some displays and on some OMRON products, often means
“word” and is abbreviated “Wd” in documentation in this sense.
The abbreviation “PC” 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.
OMRON, 1990
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.
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.
ii
About this Manual:
This manual describes the installation of the C500 Programmable Controller and includes the sections
described below.
Please read this manual carefully and be sure you understand the information provided before attempting
to install and operate the C500 Programmable Controller. Be sure to read the following section before
operating the C500 Programmable Controller.
Section 1
ble Controller can do and how a Programmable Controller works is provided.
Section 2
of each Unit are given.
Section 3
vided.
Section 4
tems.
Section 5
venting electrical noise are included.
Section 6
Section 7
Appendixes
is an introduction to Programmable Controllers. General information about what a Programma-
provides a description of all the components of the C500. The names of all the individual parts
explains how to assemble the C500. A detailed description of how to mount each Unit is pro-
outlines the system connections involved in installing a C500 Programmable Controller Sys-
contains the requirements for the installation environment of the C500. Suggestions for pre-
explains the power considerations involved in installing the C500.
lists safety considerations that should be kept in mind while installing the C500.
, a
Glossary
, and an
Index
are also included.
!
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 vii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 Intended Audience viii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 General Precautions viii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Safety Precautions viii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Operating Environment Precautions ix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Application Precautions ix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 – Introduction 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1 What is a Control System? 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2 The Role of the PC 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2-1 Input Devices 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2-2 Output Devices 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3 How Does a PC Work? 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – Description of All Components 9 . . . . . . . . . . . . . . . . . . . . . . .
2-1 CPU Rack 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2 CPU Power Supply 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3 Expansion I/O Backplane 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4 I/O Power Supply 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5 I/O Control Unit 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6 I/O Interface Unit 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7 I/O Units 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-8 Memory Packs 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 – Assembly 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1 Mounting the Units 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2 Memory Packs 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3 System Configurations 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 – System Connections 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1 Current Consumption 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2 I/O Connections 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 – Installation Environment 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1 Cooling 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2 Mounting Requirements 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3 Duct Work 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4 Preventing Noise 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 – Power Considerations 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 – Safety Considerations 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A Inspection and Maintenance 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B Specifications 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C Standard Models 97 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Glossary 103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index 107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
v
PRECAUTIONS
This section provides general precautions for using the Programmable Controller (PC) and related devices.
The information contained in this section is important for the safe and reliable application of the PC. You must read
this section and understand the information contained before attempting to set up or operate a PC system.
1 Intended Audience viii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 General Precautions viii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Safety Precautions viii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Operating Environment Precautions ix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Application Precautions ix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
vii
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 OMRON PCs.
Be sure to read this manual before attempting to use the software and keep this
manual close at hand for reference during operation.
3Safety Precautions
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 abovementioned
applications.
3 Safety 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.
viii
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.
• 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.
5Application Precautions
Caution The operating environment of the PC system can have a large effect on the lon-
!
gevity 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 con-
necting 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 Units, 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.
ix
• 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 this manual. 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-circuiting in external wiring. Insufficient safety measures against short-circuiting may
result in burning.
• 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 voltage 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 this manual. 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.
• Double-check all wiring and switch settings before turning ON the power supply. Incorrect wiring may result in burning.
• Wire correctly. Incorrect wiring may result in burning.
• Mount Units only after checking terminal blocks and connectors completely.
• 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 ef fect 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.
• Use crimp terminals for wiring. Do not connect bare stranded wires directly to
terminals. Connection of bare stranded wires may result in burning.
• 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.
5Application Precautions
x
SECTION 1
Introduction
1-1 What is a Control System? 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2 The Role of the PC 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2-1 Input Devices 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2-2 Output Devices 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3 How Does a PC Work? 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
Introduction
This section provides general information about Programmable Controllers
(Systems) and how they fit into a Control System.
1-1 What is a Control System?
A Control System is the electronic equipment needed to control a particular
process. It may include everything from a process control computer, if one is
used, to the factory computer, down through the PCs (and there may be
many of them networked together), and then on down through the network to
the control components: the switches, stepping motors, solenoids, and sensors which monitor and control the mechanical operations.
Process Control Computer
Section 1Introduction
Factory Computer
PCs
PC PC PC
Control Components
A Control System can involve very large applications where many different
models of PC are networked together or it could be an application as small
as a single PC controlling a single output device.
2
Position Control System
Section 1Introduction
Position Control Unit Input Unit
PC
Signal line for
Servomotor
driver control
Power
source
DC Servomotor
Driver
DC Servomotor
Power
source
DC Servomotor
Driver
DC Servomotor
Handheld
Programming
Console
Control panel
Control switch
In the typical Control System example shown above, a PC controls the movement of the workpiece bed across two horizontal axes using Limit Switches
and Servomotors to monitor and control movement.
1-2 The Role of the PC
The PC is the part of the Control System that directly controls the manufacturing process. According to the program stored in its memory, the PC accepts data from the input devices connected to it, and uses this data to monitor the controlled system. When the program calls for some action to take
place, the PC sends data to the output devices connected to it to cause that
action to take place. The PC may be used to control a simple, repetitive task,
or it may be connected to other PCs, or to a host computer in order to integrate the control of a complex process.
3
1-2-1 Input Devices
PCs can receive input from either automated or manual devices. The PC
could receive data from the user via a pushbutton switch, keyboard, or similar device. Automated input could come from a variety of devices: microswitches, timers, encoders, photosensors, and so on. Some devices, like the
Limit Switch shown below, turn ON or OFF when the equipment actually
makes contact with them. Other devices, like the Photoelectric Switch and
Proximity Switch shown below, use other means, such as light or inductance,
in order to get information about the equipment being monitored.
Section 1Introduction
Photoelectric Switch
1-2-2 Output Devices
A PC can output to a myriad of devices for use in automated control. Almost
anything that you can think of could be controlled (perhaps indirectly) by a
PC. Some of the most common devices are motors, Solenoids, Servomotors,
Stepping Motors, valves, switches, indicator lights, buzzers, and alarms.
Some of these output devices, such as the motors, Solenoids, Servomotors,
Stepping Motors, and valves, affect the controlled system directly. Others,
such as the indicator lights, buzzers, and alarms, provide output to notify personnel.
Proximity Switch
Limit Switch
Solenoid
Stepping Motor
Servomotor
4
1-3 How Does a PC Work?
PCs operate by monitoring input signals and providing output signals. When
changes are detected in the signals, the PC reacts, through the user-programmed internal logic, to produce output signals. The PC continually cycles
the program in its memory to achieve this control.
Block Diagram of PC
Section 1Introduction
Power Supply
Memory
Scanning Cycle
Signals
from
switches,
sensors,
etc.
Input Output
CPU
Programming
Device
Signals
to Solenoids,
motors,
etc.
A program for your applications must be designed, and stored in the PC. This
program is then executed as part of the cycle of internal operations of the
PC.
When a PC 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 the following four categories:
1. Common (or overseeing) processes, such as watchdog timer operation
and testing the program memory.
2. Data input and output.
Cycle Time
3. Instruction execution.
4. Peripheral device servicing.
The total time required for a PC to perform all these internal operations is
called the cycle time. The flowchart and diagram on page 7 illustrate these
internal operations for a typical PC.
Timing is one of the most important factors in designing a Control System.
For accurate operations, it is necessary to have answers to such questions
as these:
• How long does it take for the PC to execute all the instructions in its memory?
5
Section 1Introduction
• How long does it take for the PC to produce a control output in response to
a given input signal?
The cycle time of the PC can be automatically calculated and monitored, but
it is necessary to have an understanding of the timing relationships within the
PC for effective System design and programming.
6
Section 1Introduction
PC Operation
Flowchart
Sets error flag and
lights indicator
Power application
Clears data areas and re-
sets System counters
Checks I/O Unit connection
Resets watchdog timer
Checks hardware and
program memory
No
Check OK?
Initial
processing
on
power
application
Common
processes
Error or alarm?
Error
Alarm
IR data to Output Units
Processes Remote I/O
Resets watchdog timer
Services peripheral devices
Has the application program
been completely executed?
Yes
Resets watchdog timer
Resets watchdog
timer and application
program counter
Executes the program
End of Program?
No
Yes
Mathematical
processes
No
Out
refresh
Remote
I/O
processes
Servicing peripheral
devices
In refresh
PC
cycle
time
Data from Input
Units to IR Area
7
SECTION 2
Description of All Components
2-1 CPU Rack 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2 CPU Power Supply 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3 Expansion I/O Backplane 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4 I/O Power Supply 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5 I/O Control Unit 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6 I/O Interface Unit 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7 I/O Units 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-8 Memory Packs 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
Introduction
2-1 CPU Rack
Section 2Description of All Components
This section provides information about the individual Units that make up the
C500 PC. First the names of all the parts of the PC are given, followed by
any details that apply to the Units that make up the PC. For a description of
how the Units fit together to become a PC, refer to
. For information about the model numbers of any of the parts described
tions
in this section, refer to
The following figure shows the names of all the parts of the CPU Rack.
There are seven models of CPU Racks available for the C500 PC. Choose a
Backplane with 3, 5 (2 models), 6, 8 (2 models), or 9 I/O slots, depending on
your application. Connect the CPU Backplane to an Expansion I/O Rack via
the Expansion I/O Connector.
Appendix C Standard Models
3-3 System Configura-
.
Expansion I/O Connector
Connects the CPU Rack
to an Expansion I/O
Rack. When not used,
cover with cap.
I/O Control Unit
An I/O Control Unit must be
mounted to the Rack in order to connect the CPU
Rack to an Expansion I/O
Rack.
Backplane
I/O Units
(3, 5, 6, 8, or 9 I/O Units depending on the Backplane
used)
CPU
CPU Power Supply
10
CPU
Section 2Description of All Components
The CPU executes the user program. The model available for the C500 PC
does not have a built-in Power Supply or Memory Pack. Choose the Power
Supply and memory pack suitable for your application. A peripheral device
connector and a memory pack compartment are provided.
Peripheral Device
Connector
Indicators
SYSMAC C500
PROGRAMMABLE CONTROLLER
POWER
RUN
ERR
ALARM
OUT INMB
OMRON
Memory Pack
and Battery
Compartment
Peripheral device
mounting screw
Peripheral device
•
connector cover
CPU mounting
screw
Peripheral device
mounting screw
The CPU is equipped with one connector for peripheral devices. A peripheral
device, such as the CPU-Mounting Programming Console, can be mounted
directly to the CPU and does not require a connecting cable. To mount the
CPU-Mounting Programming Console or any other peripheral device directly
to the CPU, follow these steps:
1. Detach the cover of the peripheral device connector with a standard
screwdriver.
2. Connect the CPU-Mounting Programming Console to the peripheral de-
vice connector.
3. To ensure a positive connection, secure the Programming Console to
the CPU by tightening the mounting screws located on the surface of the
CPU.
11
2-2 CPU Power Supply
C
The CPU Power Supply is mounted to the rightmost slot of the CPU Rack.
Three models of Power Supplies are available: 100 to 120 VAC, 200 to 240
VAC, and 24 VDC. The following table summarizes the output capacity of the
three models and the current available for I/O Units mounted on the CPU
Rack.
Section 2Description of All Components
3G2A5-PS221-E
Mounting screw
Do not loosen this screw.
Fuse holder
Contains a MF61NR fuse
•
(3 A, 250 V, 6.35-dia. x32)
POWER indicator
Lights when power is supplied.
Mounting screw
Do not loosen this screw.
3G2A5-PS221-E
3G2A5-PS223-E
3G2A5-PS213-E 24 VDC 9 A 5 VDC 5 A Not provided
Note Be sure to keep the total power consumed by all the Units mounted
Terminals for
external connections
Model Supply Voltage Output
Capacity
100 to 120/
200 to 240 VA
(selectable)
7 A 5 VDC 5 A Provided
12 A 5 VDC 10 A Not provided
Available Current
for I/O Units
24 VDC Output
Terminal
on a Rack within the value stated in the table above. For example, do
not mount I/O Units with a total current consumption of 6 A to a Rack
supplied by a 7 A Power Supply. As shown in the table above, the
available current for I/O Units is only 5 A. For details concerning current consumption, refer to
AC input
Voltage selector
Short: 100 to 120 V
Open: 200 to 240 V
LG
GR
+
+
0.8 A, 24 VDC output
–
START input
RUN output
Section 4 System Connections
Connect a 100 to 120 VAC or 200 to
240 VAC power source.
Short these terminals to select 100 to
120 VAC. Open them to select 200 to
240 VAC.
Ground this terminal at a resistance of
less than 100
munity or prevent electric shock.
Ground this terminal at a resistance
of less than 100
shock.
Use these terminals to supply power
to DC Input Units. Use a separate
Power Supply if the I/O Unit requires
more than 0.8 A. If a current higher
than 0.8 A is output, the PC stops.
These terminals are short-circuited as
a factory-set condition. Remove the
short-circuit bracket to start or stop
the PC with an external signal. Normally, leave them short-circuited.
These terminals are turned ON during RUN operation.
Ω to improve noise im-
.
Ω to prevent electric
12
3G2A5-PS223-E
Section 2Description of All Components
Mounting screw
Do not loosen this screw.
•
3G2A5-PS213-E
Fuse holder
Contains a MF61NR fuse
(3 A, 250 V, 6.35-dia. x32)
POWER indicator
Lights when power is supplied.
Terminals for
external connections
Mounting screw
Do not loosen this screw.
Mounting screw
Do not loosen this screw.
AC input
Voltage selector
Short: 100 to 120 V
Open: 200 to 240 V
LG
GR
START input
RUN output
+
Connect a 100 to 120 VAC or 200
to 240 VAC power source.
Short these terminals to select 100
to 120 VAC. Open them to select
200 to 240 VAC.
Ground this terminal at a resistance of less than 100
prove noise immunity or prevent
electric shock.
Ground this terminal at a resis-
tance of less than 100
vent electric shock.
24 VDC output terminals are not
provided.
These terminals are short-circuited
as a factory-set condition. Remove
the short-circuit bracket to start or
stop the PC with an external signal.
Normally, leave them shortcircuited.
These terminals are turned ON
during RUN operation.
Ω to im-
Ω to pre-
Fuse holder
Contains a MF61NR fuse
•
(3 A, 250 V, 6.35-dia. x32)
POWER indicator
Lights when power is supplied.
Terminals for
external connections
Mounting screw
Do not loosen this screw.
24 VDC input
-
LG
GR
START input
RUN output
Connect a 24 VDC power source
(2.3 A min.)
Ground this terminal at a resistance
of less than 100
immunity or prevent electric shock.
Ground this terminal at a resistance
of less than 100
tric shock.
24 VDC output terminals are not
provided.
These terminals are short-circuited
as a factory-set condition. Remove
the short-circuit bracket to start or
stop the PC with an external signal.
Normally, leave them shortcircuited.
These terminals are turned ON during RUN operation.
Ω to improve noise
Ω to prevent elec-
13
2-3 Expansion I/O Backplane
The Expansion I/O Backplane shown in the following diagram, can be used
to expand the C500 PC. An Expansion I/O Rack is just like a CPU Rack, except a CPU is not mounted. However, a Power Supply is needed for each
Expansion I/O Rack. There are three models of Expansion I/O Backplane
available.
I/O Units
I/O Interface Unit
An I/O Interface Unit must be mounted to an Expansion I/O Rack in order to connect the Expansion I/O Rack to another Expansion I/O Rack.
Expansion I/O Backplane
Section 2Description of All Components
Expansion I/O Power Supply
2-4 I/O Power Supply
Just as a Power Supply must be mounted to the CPU Rack, a Power Supply
must also be mounted to each Expansion I/O Backplane. There are two
Power Supplies available; 100 to 120/200 to 240 VAC and 24 VDC, both of
which are explained below. For details, refer to
Model Supply Voltage Output
3G2A5-PS222-E 100 to 120/200
3G2A5-PS212-E 24 VDC 7 A 5 VDC 6.5 A Not provided
Note Be sure to keep the total power consumed by all the Units mounted
on a Rack within the value stated in the table above. For example, do
not mount I/O Units with a total current consumption of 7A to a Rack
supplied by a 7 A Power Supply. As shown in the table above, the
available current for I/O Units is only 6.5 A. For details concerning
current consumption, refer to
to 240 VAC
(selectable)
Appendix B Specifications
Available
Capacity
7A 5 VDC 6.5 A Provided
Current for I/O
Units
240 VDC
Output
Terminal
Section 4 System Connections
.
.
14
3G2A5-PS222-E
Mounting screw
Do not loosen this screw.
Section 2Description of All Components
Fuse holder
Contains a MF61NR fuse
•
(3 A, 250 V, 6.35-dia. x32)
POWER indicator
Lights when power is supplied.
Mounting screw
Do not loosen this screw.
3G2A5-PS212-E
Terminals for
external connections
AC input
Voltage selector
Short: 100 to 120 V
Open: 200 to 240 V
LG
GR
+
0.8 A, 24 VDC output
-
Connect a 100 to 120 VAC or 200 to
240 VAC power source
Short these terminals to select 100 to
120 VAC. Open them to select 200 to
240 VAC.
Ground this terminal at a resistance
of less than 100
immunity or prevent electric shock.
Ground this terminal at a resistance
of less than 100
shock.
Use these terminals to supply power
to DC Input Units. Use a separate
Power Supply if the I/O Unit operate
on more than 0.8 A. If a current higher
than 0.8 A is output, the PC stops.
These terminals are used to supply
external DC Input Units. If the Unit requires more than 0.8 A a separate
supply must be used. The PC shuts off
automatically if a current of more than
0.8 A is drawn from the supply.
Ω to improve noise
Ω to prevent electric
Mounting screw
Do not loosen this screw.
Fuse holder
Contains a MF61NR fuse
•
(3 A, 250 V, 6.35-dia. x32)
POWER indicator
Lights when power is supplied.
Terminals for
external connections
Mounting screw
Do not loosen this screw.
+
-
24 VDC input
LG
GR
Connect a 24-VDC power source (2.3
A min.)
Ground this terminal at a resistance
of less than 100
immunity or prevent electric shock.
Ground this terminal at a resistance
of less than 100
shock.
Ω to improve noise
Ω to prevent electric
15
2-5 I/O Control Unit
An I/O Control Unit must be mounted to the CPU Rack in order to connect
the CPU Rack to an Expansion I/O Rack. An I/O Control Unit can be
mounted even if no Expansion I/O Rack is used.
2-6 I/O Interface Unit
An I/O Interface Unit is needed on each Expansion I/O Rack, in order to expand the PC. If there is not an I/O Interface Unit on each Expansion I/O
Rack, data communication cannot take place. The I/O Interface Unit is
mounted to the leftmost I/O position on the Expansion I/O Backplane.
2-7 I/O Units
I/O Units come in 5 shapes; A-shape, B-shape, C-shape, D-shape, and Eshape. Refer to
A-shape
Appendix B Specifications
Mounting screw
Provided at top and bottom
Nameplate
Fuse blowout alarm indicator
Provided on OD411/OA121/
OD217/OA222
Section 2Description of All Components
for the dimensions of each Unit.
I/O indicators
Indicate ON/OFF status points
Terminal block mounting screw
Provided at top and bottom
20-terminal terminal block
Removable
16
B-shape
Section 2Description of All Components
Mounting screw
Provided at top and bottom
Nameplate
I/O indicators
Indicate ON/OFF status of I/O
signal
Terminal block mounting screw
Provided at top and bottom
38-terminal terminal block
Removable
C-shape
Mounting screw
Provided at top and bottom
Nameplate
I/O indicators
Indicate ON/OFF status of points
Terminal block mounting screw
Provided at top and bottom
38-terminal terminal block
Removable
17
D-shape
Section 2Description of All Components
Mounting screw
Provided at top and bottom
Nameplate
I/O indicators
Indicate ON/OFF status of points
Two 40-terminal terminal
block connectors
Removable
E-shape
Mounting screw
Provided at top and bottom
Nameplate
I/O indicators
Indicate ON/OFF status of points
Two 24-terminal terminal block plugs
4-terminal terminal block
18
2-8 Memory Packs
The Memory Pack fits into the slot located on the left side of the CPU. Because the Memory Pack is not provided with the PC upon delivery, a Memory
Pack must be selected and installed in the CPU. There are two Memory
Packs available, either RAM or ROM, that can be used in the C500H PC.
RAM Pack
Data can be randomly written to and read from the RAM Pack, making it possible to enter your own program into the CPU. However, because this is not a
fixed program, the memory of the RAM Pack is erased when power is not
supplied to the CPU or when the RAM Pack is removed from the CPU.
Caution Do not remove the battery in the CPU when the RAM Pack has been removed
!
from the CPU.
Section 2Description of All Components
CHIP 0 CHIP 1 CHIP 264 128
RAM Pack
Two models of RAM Packs are available, which vary in memory capacity:
16K, and 24K words. Refer to
bers.
Using a Programming Console, execute FUN (01) and a search operation to
check the amount of memory available.
Appendix C Standard Models
for model num-
19
ROM Pack
Section 2Description of All Components
Data contained in the ROM Pack is stored on EPROM chips and cannot be
altered or erased during the CPU’s operation. Write the user’s program to the
EPROM chips and mount the chips (3 max.) on the ROM chip. The entire
pack is installed in the CPU. Once the data is written to the chip the data will
not be lost when the power to the PC is OFF.
CHIP 0 CHIP 1 CHIP 264 128
RAM Pack
20
SECTION 3
Assembly
3-1 Mounting the Units 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2 Memory Packs 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3 System Configurations 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
Introduction
When we speak of a PC, we usually think of it as a single object. But actually
even the simplest PCs are usually composed of several different devices. In
fact a single PC can be physically spread throughout a building, but we still
call it one PC.
In this section, we will start with a Backplane and use all the Units discussed
Section 2 Description of All Components
in
3-1 Mounting the Units
There is no single Unit that can be said to constitute a Rack PC. To build a
Rack PC, we start with a Backplane. The Backplane for the C500 is shown
below.
Section 3Assembly
to build a PC.
C500 Backplane
The Backplane is a simple device having two functions. The first is to provide
physical support for the Units to be mounted to it. The second is to provide
the connectors and electrical pathways necessary for connecting the Units
mounted to it.
The first device we will add to the Backplane is a Power Supply. The Power
Supply fits into the rightmost position on the Backplane and provides electricity at the voltages required by the other Units of the PC. It can also be used
to power devices other than the PC if necessary.
Power Supply
The core of the PC is the CPU. The CPU contains the program consisting of
the series of steps necessary for the control task. The CPU fits into the position directly to the left of the Power Supply.
22
CPU
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