Omron WIRED REMOTE I-O SYSTEM MANUAL
Cat. No. W120-E1-08
SYSMAC
C-series Rack PCs
Wired Remote I/O
Wired Remote I/O
System Manual
Revised April 2003
iv
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
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serious injury.
WARNING Indicates a potentially hazardous situation which, if not avoided, could result in death or
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serious injury.
Caution Indicates a potentially hazardous situation which, if not avoided, may result in minor or
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moderate injury, or property damage.
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, 1989
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.
v
vi
TABLE OF CONTENTS
PRECAUTIONS xi. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 Intended Audience xii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 General Precautions xii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Safety Precautions xii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Operating Environment Precautions xiii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Application Precautions xiii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 EC Directives xv. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1
Introduction 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1 Remote I/O Systems 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2 Wired Remote I/O Systems 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2
System Design 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1 Basic System 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2 C200H Systems 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3 Combined Systems 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4 Optical Connections in Wired Systems 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5 Multilevel Systems 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3
Data Exchange and Operations 21. . . . . . . . . . . . . . . . . . . .
3-1 Block Diagrams 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2 Unit Numbers and I/O Word Allocation 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3 Setting Procedure 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4 Delayed Activation of Slaves 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4
Unit Components and Switch Settings 45. . . . . . . . . . . . . . .
4-1 Masters and Slaves 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2 Remote Terminal 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5
System Installation 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1 Dimensions 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2 Differentiating Units 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3 I/O Block Connections 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4 Mounting and Wiring Precautions 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5 Wiring 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6
I/O Response Times 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1 Introduction 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2 C500 Systems 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3 C1000H and C2000H Systems 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4 C200H Systems 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS
SECTION 7
Error Processing 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1 Self-Diagnosis 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2 Error Codes and Monitoring 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3 Locating Transmission Errors 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4 CONTINUE and STOP Mode Operation 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5 Recovery in STOP Mode 95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-6 I/O Table Creation Problems 95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-7 Slave Unit Numbers with Multiple Terminators 95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendices
A Standard Models 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B Specifications 103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C When Using CS1-series PCs 107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Glossary 111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index 117. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Revision History 121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
viii
About this Manual:
This manual describes the means and Units necessary to construct a Wired Remote I/O System consisting of at least one Remote I/O Master Unit and one or more Remote I/O Slave Units or Remote
Terminals. (The term “Wired” refers to the links used to create the Remote I/O System, e.g., that between a Remote I/O Master Unit and a Remote I/O Slave Unit.) Remote I/O Systems reduce wiring
requirements for remote control from a PC by performing distributed control actions through execution
of a program in the memory of a single PC’s CPU. The 3G2A5-RM201 Remote I/O Master Unit can
be used with any C-series Rack PC except the C200H PC. The C200H-RM201 Remote I/O Master
Unit is used with a C200H PC. Remote I/O Slave Units, though generally used with the corresponding
Remote I/O Master Unit, can be used in “combined” system configurations.
This manual has been prepared to explain how to incorporate Wired Remote I/O Systems into C120,
C500, C200H, C1000H, and C2000H PC Systems. It provides the necessary information, such as
system configuration, settings, and I/O word allocation, for connecting Remote I/O Master Units, Remote I/O Slave Units, and I/O Units.
Before attempting to set up and operate your Remote I/O System, familiarize yourself with all relevant
parts of this manual. For more detailed descriptions of manual content, refer to the introductions for
individual sections.
Section 1 introduces Wired I/O Systems and describes their characteristics.
Section 2 describes some of the many possible system configurations and the limitations of each
type of system.
Section 3 provides names and descriptions of basic functions, internal circuits, and methods for dif-
ferentiating differentiating unit types. Settings required to operate the system and successfully communicate program actions are explained, and example system settings are provided.
Section 4 provides details on Wired Remote I/O Systems, and the main Units used to build these
Systems, included within these are mounting restrictions and wiring considerations of the systems.
Parts of the Units, switch setting, and examples of switch settings are provided.
Section 5 explains how to install Wired I/O Systems and includes information on dimensions, differences between Units, and wiring.
Section 6 offers details on response time computations.
Section 7 describes error indications and error processing. Both indicator lights and dedicated error-
related flags are provided.
Appendix A provides a list of the basic specifications and complete model numbers of products used
in Wired I/O Systems.
Appendix B provides technical specifications.
Appendix C provides information on using CS1-series PCs.
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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.
ix
PRECAUTIONS
This section provides general precautions for using the Wired Remote I/O System and related devices.
The information contained in this section is important for the safe and reliable application of the Wir ed Remote I/O
System. You must read this section and understand the information contained before attempting to set up or operate
the Wired Remote I/O System.
1 Intended Audience xii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 General Precautions xii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Safety Precautions xii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Operating Environment Precautions xiii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Application Precautions xiii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 EC Directives xv. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
xi
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 relevant 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 System.
Be sure to read this manual before attempting to use the System and keep this
manual close at hand for reference during operation.
5Safety Precautions
WARNING It is extremely important that the Wired Remote I/O System 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 the Wired Remote I/O System to the
above-mentioned applications.
3 Safety Precautions
WARNING Do not attempt to take any Unit apart while the power is being supplied. Doing so
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may result in electric shock.
WARNING Do not touch any of the terminals or terminal blocks while the power is being
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supplied. Doing so may result in electric shock.
Caution Tighten the screws on the terminal block of the AC Power Supply Unit to the
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torque specified in the operation manual. The loose screws may result in burning
or malfunction.
Caution Execute online edit only after confirming that no adverse effects will be caused
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by extending the cycle time. Otherwise, the input signals may not be readable.
WARNING Do not attempt to disassemble, repair , or modify any Units. Any attempt to do so
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may result in malfunction, fire, or electric shock.
xii
WARNING Provide safety measures in external circuits (i.e., not in the Programmable
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Controller), including the following items, in order to ensure safety in the system
if an abnormality occurs due to malfunction of the PC or another external factor
affecting the PC operation. Not doing so may result in serious accidents.
• Emergency stop circuits, interlock circuits, limit circuits, and similar safety
measures must be provided in external control circuits.
• The PC will turn OFF all outputs when its self-diagnosis function detects any
error or when a severe failure alarm (FALS) instruction is executed. As a countermeasure for such errors, external safety measures must be provided to ensure safety in the system.
• The PC outputs may remain ON or OFF due to deposition or burning of the
output relays or destruction of the output transistors. As a countermeasure for
such problems, external safety measures must be provided to ensure safety in
the system.
4 Operating Environment Precautions
Caution Do not operate the control system in the following locations:
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• 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.
5Application Precautions
Caution Take appropriate and sufficient countermeasures when installing systems in the
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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 Wired Remote I/O 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 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 Wired Remote I/O 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 Units, or any other
Units.
xiii
• 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
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Wired Remote I/O 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.
• 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 . In su f ficient 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.
• 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 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.
5Application Precautions
xiv
6 EC Directives
6EC Directives
• 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.
Remote I/O products conform to EMS and low-voltage level directives as follows:
EMC Directives
OMRON devices that comply with EC Directives also conform to the related
EMC standards, so that they can more easily be built in to other devices or the
overall machine. The actual products have been checked for conformity to EMC
standards. Whether they conform to the standards in the system used by the
customer, however, must be checked by the customer.
EMC-related performance of the OMRON devices that comply with EC Directives will vary depending on the configuration, wiring, and other conditions of the
equipment or control panel on which the OMRON devices are installed. The customer must, therefore, perform the final check to confirm that devices and the
overall machine conform to EMC standards.
Low-voltage Level Directives
Always ensure that devices operating at voltages of 50 to 1,000 VAC and 75 to
1,500 VDC meet the necessary safety standard for the PC (EN61131-2).
DeviceNet products that comply with EC Directives must be installed as follows:
1, 2, 3... 1. Remote I/O Units are designed for installation inside control panels. All Re-
mote I/O Units must be installed within control panels.
2. Use reinforced insulation or double insulation for the DC power supplies
used for the communications power supply, internal circuit power supply,
and the I/O power supplies.
3. Remote U/O products that comply with EC Directives also conform to the
Common Emission Standard (EN50081-2). Radiated emission characteristics (10-m regulations) may vary depending on the configuration of the control panel used, other devices connected to the control panel, wiring, and
other conditions. You must therefore confirm that the overall machine or
equipment complies with EC Directives.
4. Remote I/O products that comply with EC Directives have configurations
with less than 30 m of I/O wiring, and less than 10 m of power supply wiring.
xv
This section introduces Wired I/O Systems and describes their characteristics.
1-1 Remote I/O Systems 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2 Wired Remote I/O Systems 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1
Introduction
1
Remote I/O Systems Section 1-1
1-1 Remote I/O Systems
Assembly lines are often extremely long, making it difficult if not impossible to
wire all I/O devices directly from CPU Racks or Expansion I/O Racks. A Remote I/O System can be used to solve this problem. In a Remote I/O System,
a Rack can be located farther from the CPU Rack than is possible with Expansion I/O Racks connected directly to the CPU Rack.
By locating a Rack farther from the CPU Rack, a Remote I/O System eliminates the time and mess in wiring (or changing wiring) to many devices that
are separated from the CPU Rack. Although all I/O points must ultimately be
wired individually, the question is one of distance: Do you want to wire dozens of terminals all the way across a factory complex or do you want to run a
single cable for most of the distance and then wire individual terminals locally?
The following diagram illustrates how a simple Remote I/O System would be
set up. Slave Racks, described below, are controlled by the CPU Unit
through the Master. The dotted circles show the devices that would be controlled through the Units on each Rack.
Processing
machine
Assembly line
Slave
Slave Rack
Processing
machine
Sensor Sensor Sensor
Slave Rack
Processing
machine
Slave
Wiring distance could also be reduced by placing an independent CPU Rack
near every location that required control, but in doing so, each PC would
have to be programmed independently and the activities of all the PC programs would need to be coordinated, a very difficult job. Here too, a Remote
I/O System simplifies the task by allowing a single CPU Unit, and thus a single program, to integrate control of the entire process. A Remote I/O System
thus has these two advantages: Racks can be located a greater distance
from the CPU Rack and coordinating control actions is simplified because all
control is exerted by one program.
A third advantage of Remote I/O Systems is reduced noise interference. This
is the result of the single cable that replaces the otherwise numerous wires
that would be required all the way from the CPU and Expansion I/O Racks to
the I/O devices.
Master
Processing
machine
CPU Rack
2
Remote I/O Systems Section 1-1
A Remote I/O System directly involves only one PC and the program in it and
through it a large number of I/O points can be controlled a greater distance
from the PC. This is achieved by mounting a Remote I/O Master Unit to the
CPU Rack to control I/O points located possibly many kilometers away. Each
Master serves as a ‘switching point’ for controlling all of the I/O points accessed through it. These I/O points are accessed through the Master, not
controlled by it. All I/O control comes from the program in the CPU Unit.
More than one Master can be mounted to a single PC, with each Master
forming the starting point of a Remote I/O Subsystem, i.e., a Remote I/O
Subsystem includes one Master plus all of the Remote I/O Units controlled
through it.
The Remote I/O Units that can be included in each Subsystem depend on
the specifications of the Master. Masters are available either with optical or
wire specifications. Optical Remote I/O Systems transfer data through opti-
cal fiber cables to enable the greatest transmission distance and the greatest resistance to electrical noise. Wired Remote I/O Systems use wire ca-
bles which don’t offer as great a distance as Optical Subsystems, but do
greatly reduce the burden of wiring remote I/O and afford greater resistance
to noise than independently wired I/O points. Both types of Master can be
mounted to the same PC to meet specific distance and noise-resistance requirements.
PC
Master
on Rack
PC
Optical and
Wired Masters
on Rack
Remotely Controlled I/O Devices
Label printer
Wired Subsystem
Auto welder
Optical Subsystem
Conveyer
Glue coater
Polisher
Packing machine
All Remote I/O Systems consist of at least one Remote I/O Master Unit connected in series to one or more Units accessed through it. One of these Units
that is common to most Remote I/O Systems is a Remote I/O Slave Unit.
3
Wired Remote I/O Systems Section 1-2
A Master is mounted to the CPU Rack or an Expansion I/O Rack; a Slave is
mounted to a Backplane to form what is called a Slave Rack. To a Slave
Rack is mounted the same other Units as those mounted to the CPU or Expansion I/O Rack, with only a few exceptions (e.g., Link Units other than
Slaves cannot be mounted to Slave Racks). The advantage of a Slave Rack
is that it can be located a considerable distance from the CPU Rack with the
only connection required being a cable running from the Master to the Slave.
The actual distance a Slave Rack can be removed from the Master, as well
as the other Units used to configure a Remote I/O System, depends on the
type of Remote I/O System being used. Collectively, all of the Units connected in a Remote I/O System are referred to as Remote I/O Units.
This manual describes Wired Remote I/O Systems. Optical Remote I/O Units
are described in the Optical Remote I/O System Manual (W136).
1-2 Wired Remote I/O Systems
In a Wired Remote I/O System, the Master is connected to other Remote I/O
Units through wire cable. These Remote I/O Units include Wired Masters,
Wired Slaves, and Remote Terminals. Link Adapters can also be included in
the System to enable the use of optical cable links.
A basic Wired Remote I/O System is shown below.
Remote Terminals
C2000H CPU Rack Slave Rack
Master
Wire cable
Slave
Slave Rack
Slave
Remote
Terminal
Remote
Terminal
A Remote Terminal can be used when there is only a limited number of I/O
points required in a single location. Each Remote Terminal provides up to 16
input or output points.
There are two basic types of Remote Terminal. A G72C Remote Terminal is a
‘stand-alone’ Unit that occupies one location in the Remote I/O System. It
provides 16 fixed transistor inputs or outputs and can be used for any application suited to these.
4
Wired Remote I/O Systems Section 1-2
The other basic type of Remote Terminal consists of two parts: a Remote
Interface and an I/O Block. The Remote Interface functions to transmit input
or output signals between the Remote I/O System and the I/O Block. I/O
Blocks enable easy removal and replacement of individual relays, including
relays with a large switching capacity, making them ideal for controlling
large motors, heavy equipment, etc. An I/O Block is available for either 16
input points or 16 output points.
Remote Interface Input Block
Replaceable
relays
Terminals
The types of field devices that can be handled is the only functional difference between G72C Remote Terminals and Remote Interfaces connected to
I/O Blocks. There is no difference that affects the software operation of the
Remote I/O System. In the remainder of this manual, the term Remote Terminal will be used to refer collectively to both types of Remote Terminals unless
there is a reason to specify one or the other.
Link Adapters
Converting Link Adapters can be used to create optical cable links within an
otherwise Wired System. The connections to Masters, Slaves, and Remote
Terminals are still wire cable; the optical connections are only between Link
Adapters. Refer to 2-4 Optical Connections in Wired Systems for details.
Branching Wired Remote I/O Systems through Branching Link Adapters is
not possible.
5
SECTION 2
System Design
Although there are many possible Remote I/O Systems that can be built out of Masters, Slaves and Remote Terminals,
each System is limited by the capacity of the PC and the nature of the other Units in the System. Section 2-1 describes
System configurations based on the C500-RM201 Master and C500-RT201 Slave (i.e., for C120, C500, C1000H, and
C2000H Systems), and outlines connection requirements, mounting restrictions, and System size limitations. Section 2-2
provides the same information for C200H Systems. Section 2-3 explains combining Masters and Slaves from different
Systems. Finally, Section 2-4 describes how to incorporate optical links into Wired Remote I/O Systems.
2-1 Basic System 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1-1 C120 Systems 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1-2 C500 Systems 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1-3 C1000H and C2000H Systems 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2 C200H Systems 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3 Combined Systems 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4 Optical Connections in Wired Systems 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5 Multilevel Systems 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
Basic System Section 2-1
2-1 Basic System
The following figure shows a basic System configuration illustrating some
aspects of Wired Remote I/O Systems designed with the C500-RM201 Master. Refer to following subsections for specific examples and limitations.
2-conductor cable
C500(F), C1000H(F),
C2000H, CV500, CV1000,
CV2000, CVM1 CPU Rack
Slave Racks
Wired Slaves
Wired Master
C500-RM201
C500-RT201
Unit Connection
Mounting Remote I/O Units
Remote Terminal
I/O Block
Remote Terminal
At least one Master is always necessary to connect Slaves and/or Remote
Terminals. Connect each Master and all the Remote I/O Units controlled
through it in series. All Units can be combined in any fashion and connected
in any order as long as they are in series and the Master is on one end of the
line. I/O Blocks are mounted to Remote Interfaces.
Masters can be mounted to any I/O slot on the CPU or Expansion I/O Rack in
all but C120 Systems. In C120 Systems, Masters must be mounted to the I/O
Interface Unit’s position (leftmost slot) on C500 Backplanes.
8
Basic System Section 2-1
Remote Terminals
Maximum Number of
Connectable Remote I/O
Units
Remote Interface and I/O Blocks are used in pairs, each of which provides
16 points. The I/O Block is easily connected to the Remote Terminal by way
of a connector. G72C Remote Terminals, on the other hand, do not require a
separate I/O Block. Remote Interface and I/O Blocks are paired as follows:
I/O I/O Block Remote Terminal
AC Input G7TC-IA16 100/110 VAC or
G7TC-IA16 200/220 VAC
DC Input G7TC-ID16 12 VDC
G7TC-ID16 24 VDC
Output G7TC-OC16 12 VDC
G7TC-OC16 24 VDC
G71-IC16 12 VDC or G71-IC16
24 VDC
G71-IC16 12 VDC
G71-IC16 24 VDC
G71-OD16 12 VDC
G71-OD16 24 VDC
The number of Units in any one System is limited by the capacity of the PC.
Detailed limitations are provided in the following table. These totals include
all Optical and Wired Master Subsystems controlled by the PC.
PC C120 C500, CV500,
CVM1-CPU01-EV2
Masters per PC 4 4 8
Slaves per Master 2 2 8 (see note)
Slaves per PC 8 8 16 (see note)
Remote Terminals
per Master
Words per Master 16 (256 points) 32 (512 points)
16 32 32
C1000H, C2000H,
CV1000, CV2000,
CVM1-CPU11-EV2
/CPU21-EV2
Example
Always set the address number of the Remote I/O Unit in order starting from
Note
#0. The CPU Unit will determine the number of Slaves connected according
to the address number of the Remote I/O Unit, as shown in the following
table, even if only one Slave is actually connected. Therefore, if the address
number is designated from the larger number, the actual total number of Remote I/O Units that can be connected to one PC will be limited.
Largest Unit
No. Set
0 or 1 2
2 or 3 4
4 or 5 6
6 or 7 8
Number of Slaves Connected
(as Determined by the CPU
Unit)
If three Slaves connected to separate Masters mounted to the same CPU
Rack were set as Unit number 4, the PC would assume, as shown above,
that each Master had six Slaves attached, for a total of 18, or two more than
allowed in the System. An error would thus be generated, even if the three
Slaves were actually the only Slaves in the System.
9
Basic System Section 2-1
Total I/O Points
The total number of I/O points in the System must not exceed the number of
I/O points provided by the PC to which the Master(s) is mounted or
connected.
PC Maximum Number of I/O Points
C2000H 2,048
C1000H 2,048*
C500 512
C120 256
*The total number of I/O points in a C1000H System can be up to 2,048, as
long the number of I/O points on the CPU Rack and Expansion I/O Racks
connected to the CPU Rack (i.e., not I/O points on Slave Racks) is limited to
1,024.
Total number of points for the PC
=
Total number of points on CPU Racks and
Expansion I/O Racks
+
Total number of points on Slave Racks
+
Total number of points on Remote Terminal
+
Total number of points in Optical Remote Subsystems
10
Basic System Section 2-1
2-1-1 C120 Systems
In C120 Systems, up to four Masters can be connected to the same PC, and
up to two Slaves and 16 Remote Terminals can be connected to any one
Master. Note that a Master in a C120 System must be mounted to an I/O slot
on a C500 Expansion I/O Rack.
C120 PCs provide 256 I/O points. This means that the total number of points
used in the System must be 256 or less. If, for example, 256 points are controlled by one Master connected to a C120 PC, there cannot be any more
Masters or I/O points employed for that C120 PC.
C120 CPU Rack
C500 Expansion
I/O Rack
C500 Master
C500-RM201
C500 Slaves
C500-RT201
Slave Racks
Remote Interface
G7TC I/O Block
Remote Terminal
11
Basic System Section 2-1
2-1-2 C500 Systems
In C500 Systems, up to four Masters can be connected to the same PC, and
up to two Slaves and 32 Remote Terminals can be connected to any one
Master.
C500 PCs provide 512 I/O points. This means that the total number of points
used in the System must be 512 or less. If, for example, 512 points are controlled by one Master connected to a C500 PC, no more Masters or I/O
points can be employed for that C500 PC.
C500 CPU Rack
Slave
Racks
C500 Slaves
C500 Master
C500-RM201
C500-RT201
Remote Interface
Remote Terminal
I/O Block
12
Basic System Section 2-1
2-1-3 C1000H and C2000H Systems
In C1000H and C2000H Systems up to eight Masters can be connected to
the same PC. In C1000H and C2000H Systems, up to eight Slaves and 32
Remote Terminals can be connected to any one Master.
When a Remote I/O System is included, C1000H and C2000H PCs provide
2,048 I/O points. This means that the total number of points used in the System must be 2,048 or less. If, for example, 2,048 points are controlled by four
Masters on C1000H and C2000H PCs, no more Masters or I/O points can be
employed on the PCs. (The number of I/O points for the I/O Units on a
C1000H CPU Rack and Expansion I/O Racks must be kept to within
1,024.)The number of points for any one Master, must be kept to 512 or less.
C1000H
or
C2000H
CPU
Rack
Slave Rack
C500 Master
C500-RM201
C500 Slaves
C500-RT201
Remote Interface
Remote Terminal
I/O Block
13
C200H Systems Section 2-2
2-2 C200H Systems
When constructing a Remote I/O System from C200H Masters and Slaves,
up to 2 Masters, 5 Slaves (regardless of the number of Masters), and 32 Remote Terminals can be included. Optical Masters and Slaves, if controlled by
the PC, must be included in these totals. Expansion I/O Racks can be connected to Slave Racks, however this limits the number of Slaves which the
PC can control i.e., each such Expansion I/O Rack must be counted as a
Slave Rack. The basic rules for Remote I/O Systems apply, e.g., each Master
Subsystem must be connected in series with a Master on one end and a terminator (either a Remote Terminal or Slave) on the other end.
Mounting Locations
Special I/O Units
Group A
High-Speed Counter Unit Multi-Point I/O Temperature Sensor
Position Control Unit
(C200H-NC111/112,
C200HW-NC113/213)
ASCII Unit
Analog I/O Units
4 total 8 total 6 total 2 total
Masters can be mounted to any slot on the C200H CPU Rack or Expansion
I/O Rack. Masters should not be mounted, however, to either of the rightmost
two slots of the CPU Rack, as this would prevent mounting devices directly to
the CPU Unit. I/O Blocks are mounted to the Remote Interface, just as in
Systems using C500-RM201 Masters (see 2-1 Basic System). Masters
cannot be mounted to Slave Racks or to Expansion I/O Racks connected to
Slave Racks
Note 1. The only Units that can be mounted to Remote I/O Slave Racks are Basic
I/O Units and Special I/O Units.
2. High-density I/O Units (Group 2) and B7A Interface Units (Group 2) cannot
be used on Remote I/O Slave Racks.
3. A Remote I/O Master Unit cannot be used if the CPU Unit is the
C200H-CPU02.
4. High-density I/O Units mounted on a Remote I/O Slave Rack can be used
only if the Remote I/O Master Unit is the C200H-RM201.
The numbers of Special I/O Units that can be mounted to any one Slave
Rack are shown in the following table. These figures assume that Units are
used only from one of the three groups.
Group B Group C Group D
Position Control Unit
Voice Unit
--- --- ---
(C200H-NC211, C200HWNC413)
Motion Control Unit (C200HMC221)
Transmission Time
14
If Units from more than one group are used, the following equations must be
met:
3A + B + 2C + 6D ≤ 12
A + B + C + D ≤ 8
The total number of Special I/O Units that can be used on all Racks com-
bined is 10. If PC Link Units are also used in the PC System, they must also
be included in the total.
Transmission time will be decreased with the same number of Slaves if two
Masters are used rather than one. Refer to Section 6 I/O Response Times.
C200H Systems Section 2-2
Example System 1: One Master
C200H PC
Example System 2: Two Masters
C200H Master
C200H PC
Slave Rack Slave Rack Slave Rack
C200H SlaveC200H Master
Slave RackSlave Rack
Slave Rack Slave Rack
Expansion
I/O Rack
C200H Master
Example System 3: Master
with Extra Expansion I/O
Racks
Slave Rack
Slave Rack
Remote Interface I/O Block
Slave Rack
Remote Terminal
A maximum of two C200H Expansion I/O Racks can be connected to a Slave
Rack. I/O Connecting Cable (2-conductor cable) is used to connect the extra
Expansion I/O Racks.
15
Combined Systems Section 2-3
Individual sections of cable must not be longer than 2 m. Each extra Expansion I/O Rack must be counted as a ‘Slave’ when computing the number of
Slaves controlled by the PC.
C200H Master
Slave Rack
I/O Connecting
Cable
2-3 Combined Systems
C500 and C200H Remote I/O Units can be combined into the same System.
That is, C500 Slaves can be connected to C200H Masters; C200H Slaves, to
C500 Masters.
Example 1: C500 Master
and C200H Slaves
C-Series
PC other
than the
C200H
The maximum number of connectable Units is the same as in any Remote
I/O System based on the C500-RM201 (see 2-1 Basic System). Word
assignments will be based on the C500 PC, i.e., based on the order and
positions of I/O Units mounted, and not on fixed slot words. Special I/O Units
cannot be mounted to C200H Slave Racks controlled by a C500 Master; all
mounted Units will be assigned only one word each. The “type of Master”
switch an all C200H Slaves controlled by C500 Masters must be turned ON
to designate a Master other than the C200H Master.
C200H
Slave Rack
C200H PC
Expansion I/O Rack
C200H
Slave Rack
I/O Connecting
Cable
Slave Rack
Expansion I/O Rack
Expansion I/O Rack
Remote Interface
16
C500 Master
G7TC I/O
Block
C200H Slave
Remote Terminal
Caution When C200H Slave Racks are connected to Masters on PCs other than the
!
C200H/C200HS, all Output Units on these Slave Racks will be treated as having
at least 16 output points. disabling the Fuse-burnout and Alarm Detection Bits on
Units that normally provide them (e.g., C200H-OD411, C200H-OD213,
C200H-OD214, and C200H-OA221).
When using the C200H Backplane for 10 slots as a remote I/O Slave for the
CVM1/CV500/CV1000/CV2000, only the 8 slots from the left can be used; the
9th and 10th slots from the left cannot be used.
Optical Connections in Wired Systems Section 2-4
Example 2: C200H Master
and C500 Slaves
When connecting C500 Slaves to C200H Masters, each C500 Slave must be
counted as 2 Slaves when figuring the total number of Slaves. This total,
which includes all optical and wired Slaves, must be no greater than 5 for any
one C200H PC. Here, Special I/O Units can be mounted to C500 Slave
Racks. Word assignments will be based on the C500 PC’s System, i.e.,
based on the order and positions of I/O Units mounted (starting at the left),
and not on fixed slot words.
C200H PC
C200 Master
C500 Slave Rack
C500 Slave
2-4 Optical Connections in Wired Systems
Two B500-AL007-P Link Adapters can be used to extend the transmission
distance and/or to prevent interference from noise by inserting an optical link
between two Remote I/O Units. The two Link Adapters convert between wire
and optical signals, transmitting over the optical link between them. The
AL007-P Link Adapter is thus always used in pairs, and always between
Wired Remote I/O Units. The entire Master Subsystem, from Master to terminator, must still be connected in series.
Up to 8 Link Adapters (4 pairs) can be used for each Master. To take full advantage of an optical link, shorten wire links as much as possible, even to the
point of placing the Link Adapter on the same control panels as the Remote
I/O Units.
Maximum cable length for any one section of optical cable is 20 m for
all-plastic optical fiber cable (APF); 200 m for plastic clad optical fiber cable
(PCF).
Refer to the Link Adapter manual for details on this and other uses of Link
Adapters.
C500 Slave Rack
C500 Slave
Link Adapter
B500-AL007-P
RS-485
cable
C500 CPU Rack
C500 Master
Link Adapter
B500-AL007-P
APF/PCF
optical
cable
C500 Slave Rack
C500 Slave
RS-485 cable
Remote
Interface
Terminator
I/O Block
17
Multilevel Systems Section 2-5
Handling Optical Fiber
Cable
1, 2, 3...
Although special characteristics of optical fibers call for care in connecting
optical devices, laying optical fiber cables basically does not differ from laying
wire cables. All OMRON PCF Cables and the 3G5A2-PF101 APF (length: 1
m) Cable come with connectors attached. Connectors for all other APF
Cables must be assembled by the customer. Note the following precautions
when handling optical fiber cables:
1. Always turn the power off to the Link Adapter when connecting or disconnecting an optical fiber cable.
2. Always hold the connect when disconnecting an optical fiber cable;
never pull on the cable.
3. APF and PCF connectors are designed to be inserted only in one direct;
do not try to force them in the wrong way.
4. Insert APF and PCF connectors until they lock into position.
5. Always place the protective caps on unused Link Adapter modules.
6. If dirty, clean connectors gently with a tissue or sanitary cotton, using
ethyl alcohol if necessary. Do not use any solvent other than ethyl alcohol.
7. Do not allow heavy objects to fall on optical cable or otherwise subject it
to excessive shock or strain.
2-5 Multilevel Systems
There is no reason that a Remote I/O System must remain restricted to either
wired or optical communications. PCs support multiple Masters, some of
which can be Wired and some of which can be Optical.
Although the number of Subsystems supported by each PC is limited, each
Subsystem can be considered independently from the others as long as the
total capacity of the PC is not exceeded. It is important to note that although
both Wired and Optical Masters can be controlled by the same CPU Unit,
Optical and Wired Remote I/O Units cannot be combined in the same Subsystem, i.e., Optical Masters can be connected only to Optical Slaves, Optical I/O Units, and I/O Link Units; Wired Masters can be connected only to
Wired Slaves and Remote Terminals.
In the following example, two CPU Racks are used. The one in the upper left
corner controls two Remote I/O Subsystems, one Wired and one Optical.
The Optical System contains an I/O Link to the other CPU Rack (at the right),
which has one Remote I/O Subsystem controlled by it.
The Optical I/O Units, Slave Rack, and Expansion I/O Rack beneath the CPU
Rack at the right are controlled through the Optical Master on this CPU Rack.
Note that if there was no Master on this Rack and the Optical I/O Units and
Slave Rack were connected through the I/O Link Unit, they would become
the last Units in the Optical Remote I/O Subsystem controlled by the CPU
Unit at the upper left, and be controlled by it.
18
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