OMRON C200HX/HG/HE PLC Troubleshooting

Check and reset the unit numbers for TOO MANY UNITS E1 special I/O unit numbers that are duplicated, 64 point high-density I/O unit numbers that are out of range, and more than 2 interrupt input units.

INPUT-OUTPUT I/O TABLE ERROR E0: The registered I/O table does not match the actual unit. Perform I/O table generation operation (MI command or programmer operation).

FALS ERROR 01-99/9F 01-99/9F program execution FALS (07) or watchdog timeout. Check the program logic based on the FAL number. If it is 9F, check the cycle time.

Fatal error clearing: The physical cause needs to be eliminated first, and then the error must be cleared through the programmer (error clearing operation is performed in Program mode). Some errors require a power outage and restart.

I/O table registration and verification

C200HX/HG/HE supports automatic identification of installed units through I/O tables, but if the unit model or rack configuration changes, it will generate "I/O VER ERR" or "I/O SET ERROR". The correct operation steps are as follows:

Register I/O table (Program mode, DIP switch 1 is OFF):

Press CLR → FUN → CHG → 97 → 1 → 3 → WHITE → VER.

Verify I/O table: Use FUN → MONTR and select "I/O TABLE VERITY" to compare the registry with the actual installation.

Clear I/O table: If reconfiguration is required, execute FUN → CHG → 97 → 1 → 3 → WHITE → CLR (caution will be exercised as all I/O assignments will be cleared).

Read the I/O table: Press FUN → MONTR → EXT to browse the display of each rack, unit model, and point count.

In special circumstances, if the installed unit uses C500 remote I/O slave rack, its I/O word allocation will occupy two unit numbers. It should be noted that the unit number cannot be set to 4 (because there is no 5).

Memory card operations for programs and data

C200HX/HG/HE supports EEPROM (C200HW-ME series) and EPROM (C200HS-MP16K) memory cards, which can be used for automatic program loading, fixed DM, and PC setup, achieving battery free operation.

4.1 Writing UM data to EEPROM memory card (program, fixed DM, extended DM, I/O comments, etc.)

Ensure that DIP switch pin 1 is OFF (allowing UM writing) and memory card switch 1 is OFF (allowing writing).

Switch the PC to Program mode.

Set SR27000 (Save UM to Cassette Bit) from the programmer or SSS, and the bit will automatically reset after data transfer is completed.

To write protection, turn on memory card switch 1.

4.2 Automatically loading UM data from memory card

Set pin 2 of the CPU unit DIP switch to ON.

Insert the memory card and automatically transfer data after power on. If it fails, a memory error will occur.

4.3 Storage and loading of IOM data (IR/SR/LR/HR/AR/DM/EM/timer counter PV)

Use SR27300 (Save IOM) and SR27301 (Load IOM). Note that the memory card capacity must match the EM configuration of the CPU: a 16K memory card can only store EM bank 0; A 32K memory card can store bank 0-2.

SR27308-27315 indicates the stored EM bank information.

4.4 Battery free operation settings

When using EEPROM/EPROM memory cards and accepting DM data loss, battery free operation can be achieved. Must meet:

Program written to memory card, DIP switch pin 1=OFF, pin 2=ON.

Do not use internal clock (battery required).

Low battery detection is prohibited in PC Setup (bit12-15=1 for DM6655).

Use the Always OFF Flag (SR25314) in the program to ensure that the output OFF position (SR25215) remains OFF.

The forced state hold bit (SR25211) and I/O state hold bit (SR25212) are set to reset at startup in PC Setup (DM6601=# 0000).

Migration program from C200H/C200HS to C200HX/HG/HE

The programs for C200H and C200HS can be directly used for C200HX/HG/HE, but the following differences should be noted:

Loop time difference: The basic instruction execution speed of C200HX/HG/HE is faster (LD instruction: C200HX is 0.104 μ s, C200HS is 0.375 μ s). Program segments that rely on timing may require adjusting latency or adding null operations.

DM area address change:

The error history of C200H is located at DM0969-DM0999, while C200HX/HG/HE is located at DM6000-DM6030. If a program accesses these addresses, it must be modified.

Some of the settings and functions of the fixed DM area (DM6144-DM6655) are different from those of C200H and need to be reconfigured according to the manual.

SET SYSTEM instruction (SYS (49)): If this instruction is present in the C200H program, it will be written to the new PC Setup (DM6600, DM6601, DM6655) after migration, which may overwrite the existing model parameters. It should be confirmed before use.

Extended instructions: Some instructions (such as BXF2, IEMS, IORD, IOWR, PMCR, STUP, XFR2, etc.) are only supported by C200HX/HG/HE and cannot be executed on C200HS after migration.

I/O table migration: C200H programs usually do not include I/O tables, which can be used after re registering the I/O tables on C200HX/HG/HE.

Migration steps (using SSS):

Set SSS to C200H model and read the source program, DM data, and I/O table (if any) into the workspace.

Offline change the SSS model to C200HX/HG/HE.

If I/O comments need to be retained, allocate UM area.

Connect the target CPU online (ensure pin 1 is OFF), download programs and data.