Whatisaplc

1 - 8 0 0 - 6 3 3 - 0 4 0 5eCS-2 Control Systems OverviewVolume 13

What is a Programmable Controller?What are programmablecontrollers and how dothey work?Programmable controllers are oftendefined as miniature industrial computersthat contain hardware and software usedto perform control functions. A controllerconsists of two basic sections: the centralprocessing unit (CPU) and the input/outputinterface system. The CPU, which controlsall system activity, can further be brokendown into the processor and memorysystem. The input/output system is physi-cally connected to field devices (e.g.,switches, sensors, etc.) and provides theinterface between the CPU and the infor-mation providers (inputs) and controllabledevices (outputs).

To operate, the CPU “reads” input datafrom connected field devices through theuse of its input interfaces, and then“executes” or performs the controlprogram that has been stored in itsmemory system. Programs are typicallycreated in ladder logic, a language thatclosely resembles a relay-based wiringschematic, and are entered into the CPU’smemory prior to operation. Finally, basedon the program, the PLC “writes” orupdates output devices via the outputinterfaces. This process, also known asscanning, typically continues in the samesequence without interruption, andchanges only when a change is made tothe control program.

Discrete applicationsProgrammable controllers are often usedto control machines or processes that aresequential in nature, using “discrete”inputs and outputs that have definedstates. For example, if a limit switch detectsthe presence of an object, it provides an“ON” signal to the PLC; if no object isdetected, it provides an “OFF” signal. Themachine or device typically performsactions based on time or events in a pre-defined order. The expected sequence istypically interrupted only when anabnormal condition occurs.

Process control applicationsProgrammable controllers can also controlcontinuous processes that use analog I/O.For example, a temperature sensor mayprovide a variable signal, such as 0-10volts, based on the measurement of anactual temperature. The controllerprogram monitors the sensed valuescontinuously and operates devices thatmay also be analog in nature. This couldinclude setting the position of a valvebetween 0-100% open, or controlling thespeed of a motor. Continuous applicationsare so called because they typically haveno defined start or end once they are initi-ated; they maintain a process in a “steady”operating state.

Today’s controllersInitially, devices that exhibited the attrib-utes discussed here were known asProgrammable Logic Controllers (PLCs).This tended to emphasize that the mainfunctionality of these systems was LOGICoperations. As technology has advanced,so have programming languages andcommunications capabilities, along withmany other important features. Thesedevelopments seemed to demand the defi-nition of a new class of controller, theProgrammable Automation Controller(PAC), which combines features of tradi-tional PLCs with those of personalcomputers.

In the past, size was typically used to cate-gorize controllers, and was often an indi-cation of the features and types ofapplications it would accommodate.Small, non-modular PLCs (also known asfixed I/O PLCs) generally have lessmemory and accommodate a smallnumber of inputs and outputs in fixedconfigurations. Modular PLCs have basesor racks that allow installation of multipleI/O modules, and will accommodatemore complex applications. With theemergence of PACs, functionality is thedetermining factor in categorizingcontrollers.

Which programmablecontroller is right for you?Choosing the most effective controller foryour application depends on a number offactors. To begin the selection process, adrawing of the machine or process is agood start. This can help identify fielddevices and physical requirements forhardware locations. From the drawing, youcan determine how many analog and/ordiscrete devices you will have.

Once the field device requirements andhardware locations are defined, you canreview controllers that will meet yourrequirements. See the Controller SelectionWorksheet in this section that will help youwork through the considerations for deter-mining the type of controller you will need,regardless of which manufacturers you areevaluating.

CompanyInformation

SystemsOverview

ProgrammableControllers

Field I/O

Software

C-more & other HMI

Drives

SoftStarters

Motors &Gearbox

Steppers/Servos

Motor Controls

ProximitySensors

Photo Sensors

Limit Switches

Encoders

CurrentSensors

PressureSensors

TemperatureSensors

Pushbuttons/Lights

Process

Relays/Timers

Comm.

TerminalBlocks & Wiring

Power

CircuitProtection

Enclosures

Tools

Pneumatics

Appendix

ProductIndex

Part #Index

w w w . a u t o m a t i o n d i r e c t . c o m Control Systems Overview eCS-3

The most common control systems todayare the Programmable Logic Controller(PLC), PC-based control, and the mostrecent addition, the ProgrammableAutomation Controller (PAC). While theyeach share a few attributes with the oth-ers, their differences lie mainly in formfactor and functionality.

Programmable Logic ControllerThe Farlex Dictionary defines a PLC

as follows: “A programmable micro-processor-based device that is used indiscrete manufacturing to control assem-bly lines and machinery on the shop flooras well as many other types of mechani-cal, electrical and electronic equipmentin a plant. Typically RISC based and programmed in a specific-purpose programming language, a PLC isdesigned for realtime use in rugged,industrial environments. Connected tosensors and actuators, PLCs are categorized by the number and type ofI/O ports they provide and by their I/Oscan rate.”

PLCs excel at sequential logic and basicanalog control. Their modularity andruggedness make them suitable for awide variety of automation applications.

PC-based ControlWith Personal Computer technologybooming in the 1980s and 1990s, therewas a natural progression to considerusing the processing power in these unitsto solve more complicated applicationsthat extended well beyond the realm ofdigital and analog I/O manipulation.These more advanced capabilites couldbe performed far more efficiently byhardware and software native to thecommercial personal computer.Examples of these requirements include:

• The need for a Human Machine Interface (HMI) as well as control

• Advanced data manipulation andadvanced math functions

• Data exchange with business applications (spreadsheets, ERP systems)

• One or more third-party PC cards, suchas those for motion control or visionsystems

• Communication with serial or networked field devices

• Storage or access to large amounts of data

• Large number of PID loops (64 or more)• Open architecture for C/C++ or

VisualBasic systems• Online productivity tools to analyze and

improve performance of the process

In a PC-based control system, a stan-dard operating system such as WindowsNT supports HMI and control softwarerunning on a PC platform, either a

readily available commerical model or anindustrially hardened unit. PC architectureallows the system to seamlessly support avariety of third-party I/O, specialty motionand vision systems, and field networks.

Programmable Automation Controller A programmable automation controller isa compact controller that combines thefeatures and capabilities of a PC-basedcontrol system with that of a typical pro-grammable logic controller (PLC).

This hybrid arose not only to solve complex applications with the speed andprocessing power of a PC-based system,but to do it on a platform capable ofwithstanding the environmental poundingthat PLCs have been subjected to formany years.

Ideally, a PAC encompasses the followingfeatures:

PLC Feel• Modular footprint

• Industrial reliability

• Wide array of I/O modulesand system configurations

PC Power• Large memory and

fast processing

• High-level data handling and enterprise connectivity

• Extensive communications capability, multiple protocols and

field networks

PACs are most often used for advanced machine control, process control, data acquisition and equipmentmonitoring.

Although each PAC vendor uses theirown development environment (IDE) and programming language, PAC networkingis typically based on IP and Ethernet.

This class of controller provides more mem-ory capacity and processing power whichallows for better data processing capabili-ties, and connectivity to enterprise businesssystems from the plant floor.

Additionally, PACs offer the benefit ofeasy integration for multi-domain systems comprising Human MachineInterface (HMI), discrete control andprocess control.

PLC vs. PAC vs. PC-based Control

Volume 13


Considerations for Choosing a Controller

Consideration Information to Record Why this is important

1.Proposed System ____ New system

_____ Existing system

Determine whether your system is new or existing: Will your system be installed from scratch or are there existing products alreadyinstalled? The rest of your system will need to be compatible withnew components.

Why this is important: Certain controller products may not becompatible with others. Making sure your existing products arecompatible with any new products you are researching will saveyou time and money. Check appropriate entry.

2.EnvironmentalIssues

____Codes/environmentalissues to consider

____ No codes orenvironmentalissues to con-sider

Consider any environmental issues that will affect your application(temperature, dust, vibration, codes specific to your facility, etc.).

Why this is important: Certain environments may affect the opera-tion of a controller. For example, typical controllers have an oper-ating temperature of 0-55 degrees Celsius (32-130 degrees F). Ifyour application will include any extreme environmental condi-tions, or you have specific codes at your facility that must be met,you will need to either research products that meet those specifi-cations or design the installation to meet requirements. Checkappropriate entry.

3.Discrete Devices

_____ Total inputs:

_____ AC

_____ DC

_____ Total outputs:

_____ AC

_____ DC

Determine how many discrete devices your system will have. Whichtypes (AC, DC, etc.) are needed?

Why this is important: The number and type of devices your systemwill include is directly linked to the amount of I/O that will benecessary for your system. You will need to choose a controllerthat supports your I/O count requirements and has modules thatsupport your signal types.Enter quantities and type based on corre-sponding field devices.

4.Analog Devices

_____ Total inputs:

____ Voltage

____ Current

____ Thermo

____ RTD

_____ Total outputs:

____ Voltage

____ Current

Determine how many analog devices your system will have. Which types (voltage, current, temperature, etc.) are needed?

Why this is important: The number and type of devices your systemwill include is directly linked to the amount of I/O that will benecessary for your system. You will need to choose a controller thatsupports your I/O count requirements and has modules thatsupport your signal types. Enter quantities and type based on corre-sponding field devices.

5.SpecialtyModules orFeatures(application-specific)

_____ High speed counter

_____ Positioning

_____ Servo/stepper

_____ BASIC programming

_____ Real-time clock

_____ Others (list)

Determine whether your system will require any specialty features: Will your application require high-speed counting or positioning?What about a real-time clock or other specialty feature?

Why this is important: Specialty functions are not necessarily avail-able in a controller CPU or in standard I/O modules.Understanding the special functions your system may perform willhelp you determine whether or not you will need to purchase addi-tional specialty modules. Check all features required.

Use the worksheet on the following pages as a checklist of the things to consider when determiningprogrammable controller requirements. It lists the most important areas to consider when choosinga system, and provides space for recording determinations of your system needs.

Table continued on the following page

CompanyInformation

SystemsOverview


Field I/O

Software

C-more & other HMI

Drives

SoftStarters

Motors &Gearbox

Steppers/Servos

Motor Controls

ProximitySensors

Photo Sensors

Limit Switches

Encoders

CurrentSensors

PressureSensors

TemperatureSensors

Pushbuttons/Lights

Process

Relays/Timers

Comm.


Power

CircuitProtection

Enclosures

Tools

Pneumatics

Appendix

ProductIndex

Part #Index

w w w . a u t o m a t i o n d i r e c t . c o m Control Systems Overview eCS-5

Considerations for Choosing a Controller

Consideration Information to Record Why this is important

6. CPU Required

Hardware requirements:

________ K program memory required (estimated)

________ K data memory required (estimated)

______ Fast scan time required?

______ Battery backup required?

Software/special functionrequirements:

____ PID

____ Floating Point Math

Others (see Programming section below)

Determine the type of CPU you will need: How much memory will yoursystem require? How many devices will your system have (determines datamemory)? How large is your program, and what types of instructions will yourprogram include (determines program memory)? How fast a scan time doyou need?

Why this is important: Data memory refers to the amount of memory neededfor dynamic data manipulation and storage in the system. For example,counter and timer instructions typically use data memory to store setpoints,current values, and other internal flags. If the application requires historicaldata retention, such as measured device values over a long period of time,the size of the data tables required may determine the CPU model youchoose. Program memory is the amount of memory needed to store thesequence of program instructions that have been selected to perform theapplication. Each type of instruction requires a specific amount of programmemory, typically defined in a programming manual. Applications that arebasically sequential in nature can rely on the I/O device rule of thumb to esti-mate program memory (five words of memory for each I/O device); complexapplications will be more difficult to judge.

If scan time is important in your application, consider the CPU processorspeed as well as instruction execution speed. Some CPUs are faster atboolean logic but slower with data handling instructions.

If special functions such as PID are required, the CPU you select may makethose functions easier to perform. For program memory required, follow this rule of thumb: 5 words of pro-gram memory for each discrete device and 25 words for each analogdevice. Check or calculate all requirements that apply.

7. I/O Locations

_______Local . . . only

_______ Remote Locations

Specific remote I/O protocolrequired? Which one?

____________________

Determine where your I/O will be located: Will your system require onlylocal I/O, or both local and remote I/O locations?

Why this is important: If subsystems will be needed at long distances fromthe CPU, you will need a controller that supports remote I/O. You will alsohave to determine if the remote distances and speeds supported will beadequate for your application. Serial and Ethernet-based I/O hardwareare two typical choices available for most systems. This I/O may also bereferred to as distributed I/O, and may require a particular protocol, suchas Modbus.Enter number of physical locations needed, and if/what specific protocolmay be required.

8.Commuications

_____ Ethernet

_____ PLC to PLC

_____ Modbus RTU

_____ ASCII (interface to serial devices)

_____ Other

Determine your communication requirements: Will your system be communicating to other networks, systems or field devices?

Why this is important: Communication ports (other than the programmingport) are not always included with a controller. Knowing your systemcommunication requirements will help you choose a CPU that supportsyour communication requirements, or additional communication modulesif necessary. Check any/all communications functions required.

9.Programming

_____Floatingpoint math

_____Drumsequencer

_____ PID loops

_____ number of loops needed

_____ Subroutines

_____ Direct interrupts

_____ Others (list)

Determine your programming requirements: Does your application requireonly traditional programming instructions, or are special instructions neces-sary?

Why this is important: Certain controllers may not support every type of instruc-tion. You will need to choose a model that supports all instructions that youmay need for a specific application. For example, built-in PID functions aremuch easier to use than writing your own code to perform closed-loopprocess control. Typical instructions such as timers, counters, etc. are availablein most controllers; note any other special instructions required here. Checkany/all programming functions required.


Programmable Controller SummaryThose making the buying decisions for Programmable Controllerapplications can have very different needs. Our goal is to offer a selection of controller families that best fit your specific applicationneeds. Regardless if you are a newcomer to programmable

controllers or if you are a seasoned veteran; whether you needsimple discrete control or if you need to calculate complex algorithms lightning fast, we have a controller family that is perfectfor you.

CLICKOur best value PLC

The CLICK PLC is rapidly becomingone of the industry's favorite controlsystems in the 142 I/O or less category.

Get standard PLC features (discreteand analog) in a compact yet expand-able design. The FREE software offersan extremely easy to use programmingexperience with powerful featurescommonly found in programs costingseveral hundred dollars.

• Select from a variety of Stand-alone CPU combinations with AC / DC / Relay & Analog I/O available

• Built-in communications ports (two in the Basic CPUs, three in the Analog CPUs)

• Eleven stackable, discrete I/O modules• 21 Intuitive and easy to use instructions• 8000 step program memory• Store your program and ladder

documentation in the CPU• PLCs start at $69.00 (stand-alone, DC

powered CPU with 8DC in & 6DC out)

FREE SOFTWARE

DirectLOGICThe most practical PLCs

DirectLOGIC PLCs (nano fixed I/O tomodular units) are industry workhorses,time-tested in some of the toughest indus-trial settings. Installed in thousands ofapplications, their wide range of I/O andcommunication options ensure you’vegot the tools you need to do the job.

From simple machine sequencing toprocess control, you will find a qualityprogrammable controller to suit yourapplication at a fraction of the priceyou'd normally expect to pay.

• 6 PLC platforms to chose from within the DirectLOGIC family

• DL05 stand-alone brick PLC with one available option slot (30 I/O max)

• DL06 stand-alone brick PLC with 4 available option slots (100 I/O max)

• DL105 stand-alone brick PLC with high amp relays (18 I/O max)

• DL205 powerful modular PLC with the most available option modules (up to 16,384 I/O max)

• DL305 time tested, legacy control platform (up to 368 I/O max)

• DL405 time tested, legacy control platform (up to 16,384 I/O max)

FREE SOFTWARE*

Productivity3000PAC features

for a PLC priceThe Productivity 3000 shatters theprice per feature paradigm in everycategory.

Once again, AutomationDirect chal-lenges the status quo to remain the#1 Value in Automation, with pricesthat can't be beat and a two-yearwarranty on all modules.

• Auto discovery of hardware, including remote I/O bases & GSDrives when connected to the Ethernet remote I/O network

• Tag name database programming • Task management • Advanced “fill-in-the-blank” instructions • Seamless Corporate Database

connectivity• Run-time Editing and project transfer• Project file, tag database and ladder

documentation stored in the CPU• Much more

FREE SOFTWARE

*100 word limited version. Full version cost is $395.00

CompanyInformation

SystemsOverview


Field I/O

Software

C-more & other HMI

Drives

SoftStarters

Motors &Gearbox

Steppers/Servos

Motor Controls

ProximitySensors

Photo Sensors

Limit Switches

Encoders

CurrentSensors

PressureSensors

TemperatureSensors

Pushbuttons/Lights

Process

Relays/Timers

Comm.


Power

CircuitProtection

Enclosures

Tools

Pneumatics

Appendix

ProductIndex

Part #Index

w w w . a u t o m a t i o n d i r e c t . c o m Control Systems Overview eCS-7Volume 13

Cost-effective I/O simplifies hydroelectricplant controls upgradeLockhart Power Company owns and operates a hydroelectric plant located onthe Broad River in upstate South Carolina.

The plant includes an 8-gate dam feedinga canal that channels the water flow to thepowerhouse. The powerhouse containsfive turbine generators with a combinedpower capacity of over 17 MW. The damand turbine control system receives datafrom power, flow, and level sensingdevices to perform monitoring and controlof the dam, generators, and associatedequipment.

Lockhart Power contracted North ForkElectric in Crumpler, NC, to lend theirexpertise to a renovation of the conrtolsystem.

The system consists of seven DirectLOGICDL205 micro-modular PLCs with built inPID functionality. Each of the five systemsfor generator control includes discrete andanalog I/O, and an Ethernet communica-tions module. The remaining two PLCs areconfigured in a master/slave arrangementand control the dam gates, located upriv-er from the powerhouse, via radiomodems. Operator interfaces include two6-inch color touch screen panels and aWindows NT-based PC running theLookoutDirect SCADA/HMI softwarepackage.

In the automatic mode, the PLC can start,stop, and operate the generator, and control startup and synchronization of theturbine. Changing the generator gateposition varies the flow of water to theturbine.

The dam control system controls the eightcanal gates located at the dam, whichregulate the flow of water downstream tothe turbines.

Semi cab sheetingproduction improved ITS, a design build firm in Columbus, Ohiospecializes in industrial automation. Thecompany was contacted by a division ofInternational Harvester responsible for themanufacturing of semi cabs. InternationalHarvester uses automated machines toplace aluminum rivets on sheeting that isattached to the frame of the semi cabs. Theoriginal CNC machines were becomingantiquated and needed to be upgraded.

ITS chose a DL205 PLC as the new con-troller for the machines, along with discreteI/O and an H2-CTRIO high-speed countermodule that drives a dual axis servo. An H2-ECOM Ethernet Communications card linksthe machines back to an office for dataacquisition. ITS also added a 15-inch touchscreen for diagnostics.

In the new system, an operator stampssheets of aluminum to welded frameworkwith a handful of hand rivets and thenplaces the product onto a dual axis servotable. After the operator selects one of fivedifferent parts programs, the machine willnavigate the panel under the head assem-bly, which is responsible for the drilling andriveting, with a tolerance of 1/10 of a millimeter. The panel is drilled and a rivet isinstalled and squeezed to approximately1200 PSI, producing a rivet consistencywithin .003 in. After completion of the panel(between 64 and 138 rivet locations), themachine will return to its home position andawait the next product.

The solution increased productivity byapproximately 30% and provides an easyway to run and maintain the machines.

DL06 PLC puts heaters tothe testPyromatics Automation Systems of CrystalLake, Il. was contracted by a customer todevelop a Life Cycle Test Station for its electric heating elements.

This test station needed a user-friendlygraphical interface to give operators theability to select multiple ramp/soak parame-ters, output voltages, temperature sensortypes, amperage ratings and total cyclecounts on tests for the cast-in electric heaterplatens. The system also needed to recordtemperature, volts, and current drawthroughout the test for use in quality reports.Also, a failure of the heater required a safeshutdown of the test while alerting the qual-ity department of the alarm condition.

Pyromatics selected the cost-effectiveDirectLOGIC® DL06 PLC as the heart ofthe system because of its ability to control upto eight PID loops and the multiple expan-sion slots available for thermocouple cardsand analog input modules. It also controlstwo heaters, two chillers and an array ofpanel indicators, buttons, switches andrelays.

A C-more 10-inch TFT touch-screen opera-tor interface was used to provide operatorswith the necessary interface to operate andmonitor the tests.

The completed system allows users to quick-ly connect the heater to be tested, enter testparameters, and run the test. Trend chartson the C-more panel track test parametersand quickly identify potential issues such assudden drops in current or temperature.

Alarm reporting and history are also auto-matically recorded, allowing the operator todetermine causes of failure. Data from thetest can be easily uploaded to a USB thumbdrive from the C-more panel. The data canthen be imported into the user’s choice ofword processor or spreadsheet.

Application Briefs

http://www.automationdirect.com/pn/H2-CTRIO


Programmable Controller OverviewCLICK: Brick PLC with expandableI/O and easy-to-use instructionsThe CLICK series is a fixed I/O PLC with eight inputs and six outputs, with up to eight expansion I/O modules, and features you won’t find in most bricks — seven combinationsof AC, DC, relay and analog I/O, and advanced programming functions such as drumsequencing.

• 8 discrete inputs and 6 discrete outputs for discrete units

• 4 discrete inputs / 4 discrete outputs / 2 analog inputs / 2 analog outputs for analog units

• 8 K program / 8 K data memory• Two built-in communication ports• 21 instructions• Removable terminal block• 24 VDC powered

DL05: Offers incredible featureswith an expansion slotThe DL05 series is a fixed I/O PLC with eight inputs and six outputs with one optioncard slot, and features you won’t find in most bricks — six I/O combinations of AC,DC and relay I/O, and advanced programming functions such as PID.

DL105:Fixed-I/O Micro PLCThe DL105 series is a fixed-I/O micro PLC with 10 inputs and eight outputs. Eightconfigurations are available in combinations of AC, DC and relay I/O.

• Eight inputs and six outputs• 2 K program memory• 4 K data memory• Two built-in communication ports• Over 250 instructions, including four

PID loops• Removable terminal block• 12/24 VDC powered versions• Discrete and analog I/O modules

• Thermocouple and RTD modules • Ethernet and serial communications

modules• 1-channel high-speed

input/pulse output module • Memory cartridge/real-time

clock module• DeviceNet™ / Profibus slave modules• Basic CoProcessor module

• 10 inputs and eight outputs• 2 K program memory• 384 words data memory• 110/220 VAC or 24 VDC power

supply versions• Built-in 0.5A, 24 VDC

auxiliary power supply

• One RS-232 communication port• Heavy-duty seven amp relays with

built-in surge suppression on models with relay outputs

DL06: Mighty micro PLC with 36 I/O and four expansion slotsThe DL06 series combines its fixed I/O of 20 inputs and 16 outputs with fouroption card slots for expansion all in the same package. With the DL06, you canuse the same PLC panel layout for all applications from 36 to 100 I/O.

• 20 inputs and 16 outputs• 7.5 K program memory• 7.3 K data memory• Two built-in communication

ports - one RS232 and oneRS232/422/485 port

• Over 275 instructions, includingeight PID loops and ASCII

• Removable terminal blocks• Built-in 300 mA 24 VDC

auxiliary power supply

• 12/24 VDC powered versions• Built-in real-time clock/calendar• Discrete and analog I/O modules • Thermocouple and RTD modules • Ethernet and serial communications

modules• High speed input/pulse output module• DeviceNet™ and Profibus slave

modules• Basic CoProcessor module• Optional plug-in LCD display

starts on page 2-1

starts on page 2-1

starts on page 3-1

starts on page 1-1

CompanyInformation

SystemsOverview


Field I/O

Software

C-more & other HMI

Drives

SoftStarters

Motors &Gearbox

Steppers/Servos

Motor Controls

ProximitySensors

Photo Sensors

Limit Switches

Encoders

CurrentSensors

PressureSensors

TemperatureSensors

Pushbuttons/Lights

Process

Relays/Timers

Comm.


Power

CircuitProtection

Enclosures

Tools

Pneumatics

Appendix

ProductIndex

Part #Index


DL205: The most practical micro-modular PLC with a wide range of I/O and communications modules

• Four CPUs, up to 30.4K memory and 16,384 I/O• Four base sizes available• 16 buit-in PID loops using D2-260 CPU• AC/DC input/output modules• Up to 10 A relay outputs• 12-bit and 16-bit analog I/O modules• Thermocouple and RTD input modules• Ethernet and serial communications modules

• Ethernet and serial remote I/O• High-speed counter/pulse

output module• Counter input/pulse output module• Basic CoProcessor module• Ethernet, DeviceNet™ and Profibus slave

controller modules• Triple port serial module for WinPLCs and EBCs

• Three CPUs, up to 30.8K memory and 16,384 I/O

• Three base sizes with built-in power supply• 16 built-in PID loops (D4-450 CPU),

up to 96 loops using PID modules• AC/DC input/output modules

• 10 A relay outputs• 12-bit and 16-bit analog I/O modules• Thermocouple and RTD input modules• Ethernet and serial communications modules• Ethernet and serial remote I/O master and

slave modules

Programmable Controller Overview

starts on page 4-1

If your application requires the flexibility of a modular system, a DL205 PLC is a lowcost, yet extremely versatile solution.

DL305: We’ve still got it!The DL305 series is a small modular PLC that has been marketed by variousname brand PLC manufacturers for over 27 years. This Koyo design revolution-ized the small PLC market, and you can keep your DL305 system operating withthese compatible components.

• Three CPUs, including the D3-350 with PIDcontrol and two communication ports

• Five, eight and 10 slot bases• 110/220 VAC or 24 VDC power supply

• AC, DC inputs• AC, DC and relay outputs• Analog input/output

DL405: Specialty modules for complex applicationsThe DL405 PLC product line has a wide choice of specialty I/O modules,including high-speed counting, temperature controller, and magnetic pulse input.

starts on page 5-1

• High-performance CPU with 50Mbmemory, fast scan time, and USB& Ethernet programming ports forquick and easy connectivity

• Modular rack-based footprint with36 discrete and analog I/O optionmodules, up to 115,000 I/O

• Hot-Swappable I/O for advancedtroubleshooting and system repair

• Unmatched built-in communicationscapabilities, including local and remoteI/O ports and networking

• Integrated drive communicationsover Ethernet

• System hardware Auto Discovery • Tag name database programming• Advanced “fill-in-the-blank”

instructions starts on page 7-1

Productivity3000 PAC:PAC features at a PLC priceProductivity3000 is a compact controller that combines the features and capabilities of a PC-based control system with that of a typical programmablelogic controller (PLC).

starts on page 6-1

http://www.automationdirect.com/pn/D2-260




Programmable Controller Selection Guide

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Basic CPU 8 In/6 Out 142 142 ✔ ✔ ✔

Standard CPU 8 In/6 Out 142 142 ✔ ✔ ✔ ✔

Analog CPU 4 In/4 Out 2 In/2 Out 140 140 ✔ ✔ ✔ ✔ ✔

All CPUs 8 In/6 Out 30 30 ✔ ✔ ✔ ✔✔

All CPUs 20 In/16 Out 100 100 ✔ ✔ ✔ ✔ ✔

✔

All CPUs 10 In/8 Out n/a 18 ✔ ✔ ✔

D2-230

D2-240

D2-250-1

D2-260

256

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768

1280

256

896

16,384*

16,384*

✔✔✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

D3-330

D3-340

D3-350

176

184

368

176

184

368

✔✔

✔ ✔ ✔

✔

✔

✔ ✔

✔

✔ ✔

✔

✔

D4-430

D4-440

D4-450

640

640

2048

1664

2688

16,384*

✔✔

✔

✔

✔

✔ ✔

✔

✔

✔ ✔

✔

✔

✔ ✔ ✔

P3-550 CPU 3520 116,160 ✔ ✔ ✔ ✔1 ✔ ✔ ✔ ✔ ✔ ✔ ✔

AC, D

C,

Rela

y I/O

Anal

og

In &

OutCo

ntro

ller F

amily

Clic

k PL

C

DL05

DL06

DL10

5DL

205

DL30

5DL

405

Diec

tLog

icPr

oduc

tivity

300

0

* 16384 (fully expanded H4-EBC slave bases, using V-memory & bit of wordinstructions)

1 Scan time is based on type and amount of ladder logic instructions andtotal system I/O

2 Scan times may vary during Run-Time Transfers

Selection Criteria I/O CapacityBasic

MachineControl

ProcessControl

Test &Data

AcquisitionCPU Communications

3 DeviceNet & ProfiBus Slave modules for the DL205 series are installed in place of the CPU in the CPU slot

4 High Speed inputs available on DC input models / Pulse output available on DC output models

http://www.automationdirect.com/pn/D2-250-1










http://www.automationdirect.com/pn/P3-550

http://www.automationdirect.com/pn/H4-EBC

CompanyInformation

SystemsOverview


Field I/O

Software

C-more & other HMI

Drives

SoftStarters

Motors &Gearbox

Steppers/Servos

Motor Controls

ProximitySensors

Photo Sensors

Limit Switches

Encoders

CurrentSensors

PressureSensors

TemperatureSensors

Pushbuttons/Lights

Process

Relays/Timers

Comm.


Power

CircuitProtection

Enclosures

Tools

Pneumatics

Appendix

ProductIndex

Part #Index


Programmable Controller Selection GuideM

odbu

s RT

U M

aste

r

K-Se

quen

ce S

lave

Dire

ctNe

t Sla

ve

Dire

ctNe

t Mas

ter

ASCI

I Out

ASCI

I IN

Ethe

rnet

(10/

100

Mb)

Seria

l RS-

232

& R

S-48

5

Basi

c Co

proc

esso

r

Ethe

rnet

Rem

ote

I/O

Seria

l Rem

ote

I/O

Devi

ceNe

t Sla

ve

Prof

ibus

Sla

ve

Tota

l Mem

ory

Batte

ry B

acke

d M

emor

yCl

ock

/ Cal

enda

r

Stag

e Pr

ogra

mm

ing

Run

Mod

e Ed

its

(Out

puts

pau

se d

urin

g tra

nsfe

r)

Run-

Tim

e Tr

ansf

er

(Sca

n up

date

s du

ring

trans

fer)

Built

-in H

igh

Spee

d Co

unte

r &

Pul

se O

utpu

t

Floa

ting

poin

t Mat

h

Free

form

Exp

ress

ions

in M

ath

Drum

Seq

uenc

er

Emai

l Ins

truct

ion

Sub-

Divi

ded

Prog

ram

Tas

ks

✔ ✔ ✔8k

steps

✔ ✔ ✔ ✔

✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔

✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔

✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ 6.0k ✔ ✔ ✔4 ✔ ✔ ✔

✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ 14.8k ✔ ✔ ✔ ✔4 ✔ ✔ ✔ ✔

✔ 2.4k ✔ ✔ ✔4 ✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔ ✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔3

✔3

✔3

✔3

✔3

✔3

✔3

✔3

2.4k

3.8k

14.8k

30.4k

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔ ✔

✔

✔

✔

✔

✔ ✔ ✔

3.8k

3.9k

14.8k ✔ ✔ ✔ ✔ ✔

✔

✔

✔

✔

✔

✔

✔ ✔ ✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

6.5k

22.5k

30.8k

✔

✔

✔

✔

✔

✔

✔

✔

✔ ✔ ✔

✔

✔ ✔

✔ ✔ ✔ ✔ 50Mb ✔ ✔2 ✔ ✔ ✔ ✔ ✔

Ports & Protocols Communications andSpecialty Modues Programmability


Get The Training You Need, When And Where You Need It

“Introduction to PLC Logic andPrinciples” video or DVD andtraining kitGet the most important lessons from thethree-day basic PLC seminar in a step-by-step two-video or DVD set.

“PLC analog I/O” training videoor DVD and hardwareLearn the ins and outs of using analog I/Owith PLCs in this step-by-step training set.

Check the Appendix for complete descrip-tions of the training kits and course contents.

Online training at www.interconnectingautomation.comView the complete list of videos in each "library" as well as watch sample videos;when ready to purchase, register and pay for your selected libraries on a monthlybasis. Get unlimited access anytime during the 30 days; videos can be viewed asmany times as needed. Most libraries range from $29.95 - $39.95 per month. Typical libraries include:

• Introduction to PLC Principles (for the novice non-user with limited controls knowledge)

• CLICK series PLC Training (includes Introduction to PLCs library)• Productivity3000 series Controller Training

Libraries will be added on a continuing basis.

Doug Bell andInterConnectingAutomation, Inc.Interested in a PLC or drives training coursefocused entirely on AUTOMATIONDIRECT’s prod-ucts, taught by someone who has used most of ourproducts in real-world applications? Would it beextra convenient if the training was held in a citynear you? We thought so! Doug’s offeringincludes:

• Basic PLC training course (three days) covering basic PLC theory of operation including CPU, bases, discrete I/O, analog I/O, and communications

• Advanced PLC training course (three days) covering advanced programming and debugging, with remote I/O, networking,modems and more

• PID training course (two days) covering PIDloop setup, tuning and troubleshooting, as wellas shortcuts and tools the experts use

Check Appendix for a complete schedule ofclasses for 2010-11 in cities across the U.S.

Training setsAvailable on DVD and in SpanishWant to learn how to program our PLCs in thecomfort of your own office? Doug Bell hascreated two hands-on training kits, one basedon his world-famous basic PLC training class,the other focusing on PLC analog principles.The basic PLC training kit includes two video-tapes or one DVD, a pre-wired trainercontaining a DL05 PLC, and the DL05 UserManual.

The analog training kit includes two videotapesor one DVD, a pre-wired trainer with poten-tiometers and meters, a DL05 analoginput/output module, I/O cable and 24 VDCpower supply. Each kit can be ordered directlyfrom ICA.

(DirectSOFT programming software must bepurchased separately.)

Online trainingIf you can’t travel and can’t justify a training kit, howabout inexpensive online training? Check outDoug’s online training videos for PLCs and HMI.

Interconnecting Automation

1-414-425-8348

www.interconnectingautomation.com

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