Welcome Course Coordinator: Vishal Charan

OMRON

Course Notes

Advanced Industrial Automation

Contents of the training OMRON
Automation & Drives

Contents of the training:

• Introduction: PLC
Overview OMRON PLC range
CP1L

• Software
CX-programmer

• PLC-Basic Hands-On Training

…

• Building up an Project

• PLC-Advanced Hands-on Training Hardwiring using PLC

…

Advanced Industrial Automation

Introduction OMRON

• What is a Control System

• The role of the Programmable Controller
• Input and Output Devices
• What is a Programmable Controller
• Conventional Control Panel and it’s difficulties
• Disadvantages of conventional control Panel
• PLC panel and their advantage
• Conversion of Conventional Control Circuit to PLC
• A systematic Approach of control system Design
• Programmable Controller Application
• Consider A simple Project

Advanced Industrial Automation

Component subdivision OMRON
Industrial Components Automation & Drives Sensing & Safety
•Electromechanical relays •Program. Logic Controller •Photoelectric sensors
•Timers and counters •Network systems •Displacement sensors
•Programmable relays •HMI terminals •Vision systems
•Level controllers •Inverters •Safety sensors
•Limit switches •Servo systems •Safety switches
•Push buttons •Software •Safety relays
•Low voltage switch gear •Proximity sensors
•Temperature and process •Rotary encoders
controllers •Pressure sensors
•Solid-state relays
•Panel indicators
•Power supplies

Control System is a collection of electronic devices and equipment

which are in place to ensure the stability, accuracy and smooth
transition of a process or a manufacturing activity. It takes any
form and varies in scale of implementation, from a power plant to a
semiconductor machine.
Advanced Industrial Automation
The Role of Programmable Controllers OMRON
• In an automated system, the PLC is commonly regarded as the heart of the control system

• With a control application program (stored within the PLC memory) in execution, the PLC
constantly monitors the state of the system through the field input device’ feedback signal

• It will then based on the program logic to determine the course of action to be carried out at
the field output devices.

Advanced Industrial Automation

Input Interface OMRON
• Intelligence of an automated system is greatly depending on the ability of a PLC to read in the
signal from various types automatic sensing and manual input field devices

• The sensory input of the PLC.

• Signal is provided by sensors, switches, timer/counter or encoders

Encoder

Counters/
Timers

Sensors

Advanced Industrial Automation

Output Interface OMRON
• An automatic system is incomplete and the PLC system is virtually paralysed without means of
interface to field output devices.
• The output can be connected to heater, drives, valves, light indicators, solenoid, relay and etc

SMC, VSD Drives

Relays

Advanced Industrial Automation

Overview PLC range OMRON

34 100 120 140 256 512 1184 2560 5000 I/O

Advanced Industrial Automation

What is a Programmable Controller OMRON

Advanced Industrial Automation

Conventional Control Panel and Its Difficulties OMRON
• Beginning automated machines were controlled by electromechanical relays. Hardwired inside
the control panel. In some case the control panel was so huge that it could cover entire wall.
• Every connections in relay logic musted be connected. Wiring was not perfect, takes time to
troubleshoot the system

• Disadvantage:
• Too many wiring work in the panel

• Modification can be quite difficult

• Troubleshooting may require skilful person

• Machine downtime is usually long

• Drawing are not updated over the years due

to changes

Advanced Industrial Automation

Programmable Controller Control Panel and their Advantages OMRON
• Distinguishably realized
• 80% of wiring reduced
• Power Consumption is reduced
• PLC self diagnostic functions easy fast troubleshooting of the system
• Modification of the control sequence
• Operation Indicators

Advanced Industrial Automation

Conversion of Conventional Control Circuit to PLC OMRON
• Starting and stopping of a 3-phase motor

R
W Power Circuit
B

Control
Circuit

Advanced Industrial Automation

Conversion of Conventional Control Circuit to PLC OMRON

Advanced Industrial Automation

Conversion of Conventional Control Circuit to PLC OMRON
• Ladder Logic

Advanced Industrial Automation

Example: Conventional Circuit for Sorting Machine OMRON

Advanced Industrial Automation

PLC Connected System OMRON

Advanced Industrial Automation

PLC Program OMRON
• Ladder Logic

Advanced Industrial Automation

CX-programmer V9.2 OMRON

CX-Programmer V9.2

• Designed to operate with MS Windows XP as well as MS Windows 95, 98,

ME, NT and 2000.
Recommended: MS Windows NT, 2000 or XP
• New PLC ranges supported:
- CP1L
- CS1H

Advanced Industrial Automation

Creating Projects OMRON
Small selection:
Programs
Omron
CX-ONE Programmer
File
New

Module

Communication

Advanced Industrial Automation

PLC - Basic Hands-on training OMRON

Advanced Industrial Automation

Starting a new project in CX-Programmer OMRON

Advanced Industrial Automation

Opening a new Program OMRON

Advanced Industrial Automation

Up- and downloading of PLC programs OMRON

Advanced Industrial Automation

Statement List OMRON

000.00 000.01 000.01 100.00

000.02
LD 000.00
AND 000.01
OR 000.02
AND 000.03
OUT 100.00

000.00 000.01 000.03 100.00

000.02

Advanced Industrial Automation

Statement List OMRON

000.04 000.05 100.01

000.06 000.07

000.04 000.05 100.01

LD 000.04
000.06 000.07 OR 000.06
LD 000.05
OR 000.07
000.05 AND LD
OUT 100.01

000.07

Advanced Industrial Automation

Statement List OMRON

000.00 000.01 000.02 000.03 100.02

000.04 000.05 100.03

Advanced Industrial Automation

Statement List OMRON

000.00 000.01 000.02 000.03 100.02

*

000.04 000.05 100.03

TEMPORAIRY RELAY
LD 000.00
AND 000.01
OUT TR 0
AND 000.02
AND 000.03
OUT 100.02
LD TR 0
AND 000.04
AND 000.05
OUT 100.03

Advanced Industrial Automation

 OMRON

TRY...

Advanced Industrial Automation

Program Writing – Seven steps OMRON

1. Define the purpose

2. Problem Splitting

3. Working out

4. Design

5. Writing

6. Testing

7. Finishing

Advanced Industrial Automation

Program Writing – Define the Purpose OMRON
1.
Draw the wiring diagram of the PLC connected to a start, stop button as inputs and the motor
on the output side. Use relays, indicator lamps and contactor (1Φ, 3 Φ). Identify the control
circuit and powering circuit. (10) Implement the forward reverse control.
(Hint use interlock circuit)
Materials
1 10amps CB
2 Start
2 Stop
2 contactors
3 battern holders with lamp
CP1L PLC
Communication cable usb
Relays.

Advanced Industrial Automation

 OMRON

Thanks For Listening

Advanced Industrial Automation