Tag Archives: programmable logic controller tutorial free

Productivity 1000 Series PLC System Hardware

The Productivity 1000 series of programmable logic controllers has a slim stackable super compact design. This is sometimes also referred to as a shoebox PLC because of the shape and way in which expansion modules are added. This new Productivity 1000 series PLC is the latest in the Productivity series of controllers that have hit the market.

Productivity 1000 (Stackable Micro PLC)
Productivity 2000 (Micro Modular Programmable Controller)
Productivity 3000 (Modular Programmable Controller)

These three series currently make up the Productivity Series form Automation Direct.

The Productivity 1000 series PLC provides the following features for your automation control panel.
– 50MB user memory – Can handle very complex applications easily.
– 4 built-in communication ports – Easy connectivity to your network. This would include your PC, HMI, Networks, etc.
– Data logging up to 32 GB on a microSD card
– Add up to 8 IP modules to communicate to your field sensors. This will give you a total of 128 discrete IO points or 32 analog IO channels.
– Free Software and 30 days of free training with every CPU from Automation Direct.
– Interactive PLC Configuration Tool
– Tag Names
– Auto discovery IO – Physical I/O tags will be generated based on each module’s position in the base. You can also reconfigure the setup and assign new tags manually.
– I/O Modules have QR codes under the wiring cover. This can be scanned so you can have the latest specifications / wiring diagrams for the module.
– Limitless PID – Auto tuning – Individual or Cascade Mode – etc
– Web Server and Mobile Access
– Advanced Software instruction set

We will be looking at allot of these features of this powerful controller. Let’s start by looking at the hardware. Continue Reading!

Omron CP1H Data Control Instructions

The data control instructions in the Omron CP1H programmable logic controller are used to manipulate the outputs based upon control conditions. Control is the main purpose of these instructions within the PLC. Instructions include PID (Proportional, Integral and Derivative), PID with Auto tuning, Dead Band Control, Limit, Dead Zone Control, Time Proportional Output, Scaling, etc.
We will be looking at some of these instructions in the Omron CP1H PLC. Examples of the instructions will be presented. Continue Reading!

Omron CP1H Program Control Instructions

The Omron CP1H programmable logic controller has several different ways to control the program and the way in which your program executes. Sequence control, Subroutines, and Step instructions can be used. These are just a few ways in which the controller will execute your logic using a synchronous PLC scan. Understanding the PLC program scan will explain the synchronous and asynchronous program scanning.
Interlocks, Jumps, For Next Loops, Subroutines and Step instructions are some of the ways in which we can control our program in the PLC. We will be looking at some of these instructions in the Omron CP1H PLC. Examples of some of the instructions will be presented. Continue Reading!

Omron CP1H Counters

The Omron CP1H series of programmable logic controllers are capable of having 4096 basic counters. There are two basic counter instructions in the PLC. Each of basic instructions can be either binary or BCD. The memory area for counters have separate areas for the Counter PVs (Present values) and the Counter Completion Flags. We will be looking at the basic Counter instructions in the CP1H along with some programming examples. Continue Reading!

Omron CP1H System Hardware

The Omron CP1 series of programmable logic controllers consist of three different units. CP1E is the cost effective unit, CP1L is the high performing controller that can come with embedded Ethernet and the CP1H is the position control and comprehensive programmable logic controller.
We will be looking a the CP1H for this series, but a majority of the information can be applied to the CP1E and the CP1L controllers as well.
Let’s start by looking at the CP1H hardware.

The CP1 series is designed with the same basic architecture as the CS and CJ Series. The special I/O units and CPU bus units of the CJ series can then be used. Always use CPM1A expansions units and CPM1A expansion I/O units when expanding the I/O capacity. The following diagram indicates the position of the unit with respect to the CJ and CS series. Continue Reading!

How to Troubleshoot a PLC

Your control system does not work. Where do you start? Lets walk through a series of questions in order to determine where the problem lies.

Is this a new installation or previous installation that was running fine? Determine if system has been running well in the past and has currently stop working correctly. This is the indication that the problem relies inside the system.

Is there anything that has happened outside of the system? Has there been a lightening strike, blown drives on other systems, etc.  This can point to the original cause of the malfunction.

What is the system doing now and what should it be doing? Gather all of the information you can from every resource you can.

  • Supervisors  – machine, location, time of error, other happenings in the plant, etc
  • Operators – What is it currently doing? What should it be doing? What do you think is wrong?
Operators of the equipment are your key resource in finding, correcting and ensuring the error does not happen again. They know the equipment from an operational point of view which can assist you greatly in troubleshooting.

PLC fatal and non-fatal errors:
If the machine is still running partially then this is an indication of a non-fatal error. Cannot run at all is usually a fatal error.

Take a look at the PLC indicator lights on the CPU. Refer to the operation manual for the PLC for troubleshooting specific lights on the CPU. The following are general tips:

If no lights are on then the possible cause is a power supply. This is usually the most common of errors on a PLC system. Mean time before failure (MTBF) is rated on the lowest rating of components which is usually the power supply.

If the run light is on and an error light flashing this usually indicates internal errors such as batteries, scan time, etc. It is usually not the reason for the lack of operation.

If the run light is on and no other errors are seen on the CPU we can put the PLC program on the bottom of the list of items that could be the cause.

Check the input cards of the PLC. You should see the individual sensors lighting up the inputs. If not then check the power supply to the input card / cards.

Ask the operator what is happening and what is suppose to happen. Try to follow the sequence of events in the PLC to determine either and input or output device not working.
Some items to watch:

If this is a new PLC program that you are doing start with a logic flow diagram. This will determine the procedure to start programming.
Every program can be done in several ways. The best method is the most documented one.

Documentation is the mark of a good program.

Some trouble with new programs can be racing conditions. This is usually a case of not understanding how the PLC scans logic. In general the PLC will scan from left to right, top to bottom. The output bits / words are available to the inputs of the next rung of logic. (Modicon PLC’s will scan differently.) Actual outputs and inputs are not read until the end of the scan of the PLC. Racing conditions happen when the output is set on multiple rungs, but will not get actually set until the end of the scan. Think of it as the last action will always win. So if this happens move the logic to the end of the program and see if it works. Then go back and see where the output was also set.  Cross reference guides are ideal for this purpose. (Refer to your programming software on how to get cross references.)

We have discussed just a few troubleshooting techniques. Hopefully now you know how to start looking for the errors on your  system. Let me know how you make  out.

Watch on YouTube : How to Troubleshoot a PLC

Do you know of additional tips or methods to share?

If you have any questions or need further information please contact me.
Thank you,

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