Hardware Configuration
Each C200H Alpha PLC in the cell was modified to include a Controller Link module, a Communications
module, and a Bus Connection unit. Two of the PLC’s required an upgrade to a 10-slot backplane as well.
This provided the capability for the existing PLC’s to communicate to each other over Controller Link, a high
speed, deterministic network developed by Omron.

A CS1 PLC was added as a data concentrator. This consisted of a 3-slot backplane, power supply, CPU,
Controller Link module, Ethernet module, and the Hand Held Bar Code Scanner. As a data concentrator this
PLC passes barcode information to the Controller Link network to be displayed on the NT631 touchscreen
and provides an Ethernet connection for the plant ERP system.

 The customer’s electrical contractor installed cabling and conduit, while PLC mounting and modifications
were performed by Cross Automation personnel. Installation and start up time for the entire project was
3 ½ days for all three manufacturing cells.

^^ back to top ^^

Software Configuration

For the Omron C200H Alphas to communicate and share data new network routing tables and data link
tables had to be configured and downloaded to the respective PLC. Screen shot #1 (Appendix A) illustrates
the routing table. This table is used by the PLC to identify which network the Controller Link card will reside
on. Screen shots 2 and 3 (Appendix A) illustrate the datalink table. This table maps the memory locations
that are shared between all PLC’s on the controller link network. Screen shot 2 shows the memory allocations
for the Link Relays. Screen shot 3 shows the memory allocations for the Data Memory locations.

For the Omron CS1 data concentrator routing tables were again used, but this time two networks were
assigned to the PLC. This allowed data sharing with the C200H Alphas and provided a communications
bridge between the controller link network and Ethernet. Screen shot 4 (Appendix A) shows the routing table
for the CS1 PLC. Hand held barcode communications were established using the built-in RS232 port of the
CS1W-CPU43-EV1. Ladder logic for communications and for serving up the data to the NT631C touchscreen
was developed using Omron’s CX Programmer, as was the development of the routing and Data Link tables.

 A basic network diagram can be viewed in Appendix B. This diagram provides such information as the
Ethernet IP address, the Controller Link Node addresses as well as other pertinent operational information.

^^ back to top ^^

Barcode Operation

The bar code portion of the application required the use of a hand held barcode scanner. The Omron
Model BCH5732-OP was chosen for its ease of integration. The requirement for identifying both product
ID and operator ID was easily solve by utilizing the 2 programmable switches built into the scanner. Operationally
the scanner was set up in the following manner:

^^ back to top ^^

Operator ID

To read the Operator ID into the system the operator will push the right hand push button on the barcode
scanner. A beep will be heard and the LED indicator on the scanner will flash once. The operator will then
scan their ID tag into the system.

^^ back to top ^^

Product ID

To read the Product ID into the system the operator will push the left hand push button on the barcode
scanner. A beep will be heard and the LED indicator on the scanner will flash once. The operator will then
scan the Product ID into the system.

^^ back to top ^^

Invalid Read

If an operator scans a barcode without first pushing either scanner pushbutton, the system will generate
an “Invalid Read” message. This message will clear itself once a barcode has been scanned after the operator
has pushed the Operator ID or the Product ID pushbutton on the scanner.

^^ back to top ^^

Set-Up Parameters

Symbology Variables:

1. Code 39 Enable

RS-232 Variables:

1. 7 Data Bits
2. 2 Stop Bits
3. Even Parity
4. Baud Rate 9600
5. RTS/CTS Disable
6. Xmit Postable
1. 0D0A

Switch Control:

1. Auto trigger mode
2. Left Switch Enable
3. ID Out (Left Switch)
   a. 5072
4. Right Switch Enable
5. ID Out (Right Switch)
   a. 4F70

^^ back to top ^^

Omron NT631C Operation

A major issue with the customer in this application was that the machinery was originally imported from
Japan and as a result, the touchscreen maintenance screens were all scripted in Japanese. To resolve this,
Cross Automation downloaded a new operating system into the touchscreen that provided for English
scripting in all maintenance functions.

To increase operator awareness of machine functionality, inputs from all of the C200H Alpha PLC’s were
tied into the Network via the data link tables.

An additional screen was developed to display the Operator and Product bar code information as well as
displaying the status of various inputs on the machine.

Conclusion: The ability to successfully upgrade existing machinery to provide performance data to the machine
operator and to higher level information systems through retrofits is a viable, cost effective solution. The team
at Cross Automation can provide a single source solution for your hardware and engineering needs. Give us a
call, together we’ll find a way to meet your most demanding needs.

^^ back to top ^^