Assembling of a digital and analog PLC

trainer. Click PLC Model C0-02DD2-D

fastened to a mounting board with input

(X1-X4) and output (Y1-Y4) enclosure.

Click PLC Trainer

Dane Mahaffey

Scope of Project:

Assembling of a digital and analog PLC trainer. Click PLC Model C0-02DD2-D fasted to a

mounting board with input (X1-X4) and output (Y1-Y4) enclosure. Components to be assembled are as

follows:

Component List:

4 LED Output Lights (Red, Green, Blue, Yellow)

3 Toggle Switches (1 P/S 2 Input)

3 Rubber Toggle Switch Sleeves

2 Input Buttons

1 Voltmeter

1 Resistor

1 Potentiometer

1 Potentiometer Sleeve

1 Enclosure

1 Click Koyo PLC Model C0-02DD2-D

4 Mini Hex Nuts

4 Mini Auto Locking Washers

6 Washers

4 Coasters

1 PLC power supply

The hands-on and written project is to be completed in one week.

Component List and Cost:

4 LED Output Lights (Red, Green, Blue, Yellow) $6.00 per LED

3 Toggle Switches (1 P/S 2 Input) $6.00 per toggle switch

3 Rubber Toggle Switch Sleeves Cost of sleeve included w/ switch

2 Input Buttons $5.00 per button

1 Voltmeter $25.00 included w/ potentiometer

1 Resistor Unknown

1 Potentiometer $25.00 included w/ voltmeter

1 Potentiometer Sleeve included w/ voltmeter purchase

1 Enclosure Unknown

1 Click Koyo PLC Model C0-02DD2-D $129.00

4 Mini Hex Nuts Unknown

4 Mini Auto Locking Washers Unknown

6 Washers Unknown

4 Coasters Unknown

1 Mounting Board Unkown

PLC Trainer Kit 4 Inputs / Outputs $89.95

1 PLC Power Supply $26.95

Total Cost:

PLC + trainer kit = total cost

$129.00 + 89.95 = $218.95

If components aside from enclosure, mounting board, hex nuts, washers and coasters total

$77.00 then aforementioned items must total $12.95 to meet the training kit’s cost of $89.95.

Wire Sizing:

Either one 16 AWG wire or two 18 AWG wires.

Wire Safety:

a) Either one 16 AWG wire or two 18 AWG wires per insert into PLC

b) Continuous wires that are never spliced

c) No slack in wires

d) Feed wires through wire trays

e) Avoid running lower voltage near higher voltage wires

f) Use multiple wires to avoid voltage drop

g) Keep DC wiring away from AC wiring

h) No kinks or sudden bends in wires

\I) Fuse input power

J) Add external fuses for I/O

Operator Panel Layout:

Y1 Y2 Y3 Y4

X1 X2 X3 X4

Voltmeter

Potentiometer

On

/

Off

Wiring Diagram:

7 U

I/O addressing spreadsheet:

C1 Ground w/ LED

X1 X1 X2 X2 X3 X3 X4 X4 V1

Y1 Y1 Y2 Y2 Y3 Y3 Y4 Y4 CO

AD1V Potentiometer

AD1I AD2V AD2I ACOM Voltmeter

DA1V Voltmeter DA1I

DA2V DA2I P/S + On/Off +

P/S - LED Ground P/S + Potentiometer

P/S + X1-X4 +

Instructions & Steps:

a) Select proper drill bit in order to mount Click PLC, Input/Output box to cutting board with #8

screws. Drill bit is 9/16th of an inch.

b) Utilize the rubber plug for the electrical input to measure how large the drill bit should be in

order to drill the hole into the input / output box for the power supply.

c) Drill in two large holes at the top of the PLC to feed the input, output, voltmeter,

potentiometer and grounding wires through.

d) After mounting the sticker on top of the input and output box, cut holes for the x and y inputs

and then mount the X1-X4 (buttons and toggle switches), the Y1-Y4 (the LED lights), the power

supply (toggle switch), the voltmeter and the potentiometer to the input and output box.

e) Solder the positive end of the power supply switch to one side of X1-X4 (there are no

negatives on the X1-X4 inputs). Complete the circuit by connecting the solder to the positive end of the

potentiometer.

f) Connect the negative end of the potentiometer to the grounded side of the Y1-Y4 inputs. This

is done by soldering the potentiometer end and then daisy chaining the other wires utilizing a screw bit

fastening found on the LEDs.

g) Connect a master wire with 4 wires (black, white, green and red) to the positive side of the

Y1-Y4 LED lights. The ends of the wires are stripped and screw-fastened.

h) Solder a second mater wire to the positive end of the X1-X4 toggle switches and buttons. The

wires are stripped and soldered. Just like the master wire connecting Y1-Y4, the wire connecting X1 is

black, the wire connecting X2 is white, the wire connecting X3 is green and the wire connecting X4 is

read.

i) Utilizing a third master wire containing a white and red wire, strip the white wire and solder it

to the positive terminal of the potentiometer. The red wire will be soldered to the middle of the

potentiometer and wire all of the way through to AD1V.

j) Utilize a fourth master wire also containing a white and red wire. The white wire will be

stripped, crimped and fastened to the DA1V end of the voltage meter (facing the voltmeter, the bottom-

right nut). The red wire will be stripped, crimped as fastened to the ACOM end of the voltage meter

(facing the voltmeter, the bottom-left nut).

Additional troubleshooting: k) Solder forgotten resistor to middle potentiometer output headed to AD1V

l) Drill hole in top right corner of enclosure to feed all wires through in order to provide greater

organization of PLC wiring

j) Re-solder positive potentiometer terminal hooking up to V1 and positive power supply.

Pictures: