Omron's ZEN nano controller - ZEN-10C1DR-D-V2

'A compact solution for small-scale control applications that blends simple, flexible programming and reliable easy performance. Omron's ZEN nano controller offers the ideal mix of flexibility, functionality and cost for a wide range of applications.

Here's Why:

• Combines the Functionality of Separate Timers, Counters and Relays
• Provides Flexible Programming without Rewiring
• AC or DC Inputs with 8 A Relay Outputs
• Offers Multiple Expansion Options for Future Needs
• Exceptional Value for the Cost of Installing Just Three Relays
• Simple Ladder Logic Programming Using ZEN Support Software or Operation Buttons on Front Panel (LCD Models Only)
• Save Time By Using the Memory Cassette to Transfer Programs Between ZEN Units
  
  Features:
• Compact, CPU and Expansion Units
• 8 Timers Support 4 Types of Operation and 3 Timing Ranges Available
• 4 Holding Timers Hold Data During Power Interruptions
• 8 Counters Can Be Switched Between Incremental and Decremental
• 8 Weekly Timers for Day/Time Control
• 8 Calendar Timers for Seasonal Control
• 10 I/O and 20 I/O CPUs Expandable to 34 and 44 I/O
• 16 Holding Bits Retain ON/OFF Status in Case of Power Failure; No Need for Extra Circuitry
• ZEN Battery Provides Controller CPU with 10 Years of Memory Protection
• Accurate Analog Inputs ±1.5% FS
• Flexible Mounting — Either Horizontal or Vertical
• Models with LCD Display Also Feature Real-Time Clock/Calendar and Programming Buttons
• Advanced High-Value Counting with 8-Digit Counter and 8-Digit Comparators, in Addition to 16 Standard Counters
• One 150-Hz High-Speed Counter Available On Models with DC Power Supply
• Twin-Timer Operation Allows You to Set ON and OFF Times Separately, Greatly'

• Price For: (Each) Brand/Series: ZEN Series Communication: RS-485 Current, Input: 4.5 mA Dimensions: 70mmL×56mmW×90mmH Input Type: Voltage IP Rating: IP20 Memory: EEPROM Mounting Type: DIN Rail Number of Inputs: 6 Number of Outputs: 4 Output Type: Relay Primary Type: Controller Standards: UL, cURus, CSA, CE Terminal Type: Terminal Block Termination: Terminal Block
• Type: PLC Voltage, Supply: 12-24 VDC

Current Price: $ 261.29

Touchscreen Interfaces

An HMI, or Human-Machine Interface, is a device or software that lets users communicate with a machine or automation system. Besides translating complex data into useable information, an HMI relays the user’s commands.

By providing information, alerts, commands and other tools, an HMI connects the user with the process being controlled. So the more adapted the tools are to the user, the more appropriately he or she can react.

An intuitive, user-friendly HMI can make the difference between an inefficient system and a cost-effective one.
(source : http://www.automationcontrols.com/touchscreen-interfaces)

Programmable Controllers And I/O

Compact PLC Series

CP1H - Fast Throughput, Powerful Position Control and Communications Capabilities in a Brick Style Controller 

• Built-in functions include 40 digital I/O, high-speed counters, analog, motion and communications integrated in one
• CPU expands to 320 I/O points using CPM1A expansion I/O modules and CJ1W Special I/O modules
• Built-in USB and peripheral ports and two-plug-in serial comm boards for either RS-232C and RS-422/485 simplify direct connection to serial devices and programming tools
• Network communication capabilities via serial, Profibus-DP and Omron's CompoBus/S and DeviceNet I/O Link help integrate process or machine activity with other plant floor operations
• Use CX-Programmer Jr. for simple ladder programming; use CX-One for advanced functionality
• All Omron devices connected to CP1H by Ethernet, DeviceNet, MECHATROLINK-II or serial link can be configured, programmed and monitored through a single connection using CX-One software suite

Modular PLC

Fast CJ2 CPUs offer built-in Ethernet/IP and Tag-Based Programming to simplify communications setup and data access. Use CJ1 modules for I/O, process control, motion, RFID and networking. Choose CJ2 for maximum throughput, short development time and fast time to market with your machine. For effective networking, CJ2 delivers high-capacity data exchange between PLC’s, HMI’s and I/O devices to perform both explicit and implicit messaging. 

• Tag-Based Programming lets operators’ access data without knowing the I/O addresses
• Huge memory: Up to 400K steps program, 800K DM, 3.5 MB for Function Block, Symbol and Comments
• Use CX-One software: Includes all 5 IEC61131-3 programming languages and full-featured Simulation; also converts existing CJ1 programs
• Easy connection: Built-in USB, RS-232 or Ethernet/IP ports
• Versatile: Over 100 CJ1 modules available for I/O, control and networking

Rack PLC Series

Ultra-Fast Processing Speed Improves Throughput and Productivity 

• High function controller platform supports up to 5120 I/Os, 250K-step program memory and 448K-word data memory.
• Seamless interface to open/multi-vendor networks of Ethernet, Controller Link, DeviceNet, Profibus and Modbus.
• Best fit for any large scale and complex automation system.
• Fast execution times.
• Process Loop Control CPUs handle up to 640 analog input/output points for processing applications.
• Seamlessly combine continuous path motion control or point-to-point positioning with high-speed sequencing operations using special function I/O modules.

Nano Brick Style

NEW ZEN programmable relay was upgraded with the features and functions of both a programmable controller and smart relay to allow simple yet powerful control. Apply the ZEN to small-scale control applications where simple functionality and low cost are critical. Provides an economical alternative to discrete timers, counters and general-purpose relays. 

• Wide variety of functions
• Saving and copying of programs
• Space saver-the extreme compact size allows for installation in almost any location
• Flexible expansion- up to 3 expansion I/O modules can be added for a maximum of 34 I/O points
• Slim expansion I/O modules measure just 35 mm wide
• Memory backup
• Create control programs using the 32-bit, Windows-based ZEN support software or using the operation buttons on the front panel (LCD models only).

Compact I/O

In addition to connecting analog I/O to DeviceNet, these compact slaves provide a cost-effective solution
by analyzing sample data internally and providing measuring device judgements to the controller. This
reduces processing time in the controller and offers localized functionality for quality control and error
detection. Make adjustments offline and unify sensor signals to standardize programs.

• 2-point analog output or 4-point input models
• Scaling and comparator functions built in
• Peak/valley hold function helps detect where data changes occur using data and trigger points
• Integration function allows calculation of material leakage
• Differentiation function continuously calculates rate-of-change
• Confirm settings and connections via DeviceNet to shorten troubleshooting time
• Current and voltage ranges and functionality are seleted by DIP switch

Modular I/O

SmartSlice - The most intelligent and easy to use remote I/O system currently available

Interlocking bus blocks build the backplace of the system.  The electronics module and removable terminal block plug into the backplace, enabling you to:

• Replace electronic modules while the bus structure and field wiring stay intact.  During hot-swapping, all other I/O units continue to operate
• Detach I/O terminals for pre-wiring, maintenance or testing.

Fast backup and restore

With all the intelligence and advanced functions in SmartSlice units, backup and recovery of settings are important to support fast maintenance and repair of your machine.  All I/O unit data can be backed up in the bus interface unit at the flick of a switch.  Recovery is even simpler; after hot-swapping a uhnit, all settings are automatically loaded.

Wireless I/O

• Enables up to 3,200 points of I/O via wireless DeviceNet I/O slaves (input: 1600, output: 1600)
• Optimum on-site communications method
• High-speed response ideal for information-related applications
• Relay function allows long communications distance
• Easy installation
• Setting for wireless communications possible from unit

(source : http://www.automationcontrols.com/programmable-controllers)

Serial To Ethernet Converters

Moxa's serial-to-Ethernet products are designed to make industrial devices accessible directly from the network. Legacy devices can thus be converted into Ethernet devices that can be monitored and controlled from any network location or even the Internet. Different configurations and features are available for specific applications, including protocol conversion, Real COM drivers, TCP operation modes, and more. 
External Device Servers

Industrial Device Servers are designed to make serial devices network-ready in an instant. The small size of the servers makes them ideal for connecting devices such as card readers and payment terminals to an IP-based Ethernet LAN. Use the Industrial Device Servers to give your PC software direct access to serial devices from anywhere on the network.


Embedded Device Servers

Embedded Device Servers are designed for manufacturers who want to add sophisticated network connectivity to their serial devices. Embedded Device Servers can be used to convert any device with a standard serial interface to an Ethernet -enabled device in no time. The Embedded Device Servers support 10/100 Mbps Ethernet, and provide ready-to-use operation modes, including TCP Server, TCP Client, and UDP. In addition, a Real COM driver is included for backward compatibility with legacy software.



Industrial Device Servers

Industrial Device Servers provide easy and reliable serial-to-Ethernet connectivity for industrial automation applications. The device servers can connect any serial device to an Ethernet network, and to ensure compatibility with network software, they support a variety of port operation modes, including TCP Server, TCP Client, and UDP.





Wireless Device Servers 

Wireless device servers provide industrial devices such as PLCs or RTUs with a wireless connection to an Ethernet network. Moxa offers a selection of wireless device servers tailored to specific industrial needs, with important features such as TCP operation modes and strong security protocols.


(source : http://www.automationcontrols.com/serial-to-ethernet-converters)

Video Networking Servers

IP Video

Moxa offers a complete range of IP video surveillance solutions, including video encoders, video decoders, IP cameras, and user-friendly IP surveillance software that lets you take full control of field cameras and traditional CCTV systems. By putting special emphasis on creating an industrial design and state-of-the-art compression technology, Moxa's video-over-IP products are ideally suited for industrial surveillance applications, such as traffic surveillance and factory monitoring. 

Features and Benefits 

• Industrial design with -40 to 75°C operating temperature and fiber optic Ethernet port
• Video stream up to 30 frames/sec at full D1 (720 x 480) resolution
• Pre/post-alarm video recording function for advanced surveillance
• 2-way (1 in/1 out) audio supported
• Free VPort SDK PLUS and 4-channel video surveillance software
• (source :  http://www.automationcontrols.com/video-networking-servers)

Ethernet I/O Servers

Active Ethernet I/O 

Active Ethernet I/O is an exciting new concept in Ethernet I/O that introduces active I/O messaging with easy logic control. With the patented and intuitive Click&Go interface, absolutely no programming is required to configure the I/O server's control logic. Bi-directional and direct input-to-output signal communication over Ethernet is supported, and Windows/Linux APIs are included for use in both industrial automation and IT environments.

Peer to Peer I/O

ioMirror E3000 Ethernet I/O servers provide a cable replacement solution by transmitting input signals to remote outputs over an Ethernet or IP network. With ioMirror Ethernet I/O servers, remote sensors can be connected to PLC controllers, DCS systems,or display devices over a network, without requiring additional signal wires.

Serial Remote I/O

Serial remote I/O servers are used to acquire and control remote digital and analog devices over RS-485, which remains one of the most popular industry wiring standards. Through serial remote I/O servers, proximity switches, mechanical switches, push buttons, optical sensors, LEDs, light switches, temperature sensors, and more can be accessed by SCADA systems or the MXIO DLL library. Moxa's line of RS-485 I/O servers includes features that make life easier for industrial integrators:

• Modbus RTU/ASCII protocols
• Digital I/O with DI/Event Counter and DO/Pulse Output modes
• Analog I/O with mA/mV/voltage modes
• Over-current and over-voltage protection
• PLC-grade I/O design for high accuracy and reliability during field operation
• Remote management of firmware upgrades over RS-485

Modular Remote I/O

With modular remote I/O servers, sensor data and simple analog or digital devices can be monitored or controlled over Ethernet or RS-232/485. The modular design allows the I/O server to accommodate almost any number and type of I/O device. Standard Modbus support allows the I/O server to be integrated into SCADA systems relying on software such as Intellution iFix, Wonderware, and Labview.
(source : http://www.automationcontrols.com/ethernet-io-servers)

Ethernet Switches

Industrial Ethernet switches are used to form the network backbone in substation automation systems, intelligent transportation systems, and other major industrial automation projects. Moxa offers a wide variety of managed and unmanaged switches to fit different system requirements.

Unmanaged Ethernet Switches

Moxa offers a wide selection of unmanaged Ethernet switches with high port densities and different combinations of TP, SC, and ST connectors. These industrial-grade switches maintain a compact, economical footprint that is ideal for a diverse set of applications.

Managed Ethernet Switches

Managed Ethernet switches support intelligent network management functions such as QoS, IGMP Snooping/GMRP, VLAN, Port Trunking, SNMP V1/V2c/V3, IEEE802.1X, and https/SSL. For redundant network backbones, the Turbo Ring feature supports Gigabit Ethernet, copper or fiber-optic media, and network recovery within 20 ms. 

Modular Ethernet Switches

Moxa's industrial modular Ethernet switches feature high reliability, great performance, modularity, and security, and are ideal for forming the network backbone for industrial applications. Top network performance and reliability is assured with Gigabit-speed, high fault-tolerant rings (recover time < 20 ms), and many advanced management and security features.

Rackmount Ethernet Switches

Moxa's Industrial rackmount Ethernet switches, IKS series, are specially designed to handle demanding industrial applications. The IKS series meet EN60950-1, DNV/GL and NEMA TS2 environmental requirements that guarantee a high degree of adaptability to any severe condition, such as vibration and shock, high humidity, extreme temperatures, and high EMI/EMC noise.

IEC 61850-3 Ethernet Switches

IEC 61850-3 Ethernet switches are high performance switches that support IP routing protocols, including static routing and RIP V1/V2, which facilitate the deployment of mission-critical applications across networks. They are designed to meet the demands of power substation automation systems (IEC 61850-3, IEEE1613), traffic control systems (NEMA TS2), and railway applications (EN50121-4).

(source : http://www.automationcontrols.com/ethernet-switches)

Omron CS/CJ Course Modules

Omron CS/CJ (Modules 1-2)

Duration: 2 days

Course Outline

Module 1

This module takes a fundamental approach to an Omron CS/CJ system.  It begins with an overview of the architecture and migrates to an introduction to the CX-Programmer software, the programming environment.  The essentials of how the hardware interacts with the software will be covered in the memory addressing and I/O configuration lessons.  Students will receive a basic understanding of a CX-Programmer project, including an introductory look at programs, tasks and sections.  This will be followed the methods to communicate and download the project to a PLC.  At the end of this module students will be comfortable identifying CS/CJ components and will be able to reload a program into the system.

Lessons

1. Hardware Overview
2. CX-Programmer Overview
3. Memory Addressing
4. I/O Configuration
5. Project Basics
6. Communications

Module 2

This module introduces students to the core instruction set for the CS/CJ processor.  Students will cover how to add and edit the ladder logic.  The module will teach students the techniques involved in documenting a ladder logic program, as well as how to monitor the ladder logic for debugging purposes.

Lessons

1. Bit Instructions
2. Editing Logic
3. Documentation
4. Timers and Counters
5. Monitoring

(Source : http://www.automationtraining.ca/omroncscj.asp)

PLC Omron Programming for Injection Molding Machine

PLC Type Series-C Omron , Name Input / Output PLC : 

INPUT PLC : 
000.00 ; Push Button START
000.01 ; NO Contact Contactor for Temperature is Reached
000.02 ; Alarm Heater Element Bournout Detector
000.03 ; Push Button STOP
000.04 ; Alarm Motor, the Signal from the Speed Control Motor.
000.05 ; Limit Switch Reverse from Cylinder Molding
000.06 ; Limit Switch Forward from Cylinder Molding

OUTPUT PLC : 
005.00 ; Power Temperature Controller
005.01 ; Speed Control Motor ( ON / OFF Motor for Screw )
005.02 ; Solenoid to Pneumatic Cylinder Molding Forward
005.03 ; Solenoid to Pneumatic Cylinder Molding Reverse


Please Download Picture Programming Ladder PLC :

PLC Omron Programming for Injection Molding Machine



Reading Ladder PLC Programming for Injection Molding Machine :


Step 1 : Heating Process
Heater Controller with PLC

Step 2 : Injection Molding Process
a.If 010.01 = ON And 010.04 = ON And 000.04 = ON Then 010.05 = ON.
b.If 000.00 = ON And 010.05 = ON And 000.03 = OFF Then 010.06 = ON ( Hold ON ).
c.If 000.05 = ON And 000.06 = OFF And 010.06 = ON And 010.11 = OFF Then 010.07 = ON ( Hold ON ).
d.If 000.06 = ON And 000.05 = OFF And 010.06 = ON And 010.10 = OFF Then 010.08 = ON ( Hold ON ) And TIM001 Activated .
e.If 010.08 = ON And TIM001 = ON And 010.06 = ON And 010.11 = OFF Then 010.09 = ON ( Hold ON ) And TIM002 Activated.
f.If TIM001 = ON Then SET 010.10 = ON ( Hold ON ).
g.If TIM002 = ON Then SET 010.11 = ON ( Hold ON ).
h.If 010.09 = ON And TIM002 = ON And 010.06 = ON And 010.10 = ON Or 010.11 = ON Then 010.12 = ON ( Hold ON ).
i.If 010.12 = ON And 000.05 = ON Or 010.06 = OFF Then RSET 010.10 = ON ( 010.10 = OFF ) And RSET 010.11 = ON ( 010.11 = OFF ).
See Picture to Set Value Timer for :
1. Stability Current from Power to Heater
2. Volume of Materials into Molding Dies
3. Wait for the cool Material

Step 3 : Output PLC
a.If 010.01 = ON Then 005.00 = ON.
b.If 010.08 = ON Then 005.01 = ON.
c.If 010.07 = ON Then 005.02 = ON.
d.If 010.12 = ON Then 005.03 = ON.

(source : www.program-plc.blogspot.com)