Advance PLC Introduction

MECHATRONICS SERVICING NCIV
Advance PLC
Introduction
The new platform in PLC control
Philip Marvin D. Joven, P.E.E.

MTC Director/ICC VP-ENG’G
MECHATRONICS
A synergistic combination of Mechanical,
Electrical, Electronics, Computing and Control
Engineering and Technology.
The new “term or name” used, in place of

INDUSTRIAL AUTOMATION
MECHATRONICS
This inter-disciplinary combination of fields
aims to provide solutions to and approach to
design and development, prototyping and
implementation, and maintenance of
Machines and Processes.
MECHATRONICS
MECHATRONICS
MECHA TRONICS AUTOMATA
MECHANICAL ELECTRONICS
AUTOMATION
ENGINEERING ENGINEERING
• Machine • Control System • Self-Operating
Components • Circuit Design System (less/no
• Mechanical Design • Programming human
• Electropneumatics intervention)
• Networking
• Electro-Hydraulics • Artificial
• Digital Signal
Intelligence
• Thermodynamics Processing
(Programmable
• Robotics Controllers)
MECHATRONICS TRAINING REGULATION

Core Competencies Training Workshops Required Job Qualifications/Positions
(Practical Skills to be Assessed) (Underpinning Skills & Knowledge) Qualified
MECHATRONICS SERVICING NCII
- Install mechatronics devices - Electro pneumatics / hydraulics - Electro-pneumatic technician
- Configure and test mechatronics devices - Sensors - Electromechanical technician
- Basic PLC
- PLC installer and technician
- Industrial motor
MECHATRONICS SERVICING NCIII

- Develop mechatronics control circuits and - Intermediate PLC programming - PLC programmer
software application programs - Motion control : - PLC repair/maintenance
VFD and servo motors
- Develop Motion Control Systems technician
- Maintain and repair mechatronics devices - VFD technician
- commission mechatronics system - Advanced PLC programming - Senior automation technician
- diagnose & troubleshoot mechatronics - Human machine interface (HMI) - HMI /SCADA technician
- SCADA
system - Senior PLC/HMI /SCADA
programmer
- Industrial Automation and
Mechatronics Engineer
Mechatronics and Automation

CERTIFICATION EXAMINATION
FOR
CERTIFIED M&A ENGINEER
CERTIFIED M&A SPECIALIST
CERTIFIED M&A MASTER TECH
Chairman: ENGR. JOEL BAJADOR, PECE

Members: ENGR. PHILIP MARVIN JOVEN, PEE
ENGR. JAMES BERNARD ITAO, ME
CONTROL SYSTEMS
Control systems are a set or combination of components that
act together to maintain actual system performance close to a
desired set of performance specifications
INPUT CONTROL/LOGIC
OUTPUT DEVICES
DEVICES DEVICES
Devices and equipments

Any device or equipment
that when combined to
that is used to provide Devices that can be
a proper configuration,
data or control signals controlled to create a
can create logic to
into particular specified output.
perform a specific
processing system.
function.
CONTROL SYSTEMS
Basic Control System
Open Loop System
INPUT LOGIC OUTPUT
-Pushbuttons -Relays -Motors

-Limit Switches -Timers -Solenoid
-Level Switches -Counters valves
-Photoelectric -Lamps
sensor
-Proximity Programmable Logic Controller
Sensors (PLC)
CONTROL SYSTEMS
Basic Control System
Examples:
1. Motor Control – Conveyor, Fans, Mixer
2. Electro-pneumatics Control – Stamping, Indexing, Pick and Place
3. Manufacturing Machines – Filling, Packaging, Palletizing M/Cs

CONTROL SYSTEMS
Feedback Control System
Closed Loop System
Final Control Process

Error Controller
Element Variable
+ Temperature
Set value Flow
_ Pressure
Level
Process
Process Sensor
Variable Primary
Element / Transducer
CONTROL SYSTEMS
Feedback Control System- Process Control
Closed Loop System
4-20mA OUTPUT
A A
I O
Pneumnatic
Control Valve
Temperature
4-20mA 3-15psi
Pressure
4-20mA
I/P
Transducer
Level
Flow
NEW PLC Design Goals
Compact Modular
Size Programming
Powerful Fast
Networking Processing
CF Card Powerful
Support Instruction
Set
Large I/O
Capacity Many Panoply of
Special I/O Software
CJ1 Hardware
I/O-Bits Program Data Memory LD Instr.

Model
Capacity Capacity Execution
CJ1G-CPU66H 2560 120 Ksteps

256 K 0,02 µs
(3 exp. Racks) Words (7)
128 K
CJ1G-CPU65H 2560 60 Ksteps 0,02 µs
(3 exp. Racks) Words (3)
128 K
CJ1G-CPU45H 1280 60 Ksteps
Words (3)
0,04 µs
(3 exp. Racks)
1280 64 K
CJ1G-CPU44H (3 exp. Racks) 30 Ksteps Words (1) 0,04 µs
960 64 K 0,04 µs
CJ1G-CPU43H (2 exp. Racks) 20 Ksteps
Words (1)
960 64 K
CJ1G-CPU42H (2 exp. Racks) 10 Ksteps 0,04 µs
Words (1)
Small
C200H Alpha Volume
90 mm High
37 % Installation Volume
64 % Installation Area
65 mm Mountable in line with other components in
Depth narrow spaces between ducts
Reduces Installation area and Volume
Lower foot print Allows thinner Control Panels
Lower volume No backplane so flexible width design
Lower depth
CJ1 versus CS1 and C200H
Maximum Number of I/O bits

CJ1-H 2560
CS1 5120
Alpha 1184
User Memory Capacity

CJ1-H 120 K steps
CS1 250
Alpha 64
Data Memory Capacity
CJ1-H 256 K words

CS1 448
Alpha 102 K words

Execution Time (Basic Instruction)
CJ1-H 0,02 µs
CS1-H 0,02 µs
0,104µs
Alpha
Overhead Time
CJ1-H 0,2 - 0,5 µs

CS1 0,2 - 0,5 µs
0,7 ms
Alpha
Execution Time (Special Instructions)
CJ1-H 0,18 - 0,25 µs

CS1 0,18 - 0,25 µs
0,417 µs
Alpha
Number of Instructions
CJ1-H 400
CS1 400
Alpha 286
Maximum Number of Connectable Units
CJ1-H 40 slots
CS1 129 slots(*)
Alpha 89 slots(*)
Maximum Number of Special I/O Units
CJ1-H 40
CS1 80
Alpha 16
Execution time 30 Ksteps
CJ1-H 1,23 ms
Alpha 33,7 ms
Modular Programming using Tasks
Scheduled Task
- A program can be divided into

Task 0
easy to manage modules (TASKS)
- Multiple programmers can each focus
on their specific jobs
Interrupt Task - Tasks can be switched ON/OFF from
or CPU Bus unit within other tasks
- Task Code first run flags
Task 1
- Tasks can be arranged according :
- Processes
- Machine functions
- Programmers
Your benefits -…..
- Easy Program maintenance

Task N - Easy and fast debugging
- Allows code reuse and
standard programming
- Inter-platform code exchange
Flash Memory + Battery Free
Flash RAM
Memory Write - User Program
- Parameter
Area
Read - Change in RAM-contents triggers a write-through

to FLASH memory
- PLC keeps working even in case of a Battery
CJ1-H
error
- The PLC code and parameters are automatically
transferred to the built-in RAM at startup
History of Machine File Applications

operations
Auto startup via Program Loading during

AUTOEXEC.* files RUN-time
Logging of Trend Data Backing up vital information

Quality data and Error Info (Simple Backup function)
Memory cards for different Easy file exchange via

types of applications FTP commands
EM-Memory banks can be

used for high speed file I/O
Up to 48 Mbytes - Easy exchange of data between the PC end
the PLC.
- Import / export feature of data within MS-Excel
- All relevant data available at PLC-side
PC-Card Adapter - Fast reconfiguration
Memory
- History of the process
card
- Accessible through the network
DOS formatted - Serves as FTP-server on Ethernet
FTP-Client Mass Memory
Powerful Scaling functions
150 Liters
Capacity
Analog Signed/Unsigned Binary
or floating point data PT-Terminal
Input
Level (mm)
(AD-Sensor)
- The conversion curve can be approached by
linear extrapolation
Arithmetic - Up to 256 line segments
Process (APR) - Several data formats (X/Y axis)
Level - 16 bits unsigned BCD
- 16/32 bits signed Binary
- Single precision floating point
- No dedicated tank farm controller required
PID Auto Tuning
Interrupting PID Control to
PID Control ON
Perform Auto Tuning
PID Control Auto Tuning PID Control
- Auto tuning possible at

AT - Startup
- During PID Control
PV - AT can be stopped
Present Value - No manual tedious calculation
necessary
SP
- Fast retuning of process
Set point
parameters
Time
MV
Manipulated Variable
Time
PID Auto Tuning
Parameters that can be set by the user
- SP (Set point) , P , I , D , sampling period and I/O resolution
- Output of PID-function when the manipulated variable equals the Set Value
- PID forward or Reverse
- Upper and lower limits for the manipulated variable
- Auto Tuning calculation Gain
- Limit cycle hysteresis

CJ1 Hardware Configuration Basic I/O
Special I/O
CJ1-Power Comm-Bus I/O(*) End-Cover
Supply CJ1-I/O Interrupt units(*)
CJ1-CPU
Control Unit
Memory Card Max 12 m Max 10 Units

Basic I/O
CJ1-Power I/O Connecting Cable Special I/O
Supply CPU-Bus I/O
End-Cover
CJ1-I/O
WARNING Interface Unit Max 10 Units
(*) Place CPU-Bus Units and I/O-Interrupt units
next to CPU (5 left slots)
IC101 CJ1 Hardware
CS1W-CN313 (0,3m)
II101 CS1W-CN713 (0,7m)
CS1W-CN223 (2 m)
CS1W-CN323 (3 m)
CS1W-CN523 (5 m)
CS1W-CN133 (10 m)
CS1W-CN133B2 (12 m)
Max. 3 racks II101 10 Units max.
Max. 12 m
II101 10 Units max.

CJ1 Hardware
CJ1W-IC101
Up to 3 expansion racks.
I/O connecting cables
0,3 up to 12 meters I/O-Control unit has to be
of CS1 connected left to the CPU.
The end-cover comes with the
CPU and with the I/O-interface
unit.
CJ1W-II101
All types of units can be used
at CPU and/or expansion racks
( Interrupts and CPU-Bus units have
WARNING
to use the 5 slots left to the CPU)
The I/O-Interface unit has an

input and an output connector
CJ1 Hardware
3 groups of CJ1-Units
Basic I/O Units Special I/O Units CPU Bus Units
CIO 0000 to CIO 0079 CIO 2000 to CIO 2959 CIO 1500 to CIO 1899
(8 , 16 , 32 or 64 points) (Refresh area :10 words/unit) (Refresh area : 25 words/unit)
D20000 to D29599 D30000 to D31599

Special I/O unit number (Setup area : 100 words/unit) (Setup area : 100 words/unit)
(40 Units maximum)
CPU Bus unit number
(16 Units maximum)
MECHATRONICS SERVICING NCIV Special I/O
Analog Input Units CJ1W-AD081-V1/AD041-V1
4 or 8 channels per unit

Resolution of 1/8000
Wire burnout detection on 4-20 mA (1-5 V)
Peak hold-function
Mean or averaging function
Up to 40 units per PLC
Analog Output Units CJ1W-DA041/DA021

2(DA021) or 4(DA041) channels
1/4000 resolution
Output hold function
Offset and Gain adjustment
Supported signal ranges : 1-5 V / 0 - 10 V
0 - 5V / -10 to + 10V and 4 to 20 mA
Analog Process Application
4-20mA OUTPUT
A A
I O
Pneumnatic
Control Valve
4-20mA 3-15psi 4-20mA

I/P
Transducer
Temperature Control Units CJ1W-TC***

Supports 2-loop or 4-loop PID or
ON/OFF control
Heater burnout detection function on two
loop models
Auto-tuning support
Direct input from thermocouple
(J,K,S,T,B or L) and PT100 sensors
Open collector output NPN or PNP
Sampling period of 500 ms
RUN/Stop control for manual tuning
Easy wiring to a removable terminal block
High-Speed Counter Unit CJ1W-CT021

2 channels per unit
Counts pulses up to 500 Khz with 32bit counting range
Support for 5,12 and 24 VDC (RS422) line driver
encoders
Supports simple counter , ring and linear counting
modes with 2 physical outputs (NPN,PNP selectable)
2 control inputs and 30 internal outputs
Up to 16 functions can be set :
Open gate,close gate,preset,reset,capture …..
Up to 40 units per master
3 Counting modes :
- Phase differential (x1,x2,x4) phase A,B and Z
- Up/Down pulse inputs
- Pulse and direction Inputs
High-Speed Counter Application

Position Control Units CJ1W-NC113/213/413/133/233/433
Support Open-loop control with pulse-train outputs

Position with automatic trapezoid or S-curve
acceleration and deceleration
Models available with 1,2 or 4 axes
Positioning data is saved in internal flash memory

eliminating the need to maintain a backup battery
Configuration through a Windows based Support
Software (CX-Position)
Position Control Application
Remote
Controlled
Weapon
System
MECHATRONICS SERVICING NCIV Communication/Bus
Serial Communication Unit CJ1W-SCU41

One RS-232C and one RS-422/485 port
Up to 16 serial communication units per PLC
The SCU supports a variety of protocols :
- Host Link (C - or FINS message) with PLC
initiative
- 1:N NT-Link protocol
- Protocol Macro for easy communications with
OMRON’s wide range of components
- Interfacing with Non-OMRON devices
Easy port-diagnostics through the loopback test
Dynamic port reconfiguration using the STUP(237)
function
Support for remote programming through the telephone
or GSM-network.
Transparent networking up to 3 network Levels
Serial Communication Application
Compobus/S Master CJ1W-SRM21 (Remote I/O Link)

Up to 128 or 256 I/O’s per master
Up to 32 slaves per master
Compatible with SRT1 and SRT2 slave
(Long distance and high speed models)
Support for Analog I/O-terminals
Segment length up to 500 m for long distance
- Requires no special configuration (fast startup)

- Easy diagnostics
- Fail safe in case break in wiring
- High refresh rate
Remote I/O Link using Siemens Profibus

Siemens ET200S
DeviceNet Unit CJ1W-DRM21

Control of up to 32000 points (2000 words/master)
3 masters/CPU without the need for a configurator
Free I/O-window allocation when using a configurator

The unit can serve as master or slave or both
Up to 16 units per CPU
The network can serve as a gateway exactly like

Controller Link and Ethernet
Support for cyclic and acyclic data transfer
DeviceNet parameters can be saved onto

the Memory card
Configuration of the master can be done through
the integrated serial port
ETHERNET
NETWORK SW
DEVICENET
Intuitive configuration Software WS02-CFDC1-E

Controller Link Unit CJ1W-CLK21

Automatic and manual data Link (Virtual shared
Memory) Up to 12000 words/node
Easy configuration tool for data link tables
Transparent internetworking (gateway or bridge)

(Up to 4 units per master)
Message service (SEND,RECV and CMND) for data
transfer throughout a layered network infrastructure
Extensive network management functions
Direct interfacing with PC’s using OMRON’s

CX-Server Concept
100% uptime through polling node backup
Ethernet Unit CJ1W-ETN11 (10Base-T)

Transparent internetworking (gateway or bridge)
(Up to 4 units per master)
Easy data exchange through OMRON’s CX-Server
Concept from MS-Excel and Visual Basic (ActiveX)
Easy IP-configuration of the unit via CX-Programmer
Exchange of files through the FTP-service using

the memory card on Ethernet networks
Inter PLC communication using easy to configure
SEND and RECEIVE instructions.
Interfacing with a variety of computer systems through
the Socket Services.
Capable of sending e-mail messages in case of
errors
omron
Network Topology
SIEMENS NETWORKING TOPOLOGY
Summary
The new platform in PLC control

NEW PLC Design Goals

Summary
Compact Modular
Size/Modular Programming
Powerful Fast
Networking Processing
CF Card Powerful
Support Instruction
Set
Large I/O
Capacity Many Panoply of
Special I/O Software
CJ1 Hardware Configuration Basic I/O
Special I/O
Summary
CJ1-Power Comm-Bus I/O(*) End-Cover
Supply CJ1-I/O Interrupt units(*)
CJ1-CPU
Control Unit
Memory Card Max 12 m Max 10 Units

Basic I/O
CJ1-Power I/O Connecting Cable Special I/O
Supply CPU-Bus I/O
End-Cover
CJ1-I/O
WARNING Interface Unit Max 10 Units
(*) Place CPU-Bus Units and I/O-Interrupt units
next to CPU (5 left slots)
THANK YOU & GOD BLESS!!!

OMRON PLC I/O ADDRESSING & MEMORY

PLC ADDRESS FORMAT
XXXXX.XX
Word/Channel Bit
Type No.
1 WORD = 1 CHANNEL = 16 BITS
Word (0-32767) BIT (00 - 15)
EXAMPLE: Bit Addressing Word Addressing
CIO100.00 or 100.00 CIO11 or 11
HR 2.00 D100
W0.00 W200

PLC MEMORY TYPE 1 WORD = 1 CHANNEL = 16 BITS
Word (0-32767) BIT (00 - 15)
CIO – Configuration I/O – The address used for our physical
input and output devices
- The address type used for internal relays
CIO 0.00 or 0.00 For Digital Input Device such as switches and PB
100.00 – for digital output device such as lamp or sol. Valve
10.07 – for internal relay (for sequencing)
Practically, any CIO Channel, not used as Physical I/O Channel,

Can be used as Internal Relays Address

Word (0-32767) BIT (00 - 15)
CIO – Configuration I/O – The address used for our physical
input and output devices
Input CH0 (0.00 – 0.11) 12 DI

CH0 CH1 Input CH1 (1.00 – 1.05) 6 DI
18 DI and 12 DO = 30 I/O PLC
Model: CP1E-E30DR-A
CH100 CH101
Output CH100 (100.00 – 100.07) 8 DO
Output CH101 (101.00 – 101.03) 4 DO

Word (0-32767) BIT (00 - 15)
OTHER MEMORY TYPE
W – Work Bit – W0.00 – W511.15
H – Holding Relay – H0.00 – H511.15 (Retentive)
T – Timer – T0 – T511
C – Counter – C0 – C511 (Retentive)
D – Data Memory – D0 – D32767 (Retentive)
A – Auxiliary Relay – A0 – A255 (Special Function)

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MECHATRONICS SERVICING NCIV

Philip Marvin D. Joven, P.E.E.

The new “term or name” used, in place of

MECHATRONICS TRAINING REGULATION

MECHATRONICS SERVICING NCIII

Mechatronics and Automation

Chairman: ENGR. JOEL BAJADOR, PECE

Devices and equipments

INPUT LOGIC OUTPUT

-Pushbuttons -Relays -Motors

1. Motor Control – Conveyor, Fans, Mixer

2. Electro-pneumatics Control – Stamping, Indexing, Pick and Place

3. Manufacturing Machines – Filling, Packaging, Palletizing M/Cs

Final Control Process

I/O-Bits Program Data Memory LD Instr.

CJ1G-CPU66H 2560 120 Ksteps

Reduces Installation area and Volume

Lower foot print Allows thinner Control Panels

Lower volume No backplane so flexible width design

Maximum Number of I/O bits

User Memory Capacity

Data Memory Capacity

CJ1-H 256 K words

CJ1 versus CS1 and C200H

CJ1-H 0,2 - 0,5 µs

Execution Time (Special Instructions)

CJ1-H 0,18 - 0,25 µs

CJ1 versus CS1 and C200H

CJ1 versus CS1 and C200H

Execution time 30 Ksteps

- A program can be divided into

- Easy Program maintenance

Flash Memory + Battery Free

Read - Change in RAM-contents triggers a write-through

History of Machine File Applications

Auto startup via Program Loading during

Logging of Trend Data Backing up vital information

Memory cards for different Easy file exchange via

EM-Memory banks can be

PID Control Auto Tuning PID Control

- Auto tuning possible at

PID Auto Tuning

Parameters that can be set by the user

- SP (Set point) , P , I , D , sampling period and I/O resolution

- PID forward or Reverse

- Upper and lower limits for the manipulated variable

- Auto Tuning calculation Gain

- Limit cycle hysteresis

Memory Card Max 12 m Max 10 Units

IC101 CJ1 Hardware

II101 10 Units max.

The I/O-Interface unit has an

D20000 to D29599 D30000 to D31599

Analog Input Units CJ1W-AD081-V1/AD041-V1

4 or 8 channels per unit

Analog Output Units CJ1W-DA041/DA021

Analog Process Application

4-20mA 3-15psi 4-20mA

Temperature Control Units CJ1W-TC***

High-Speed Counter Unit CJ1W-CT021

High-Speed Counter Application

Position Control Units CJ1W-NC113/213/413/133/233/433

Support Open-loop control with pulse-train outputs

Positioning data is saved in internal flash memory