What can a PLC do? Why do we use them?

The meaning of PLC…

“PLC” means “Programmable Logic Controller”, that’s clear. The word “Programmable” differentiates it from the conventional hard-wired relay logic. It can be easily programmed or changed as per the application’s requirement. The PLC also surpassed the hazard of changing the wiring.

The PLC as a unit consists of a processor to execute the control action on the field data provided by input and output modules. In a programming device, the PLC control logic is first developed and then transferred to the PLC.

So, what can a PLC actually do?

1. It can perform relay-switching tasks.
2. It can conduct counting, calculation and comparison of analog process values.
3. It offers flexibility to modify the control logic, whenever required, in the shortest time.
4. It responds to the changes in process parameters within fractions of seconds.
5. It improves the overall control system reliability.
6. It is cost effective for controlling complex systems.
7. It trouble-shoots more simply and more quickly
8. It can be worked with the help of the HMI (Human-Machine Interface) computer

There are many other things this little ‘mean’ thing can do, but one thing I’m sure – that PLCs are irreplaceable in many industry applications and control projects.

Here is an example of wired ABB’s AC500 programmable logic controllers.

Figure 1 – Wired ABB’s PLCs (photo credit: us.profinet.com)

Basic block diagram

Figure 1 shows the basic block diagram of a common PLC system.

Figure 2 – Block diagram of a PLC

As shown in the above figure, the heart of the “PLC” in the center, i.e., the Processor or CPU (Central Processing Unit).

• The CPU regulates the PLC program, data storage, and data exchange with I//O modules.
• Input and output modules are the media for data exchange between field devices and CPU. It tells CPU the exact status of field devices and also acts as a tool to control them.
• A programming device is a computer loaded with programming software, which allows a user to create, transfer and make changes in the PLC software.
• Memory provides the storage media for the PLC program as well as for different data.

Size of the PLC system

Usually they are classified on the basis of their size:

• A small system is one with less than 500 analog and digital I/Os.
• A medium system has I/Os ranging from 500 to 5,000.
• A system with over 5,000 I/Os are considered large.

Components of the PLC system

CPU or processor: The main processor (Central Processing Unit or CPU) is a microprocessor-based system that executes the control program after reading the status of field inputs and then sends commands to field outputs.

I/O section: I/O modules act as “Real Data Interface” between field and CPU. The PLC knows the real status of field devices, and controls the field devices by means of the relevant I/O cards.

Programming device: A CPU card can be connected with a programming device through a communication link via a programming port on the CPU.

Operating station: An operating station is commonly used to provide an “Operating Window” to the process. It is usually a separate device (generally a PC), loaded with HMI (Human Machine Software).

PLC Configurations

There are two basic configurations that commercial manufacturers offer:

1. Fixed Configuration

Fixed PLC configuration

2. Modular Configuration

Modular type PLC ‘SLC 500’ (photo credit: ab.rockwellautomation.com)

PLC Applications (VIDEOs) //

Real world applications

An Application for Industrial Process Control

PLC Bottling Application

PLC application color mixing

PLC Suited To Bottling Line Application

5 guides to study PLCs //

1. PLC – Programmable Logic Controller – Hugh Jack
2. PLC Programming – OMRON
3. PLC – Theory and Implementation – L.A. Bryan; E.A. Bryan
4. Industrial Training – SCADA System and PLC – Mr. Sonu Kumar Yadav

References //

• Industrial Automation Pocket Book – IDC Technologies
• Overview of Programmable Overview of Programmable Logic Controllers – Dr. Fernando Rios-Gutierrez

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Download Center Untuk OMRON PLC

Bingung bagaimana cara mendapatkan Manual Book atau Datasheet untuk perangkat otomatisasi dari Omron?

Caranya sangat mudah, silahkan anda menuju alamat berikut ini:
http://industrial.omron.eu/en/services_and_support/download_centre/default.html 

Setelah itu akan muncul halaman website seperti ini:

Kemudian di halaman tersebut klik "Click here to go to the download centre",  maka satu popup windows akan muncul seperti ini.

Kemudian anda masukan kata kunci di kolom Search... dan pilih Document type yang anda inginkan seperti terlihat gambar diatas. Contohnya: saya masukan kata kunci "PLC" maka secara otomatis semua file PDF tentang PLC akan muncul.... tampilannya seperti ini:

Kemudian setelah muncul seperti gambar diatas, pilih file PDF sesuai dengan bahasa yang anda inginkan. EN (English), DE (German), ES (Spanyol), FR (France, IT (Italy).

Selamat mencoba.. semoga bermanfaat.

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Omron C200-CPM1- CQM1-CQM1H password recovery

Image via Wikipedia

I got this information from forum. Please read for detail. Sometime We need this method to get solution.

Hi, I test a method for find password from CQM1H-CPU21(51-61) and share with all.
it's very easy: you must install (Plc Backup Tools V6.0) then select UM option and upload from PLC, after this, you open UM file with any HEX Editor program. Now you can see password in 0590h memory address.This metod tested for C200-CPM1- CQM1-CQM1H.

For Download:
1. PLC Backup Tools V6.0
http://mega.1280.com/file/TZVPLO29/

2. HEX Editor
http://mega.1280.com/file/O36GM9PA/

Note: You can see password in 0590h memory address from CQM1H-CPU51/61 , but can not upload program.

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Repost: Omron PLC for Beginner

Bagi anda yang ingin belajar PLC Omron, ini saya dapet buku sangat bagus untuk di praktek kan. Banyak contoh aplikasi program dalam buku ini. Bagi yang berminat silahkan download.

Untuk Download silahkan KLIK DISINI!

Untuk Melihat Isi dari buku ini silahkan klik:

Content 1.
Content 2.
Content 3.

Mau?







PLC Beginner Guide

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Omron CX-ONE Sofware Download

Hunting di 4shared.com dengan kata kunci Omron, secara kebetulan menemukan link software CX-ONE Omron untuk di download. Ada yang mau?

Silahkan Klik Disini (Click Here For Download)

I have suggestion if you're working for bussiness, please buy this software from Official Omron. Thanks.

Bagi yang buat kepengen belajar, silahkan saja di Unduh... Semoga bermanfaat

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OMRON's PLC-based Process Control

"OMRON's PLC-based Process Control = Smart Monitor and Control"

General-purpose PLCs provide everything from simple loop control to advanced process control to meet customer needs

 

Omron has taken its wealth of technical know-how in factory automation and process control technology to create this PLC-based Process Control for Hybrid Process Control.

 

 

 

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One-Stop Solution

 

Omron provides Built-in Loop Controller (BLC) - CJ1 Series CPU with built-in loop controller that is best-suited for small-scale sophisticated process control up to a maximum of 150 loops.

 

For a large-scale control process of 250 loops, Omron recommends Hybrid-Process System (HPS) - CS1 Series CS1W-LC[][]1.

 

 

 

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Built-in Loop Controller

 

Built-in Loop Controller combines the Sequence Control Engines and Loop Control Engine into one and integrated with the NS touch panel. A mini batch on control system can be released, and data trending and data logging can be viewed and monitored from the Touch Panel.

 

 

 

Hybrid Process System

 

Omron Hybrid Process System combines the benefits of the PLC and the ease of programming of Distributed Control Systems (DCS) into one. With the benefits of the PLC, flexibility and scalability of the system can be realized. Besides that, with the ease of the sequencing programming for DCS, development of control becomes easier. Thus, the Hybrid Process System simplifies the design, planning and implementation, and reduces the engineering time.

 

To meet user needs, simple tools are provided to users for easier integration of GUI monitoring and control system.  Tags can be generated and use for GUI monitoring and control.

 

Omron provides CX-Process Monitor Plus, a simple monitoring and control software to simplify data trending and process control. With the integration of CX-Process Monitor Plus or SCADA and HMI, operation control and monitoring becomes simple, and complexity in maintenance is no longer an issue.

 

 

For more controls, NS series touch panel and SCADA system can be integrated. For process control that requires redundancy system, Omron SYSMAC CS1D can be applied. With Hybrid Process System, a low-cost DCS system can be realized.

Source: www.omron.co.id

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OMRON's Solution for Analog Process Control

Omron provides a wide range of different products suitable for different analog process control, ranging from simple, single-loop control to complex, multiple-loop control.

 

 

Note: Click on the products for more details.

 

For applications which require simple distributed control, Omron's Temperature Controller and Digital Panel Meter will be able to fulfill your application needs.

 

For simple multiple-loop process, Modular Temperature Controller E5ZN will be able to control simple process up to 32 loops.

 

For sophisticated multiple-loop process, digital process controller E5[]R series and PLC-Based Process Controller will be most suitable for your application.

Source: www.omron.co.id

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Omron CX-ONE Software

Hi blogger.. I just hunting CX-ONE (Omron PLC Software).
Surprise... I got it from 4shared.com. Look at capture screen below.

You can visit : http://www.4shared.com/dir/6162497/d9777701/Omron_CxOne_Sofware.html

I suggest this software use only for learning. If you use for business Please buy from Omron.
Visit more information at Omron Site.

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ZEN Omron - Information.

Easier small-scale automatic control. That is what the ZEN from OMRON provides. The ZEN can be used almost as easily as wiring materials. The ZEN enables quick automation of small machines or facilities. Add to this the LCD screen and 8 buttons on the front panel for easy ladder program input. You want a more compact control panel or reduced assembly or wiring? AC inputs, easier circuit design, or multiple-timer control? The OMRON ZEN gives you these, and more, to fill all your automation requirements. Increase system convenience and added value using the automation excellence provided by the ZEN.


ZEn Software

http://rapidshare.com/files/122305632/Zen_Software_V200.part1.rar
http://rapidshare.com/files/122307911/Zen_Software_V200.part2.rar

Cable Interface:
http://www.ziddu.com/download/3932283/ZS414_UpDate.EXE.html

Online catalogs (PDF files) and various online manuals (PDF files) for ZEN Programmable Relays can be downloaded from Omron website.

■Operation Manual(Z211)		(8.2MB)
■Support Software Operation Manual(Z184)		(4.1MB)
■Communications Manual(Z212)		(1.5MB)

■ZEN Programmable Relays(L106)		(1.6MB)
■Correction Insert(L109)		(113KB)
■Switching Mode Power Supply (L103)		(588KB)

■Support Software Version Upgrade(Ver.4.14) ■Support Software Demo(Ver.4.14)

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PLC Timeline

Sejarah PLC? Bisa dilihat disini.

This timeline of the development of the PLC by different manufacturers is a work in progress. If you have something to contribute or correct especially concerning Siemens or Mitsubishi then please contact me.

PLCdev's article on The Birth of the PLC gives more information on how programmable logic controllers first got started.

Resources for this time line:

• You always have to start with Richard Morley's dusting off of his memory cells to tell us about the History of the PLC.
• Both Richard Morley and Allen Bradley's Odo Struger were chosen as one of InTech's 50 most influential industry innovators.
• Modicon to Gould to Schneider, Square D, Telemecanique
• Schneider Electric's complete history entitled From Modest Beginnings to World Leader, 163 years in review also in a nice pdf format.
• Original text from the Schneider Electric website listing Modicon's history.
• New Zealand has saved this little treasure.
• Allen Bradley to Rockwell Automation history
• Another good first hand account is Dr. Ernst Dummermuth's recollections in A Bit Twiddler's History of the PLC in the November 2002 A-B Journal.
• The Evolution of the PLC-5/1771 Controller System has a twisted path of development.
  
• Allen-Bradley: A Century of Quality covers the whole history of Rockwell Automation. The A-B Journal has a different layout on their timeline.
• There's an excellent timeline in the article PLC 25 Years: Rockwell Automation traces the 25-year history of the Allen-Bradley PLC.
• Omron PLCs
• Corporate History of Omron
• Automation Trends Newsletter of December 2002 Tracing Mid-Size PLC System Migration Over 15 Years
• General Electric Fanuc PLCs:
• GE Consumer & Industrial: A History of Innovation Timeline
• CIMTEC's history of the GE Fanuc PLCs
• First hand experiences and memories
• History of Manufacturing, Industrial, Factory Automation Systems as we can remember it
• Jeremy Pollard has a good series in Control Design Magazine
• Genesis of the Programmable Logic Controller
• A PLC programmer’s pain -- 1980
• The saviors of PLC programmer sanity

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Belajar PLC OMRON

Silahkan klik links di bawah ini untuk belajar PLC OMRON.

Anda bisa mendownload software SYSWIN utk belajar bikin aplikasi PLC.

Selamat Mencoba.

Contents: Chapter I Operating system

Introduction
1.1 Conventional control panel
1.2 Control panel with a PLC controller
1.3 Systematic approach to designing a process control system

Chapter II Introduction to PLC controllers

Introduction
2.1 First programmed controllers
2.2 PLC controller parts
2.3 Central processing Unit –CPU
2.4 Memory
2.5 PLC controller programming
2.6 Power supply
2.7 Input to PLC controller
2.8 Input adjustment interface
2.9 PLC controller output
2.10 Output adjustment interface
2.11 Extension lines

Chapter III Connecting sensors and output devices

3.1 Sinking-Sourcing concept
3.2 Input lines
3.3 Output lines

Chapter IV Architecture of a specific PLC controller

Introduction
4.1 Why OMRON?
4.2 CPM1A PLC controller
4.3 PLC controller output lines
4.4 PLC controller input lines
4.5 Memory map for CPM1A PLC controller

Chapter V Relay diagram

Introduction
5.1 Relay diagram
5.2 Normally open and Normally closed contacts
5.3 Short example



Chapter VI SYSWIN, program for PLC controller programming

Introduction
6.1 How to connect a PLC controller to a PC
6.2 SYSWIN program installation
6.3 Writing a first program
6.4 Saving a project
6.5 Program transfer to PLC controller
6.6 Checkup of program function
6.7 Meaning of tool-bar icons
6.8 PLC controller function modes
6.9 RUN mode
6.10 MONITOR mode
6.11 PROGRAM-STOP mode
6.12 Program execution and monitoring
6.13 Program checkup during monitoring
6.14 Graphic display of dimension changes in a program

Chapter VII Examples

Introduction
7.1 Self-maintenance
7.2 Making large time intervals
7.3 Counter over 9999
7.4 Delays of ON and OFF status
7.5 Alternate ON-OFF output
7.6 Automation of parking garage for 100 vehicles
7.7 Operating a charge and discharge process
7.8 Automation of product packaging
7.9 Automation a storage door

Appendix A Expanding the number of I/O lines

Introduction
A.1 Differences and similarities
A.2 Marking a PLC controller
A.3 Specific case

Appendix B Detailed memory map for PLC controller

Introduction
B.1 General explanation of memory regions
B.2 IR memory region
B.3 SR memory region
B.4 AR memory region
B.5 PC memory region

Appendix C PLC diagnostics

Introduction
C.1 Diagnostic functions of a PLC controller
C.2 Errors
C.3 Fatal errors
C.4 User defined errors
C.5 Failure Alarm –FAL(06)
C.6 Severe Failure Alarm –FALS(07)
C.7 MESSAGE –MSG(46)
C.8 Syntax errors
C.9 Algorithm for finding errors in a program

Appendix D Numerical systems

Introduction
D.1 Decimal numerical system
D.2 Binary numerical system
D.3 Hexadecimal numerical system

Appendix E Detailed set of instructions

Download:
Disk1 [1.24Mb]
Disk2 [1.44Mb]
Disk3 [1.44Mb]

Update Link untuk download 24.08.2010. Yg tidak bisa download silahkan di cek kembali link diatas. Terimakasih.

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