Mastering Omron Sysmac PLCs: A Step-by-Step Programming Guide

This tutorial introduces engineers to Omron’s Sysmac platform, which unifies PLC, motion, and IoT. Readers will learn how to set up a Sysmac machine controller (NJ/NX series) and program it using Sysmac Studio. Key steps—from hardware setup and EtherCAT network configuration to creating ladder and motion sequences—are covered. By walking through a sample packaging machine application, the guide demystifies Omron’s high-speed motion control, showing how built-in EtherCAT drastically speeds up and synchronizes servo axes.

By ZhuoMingyu

December 31, 2025 6 min read

Robotic arms and conveyor belt in a modern automated factory, illustrating the high-speed motion control and synchronization managed by Omron Sysmac NJ and NX series PLCs.

Omron’s Sysmac platform excels at synchronizing complex, multi-axis systems like these robotic arms and conveyors. Its built-in EtherCAT network ensures high-speed precision for advanced manufacturing lines.

Photo by Simon Kadula on Unsplash

Introduction

Modern automation demands fast, synchronized motion and seamless data handling. Traditional systems often require separate software for logic, motion, and safety, leading to integration headaches. Omron Sysmac controllers integrate PLC logic, motion control, and safety into one system. Their built-in EtherCAT network simplifies cabling and enables precise multi-axis coordination.

However, new users often face a steep learning curve, asking: “How do I start programming an Omron Sysmac PLC, and what advantages will it bring to my machine?” This tutorial addresses that by guiding you through a practical Sysmac programming example, helping you transition from basic relay logic to advanced machine speed optimization.

Key Takeaways

Unified Platform: Omron Sysmac controllers combine PLC, motion (up to 256 servo axes depending on the model), HMI, and safety in one controller, simplifying architecture. EtherCAT wiring allows one cable for all servos.
Accelerated Development: With Sysmac Studio software, engineers can program logic, motion cams, and vision in a single IDE. This integration reduces configuration time and eliminates sync issues between devices.
High-Speed Motion: The built-in EtherCAT port and advanced motion modules enable faster, more precise machines. Features like linear/circular interpolation and electronic camming can dramatically improve cycle times.
Step-by-Step Example: We cover setting up Sysmac Studio, defining I/O, and creating a sample ladder program and motion sequence for a conveyor with pick-and-place functionality.
Troubleshooting Tips: Common pitfalls (e.g., network scan settings, servo homing procedures) are highlighted to help technicians avoid downtime.

1. Understanding the Omron Sysmac Platform

Sysmac Controllers (NJ/NX Series)

The Sysmac family is divided primarily into the NJ and NX series. The NJ Series is the robust, high-end choice designed for complex machinery requiring high-speed synchronization of many axes. The NX Series (such as the NX1P2) is a compact, entry-level machine controller that brings the same advanced motion capabilities to smaller applications. A key feature across both is the built-in EtherCAT port, which serves as the backbone for high-speed communication.

Sysmac Studio Software

Unlike legacy systems that required CX-Programmer for logic and CX-Motion for servos, Sysmac Studio is an all-in-one IDE. It allows you to set up controllers, configure Omron programmable logic controllers, networks, and HMI screens in one environment. It fully supports IEC 61131-3 languages (Ladder, Structured Text, Function Block), allowing developers to choose the best language for the task.

2. Hardware Setup and Initial Configuration

Wiring and Power

Proper hardware installation is the foundation of a stable system. Mount the Sysmac controller on a standard DIN rail and connect the 24V DC power supply. Connect your servo drives (e.g., Omron 1S or G5 series) to the EtherCAT port using standard Ethernet cables. Because EtherCAT supports daisy-chaining, you can link the controller to the first drive, the first drive to the second, and so on, drastically reducing cabling complexity.

EtherCAT Network Scan

Once powered, open Sysmac Studio and connect to the PLC via USB or Ethernet. Navigate to the EtherCAT configuration tab.
1. Right-click the Master icon.
2. Select "Compare and Merge with Actual Network Configuration".
3. This function scans the network and automatically populates the project tree with all connected servos and I/O modules.

Safety and I/O

Configuring built-in safety I/O and network I/O (such as the OMRON NX I/O series) is seamless. Ensure you map your safety inputs (like E-Stops) correctly within the safety task. For standard sensors, check out our guide on integrating industrial sensors to ensure your wiring matches your software configuration.

3. Creating Your First Program

Ladder Logic Basics

In Sysmac Studio, navigate to Programming > POUs > Programs and create a new Ladder routine. A simple "Start/Stop" circuit is the best way to verify your I/O.

Defining Variables and Symbols

Sysmac uses tag-based programming (variables) rather than fixed memory addresses (like CIO 100.00).
Global Variables: Accessible across all programs and tasks (e.g., physical I/O).
Local Variables: Internal to a specific program.
Always assign meaningful names like Conveyor_Start_Btn rather than generic labels. This makes maintenance significantly easier.

Debugging Tools

Use the Watch Tab window to monitor variable values in real-time. The Online Editing feature allows you to modify code while the machine is running—vital for tweaking logic without halting production.

4. Implementing Motion Control

This is where Sysmac shines. Instead of complex register manipulation, you use PLCopen-compliant Function Blocks (FBs).

Motion Blocks (FBs)

To move a servo, you simply drag and drop a Motion FB into your ladder logic.

MC_Power: Energizes the servo motor.
MC_Home: Executes the homing sequence to establish a zero position.
MC_MoveAbsolute: Moves the axis to a specific coordinate.

For example, to move a packaging arm, you would trigger MC_MoveAbsolute when a "Package_Detected" sensor goes high.

Electronic Camming and Interpolation

For applications like rotary knifes or flying shears, mechanical cams are prone to wear. Sysmac allows you to create Electronic Cam profiles in the software, synchronizing a slave axis to a master encoder perfectly. Furthermore, understanding the difference between EtherCAT communication protocols and older standards helps explain why Sysmac can handle linear and circular interpolation so precisely—the data packet jitter is virtually non-existent.

5. HMI and Networking (Optional)

Basic HMI Connection

If you are using an Omron NA series HMI, it shares the same project file as the PLC, meaning variables are shared automatically—no re-typing tags. For third-party HMIs, you can connect via EtherNet/IP.

Data Logging and IIoT

Sysmac controllers are IIoT-ready. They support MQTT libraries, allowing you to publish machine data directly to the cloud for predictive maintenance or OEE tracking.

6. Tips and Best Practices

Structured Approach: Break complex machine code into different Sections or Function Blocks. Don't write the entire machine code in one continuous ladder file.
Online Simulation: Use Sysmac Studio’s integrated simulator. You can visualize the trajectory of your motion axes in 3D before you even purchase the hardware.
Regular Backups: Always export your project file (*.smc2) regularly. Sysmac projects contain everything, including drive parameters and comments.

Conclusion

Omron’s Sysmac platform empowers engineers to build faster, smarter, and more reliable machines. By following this guide, you should now have a basic Sysmac Studio project up and running, with PLC logic and servo motion working in concert. The unified architecture—centered around EtherCAT—cuts down on wiring and synchronization headaches. In practice, this means you can hot-swap automation control products or expand axes without redesigning the entire system, giving your factory a competitive edge.

Call to Action

Want to get hands-on with Omron PLCs? Contact Chipsgate’s technical team to discuss Sysmac solutions, or browse our extensive range of Omron controllers and components to start automating your next machine today.

Frequently Asked Questions (FAQ)

Q1: What is the difference between Omron’s NJ and NX controllers?

A1: Both are machine automation controllers with built-in EtherCAT. The NJ series is the higher-end option, offering more I/O capacity, memory, and advanced synchronization features for large production lines. The NX series is an entry-to-mid-range model, perfect for compact machines or cost-sensitive projects while still retaining powerful motion capabilities.

Q2: Do I need special cables for EtherCAT?

A2: No. EtherCAT utilizes standard shielded CAT5e or CAT6 Ethernet cables. The major advantage is the ability to daisy-chain devices, which simplifies the wiring layout significantly compared to point-to-point connections.

Q3: Can Sysmac controllers handle both motion and digital I/O on the same network?

A3: Yes. EtherCAT can carry high-speed servo commands and standard digital I/O signals simultaneously on the same cable. You simply add NX I/O modules onto the EtherCAT line, and they all appear under one network configuration in Sysmac Studio.

Q4: What programming languages does Sysmac Studio support?

A4: It fully supports the IEC 61131-3 standard, including Ladder Diagram (LD), Structured Text (ST), Function Block Diagram (FBD), and Instruction List (IL). You can mix these languages within a single project to optimize for logic or math-heavy tasks.

Q5: How does Omron handle safety functions?

A5: Omron’s Sysmac controllers integrate safety via the FSoE (Safety over EtherCAT) protocol. You can use Safety NX I/O units alongside standard I/O. For example, the NX1P2 supports Safety Torque Off (STO) features, and safety logic can be programmed directly in Sysmac Studio using safety function blocks.