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  1. 1. 1 - 8 0 0 - 6 3 3 - 0 4 0 5eCS-2 Control Systems OverviewVolume 13What 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 controlapplicationsProgrammable 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.
  2. 2. CompanyInformationSystemsOverviewProgrammableControllersField I/OSoftwareC-more &other HMIDrivesSoftStartersMotors &GearboxSteppers/ServosMotorControlsProximitySensorsPhotoSensorsLimitSwitchesEncodersCurrentSensorsPressureSensorsTemperatureSensorsPushbuttons/LightsProcessRelays/TimersComm.TerminalBlocks &WiringPowerCircuitProtectionEnclosuresToolsPneumaticsAppendixProductIndexPart #Indexw 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-3The 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 PLCas 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 andprogrammed in a specific-purposeprogramming language, a PLC isdesigned for realtime use in rugged,industrial environments. Connected tosensors and actuators, PLCs arecategorized 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 MachineInterface (HMI) as well as control• Advanced data manipulation andadvanced math functions• Data exchange with businessapplications (spreadsheets,ERP systems)• One or more third-party PC cards, suchas those for motion control or visionsystems• Communication with serial ornetworked field devices• Storage or access to large amounts ofdata• Large number of PID loops (64 or more)• Open architecture for C/C++ orVisualBasic systems• Online productivity tools to analyze andimprove performance of the processIn a PC-based control system, a stan-dard operating system such as WindowsNT supports HMI and control softwarerunning on a PC platform, either areadily 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 ControllerA 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 solvecomplex 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 configurationsPC Power• Large memory andfast processing• High-level data handlingand enterprise connectivity• Extensive communicationscapability, multiple protocols andfield networksPACs are most often used foradvanced machine control, processcontrol, data acquisition and equipmentmonitoring.Although each PAC vendor uses theirown development environment (IDE) andprogramming 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-domainsystems comprising Human MachineInterface (HMI), discrete control andprocess control.PLC vs. PAC vs. PC-based ControlVolume 13
  3. 3. 1 - 8 0 0 - 6 3 3 - 0 4 0 5eCS-4 Control Systems OverviewVolume 13Considerations for Choosing a ControllerConsideration Information to Record Why this is important1.Proposed System ____ New system_____ ExistingsystemDetermine whether your system is new or existing: Will your systembe 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-siderConsider 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_____ DCDetermine 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____ CurrentDetermine 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
  4. 4. CompanyInformationSystemsOverviewProgrammableControllersField I/OSoftwareC-more &other HMIDrivesSoftStartersMotors &GearboxSteppers/ServosMotorControlsProximitySensorsPhotoSensorsLimitSwitchesEncodersCurrentSensorsPressureSensorsTemperatureSensorsPushbuttons/LightsProcessRelays/TimersComm.TerminalBlocks &WiringPowerCircuitProtectionEnclosuresToolsPneumaticsAppendixProductIndexPart #Indexw 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-5Considerations for Choosing a ControllerConsideration Information to Record Why this is important6.CPU RequiredHardware requirements:________ K program memory required(estimated)________ K data memory required(estimated)______ Fast scan time required?______ Battery backup required?Software/special functionrequirements:____ PID____ Floating Point MathOthers (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 LocationsSpecific 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)_____ OtherDetermine your communication requirements: Will your systembe 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.
  5. 5. 1 - 8 0 0 - 6 3 3 - 0 4 0 5eCS-6 Control Systems OverviewVolume 13Programmable Controller SummaryThose making the buying decisions for Programmable Controllerapplications can have very different needs. Our goal is to offer aselection of controller families that best fit your specific applicationneeds. Regardless if you are a newcomer to programmablecontrollers or if you are a seasoned veteran; whether you needsimple discrete control or if you need to calculate complexalgorithms lightning fast, we have a controller family that is perfectfor you.CLICKOur best value PLCThe CLICK PLC is rapidly becomingone of the industrys 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-aloneCPU combinations with AC / DC / Relay& Analog I/O available• Built-in communications ports(two in the Basic CPUs, three in theAnalog CPUs)• Eleven stackable, discrete I/O modules• 21 Intuitive and easy to use instructions• 8000 step program memory• Store your program and ladderdocumentation in the CPU• PLCs start at $69.00 (stand-alone, DCpowered CPU with 8DC in & 6DC out)FREE SOFTWAREDirectLOGICThe most practical PLCsDirectLOGIC 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 priceyoud normally expect to pay.• 6 PLC platforms to chose from within theDirectLOGIC family• DL05 stand-alone brick PLC with oneavailable option slot (30 I/O max)• DL06 stand-alone brick PLC with 4available option slots (100 I/O max)• DL105 stand-alone brick PLC with highamp relays (18 I/O max)• DL205 powerful modular PLC with themost available option modules(up to 16,384 I/O max)• DL305 time tested, legacy controlplatform (up to 368 I/O max)• DL405 time tested, legacy controlplatform (up to 16,384 I/O max)FREE SOFTWARE*Productivity3000PAC featuresfor 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 cant be beat and a two-yearwarranty on all modules.• Auto discovery of hardware, includingremote I/O bases & GSDrives whenconnected to the Ethernet remote I/Onetwork• Tag name database programming• Task management• Advanced“fill-in-the-blank”instructions• Seamless Corporate Databaseconnectivity• Run-time Editing and project transfer• Project file, tag database and ladderdocumentation stored in the CPU• Much moreFREE SOFTWARE*100 word limited version. Full version cost is $395.00
  6. 6. CompanyInformationSystemsOverviewProgrammableControllersField I/OSoftwareC-more &other HMIDrivesSoftStartersMotors &GearboxSteppers/ServosMotorControlsProximitySensorsPhotoSensorsLimitSwitchesEncodersCurrentSensorsPressureSensorsTemperatureSensorsPushbuttons/LightsProcessRelays/TimersComm.TerminalBlocks &WiringPowerCircuitProtectionEnclosuresToolsPneumaticsAppendixProductIndexPart #Indexw 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 13Cost-effective I/Osimplifies hydroelectricplant controls upgradeLockhart Power Company owns andoperates 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, andcontrol 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 improvedITS, 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 amillimeter. 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 itselectric 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
  7. 7. 1 - 8 0 0 - 6 3 3 - 0 4 0 5eCS-8 Control Systems OverviewVolume 13Programmable 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 eightexpansion 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 outputsfor discrete units• 4 discrete inputs / 4 discrete outputs /2 analog inputs / 2 analog outputs foranalog units• 8 K program / 8 K data memory• Two built-in communication ports• 21 instructions• Removable terminal block• 24 VDC poweredDL05: 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 fourPID loops• Removable terminal block• 12/24 VDC powered versions• Discrete and analog I/O modules• Thermocouple and RTD modules• Ethernet and serial communicationsmodules• 1-channel high-speedinput/pulse output module• Memory cartridge/real-timeclock 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 powersupply versions• Built-in 0.5A, 24 VDCauxiliary power supply• One RS-232 communication port• Heavy-duty seven amp relays withbuilt-in surge suppression onmodels with relay outputsDL06: Mighty micro PLCwith 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 communicationports - one RS232 and oneRS232/422/485 port• Over 275 instructions, includingeight PID loops and ASCII• Removable terminal blocks• Built-in 300 mA 24 VDCauxiliary 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 communicationsmodules• High speed input/pulse output module• DeviceNet™ and Profibus slavemodules• Basic CoProcessor module• Optional plug-in LCD displaystarts on page 2-1starts on page 2-1starts on page 3-1starts on page 1-1
  8. 8. CompanyInformationSystemsOverviewProgrammableControllersField I/OSoftwareC-more &other HMIDrivesSoftStartersMotors &GearboxSteppers/ServosMotorControlsProximitySensorsPhotoSensorsLimitSwitchesEncodersCurrentSensorsPressureSensorsTemperatureSensorsPushbuttons/LightsProcessRelays/TimersComm.TerminalBlocks &WiringPowerCircuitProtectionEnclosuresToolsPneumaticsAppendixProductIndexPart #Indexw 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-9Volume 13DL205: The most practical micro-modular PLCwith 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/pulseoutput module• Counter input/pulse output module• Basic CoProcessor module• Ethernet, DeviceNet™ and Profibus slavecontroller modules• Triple port serial module for WinPLCs and EBCs• Three CPUs, up to 30.8K memory and16,384 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 andslave modulesProgrammable Controller Overviewstarts on page 4-1If 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/outputDL405: Specialty modulesfor 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 7-1Productivity3000 PAC:PAC features at a PLC priceProductivity3000 is a compact controller that combines the features andcapabilities of a PC-based control system with that of a typical programmablelogic controller (PLC).starts on page 6-1
  9. 9. 1 - 8 0 0 - 6 3 3 - 0 4 0 5eCS-10 Control Systems OverviewVolume 13Programmable Controller Selection GuideSeries/CPUBuilt-InI/OLocalI/O(withExpansion)TotalPossibleI/ODigitalI/O&SimpleLogicRequirementsStageProgramming(StateMachineControl)AnalogI/O,limitedPID,SimpleMathanddatamanipulation>16PIDloops,ComplexMathformulas&ArrayManipulationSub-millisecondScan,DataLogging&CorporatedatabaseconnectivityBuilt-InEthernet&USBBuilt-InLocalI/OExpansionPortsBuilt-InRemoteI/OBuilt-InRS-232SerialportBuilt-InRS-485Multi-dropportModbusTCPEthernetProtocolModbusRTUSalveBasic 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 CPUs20 In/16 Out100 100 ✔ ✔ ✔ ✔ ✔✔All CPUs10 In/8 Outn/a 18 ✔ ✔ ✔D2-230D2-240D2-250-1D2-260256256768128025689616,384*16,384*✔✔✔✔✔✔✔✔✔✔✔✔✔✔✔✔✔✔✔✔D3-330D3-340D3-350176184368176184368✔✔✔ ✔ ✔✔✔✔ ✔✔✔ ✔✔✔D4-430D4-440D4-45064064020481664268816,384*✔✔✔✔✔✔ ✔✔✔✔ ✔✔✔✔ ✔ ✔P3-550 CPU 3520 116,160 ✔ ✔ ✔ ✔1 ✔ ✔ ✔ ✔ ✔ ✔ ✔AC,DC,RelayI/OAnalogIn&OutControllerFamilyClickPLCDL05DL06DL105DL205DL305DL405DiectLogicProductivity3000* 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/O2 Scan times may vary during Run-Time TransfersSelection Criteria I/O CapacityBasicMachineControlProcessControlTest &DataAcquisitionCPU Communications3 DeviceNet & ProfiBus Slave modules for the DL205 series are installed in place ofthe CPU in the CPU slot4 High Speed inputs available on DC input models / Pulse output available onDC output models
  10. 10. CompanyInformationSystemsOverviewProgrammableControllersField I/OSoftwareC-more &other HMIDrivesSoftStartersMotors &GearboxSteppers/ServosMotorControlsProximitySensorsPhotoSensorsLimitSwitchesEncodersCurrentSensorsPressureSensorsTemperatureSensorsPushbuttons/LightsProcessRelays/TimersComm.TerminalBlocks &WiringPowerCircuitProtectionEnclosuresToolsPneumaticsAppendixProductIndexPart #Indexw 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-11Volume 13Programmable Controller Selection GuideModbusRTUMasterK-SequenceSlaveDirectNetSlaveDirectNetMasterASCIIOutASCIIINEthernet(10/100Mb)SerialRS-232&RS-485BasicCoprocessorEthernetRemoteI/OSerialRemoteI/ODeviceNetSlaveProfibusSlaveTotalMemoryBatteryBackedMemoryClock/CalendarStageProgrammingRunModeEdits(Outputspauseduringtransfer)Run-TimeTransfer(Scanupdatesduringtransfer)Built-inHighSpeedCounter&PulseOutputFloatingpointMathFreeformExpressionsinMathDrumSequencerEmailInstructionSub-DividedProgramTasks✔ ✔ ✔8ksteps✔ ✔ ✔ ✔✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ 6.0k ✔ ✔ ✔4 ✔ ✔ ✔✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ 14.8k ✔ ✔ ✔ ✔4 ✔ ✔ ✔ ✔✔ 2.4k ✔ ✔ ✔4 ✔✔✔✔✔✔✔✔✔✔✔✔✔✔ ✔✔✔✔✔✔✔✔✔✔✔✔✔✔✔✔✔3✔3✔3✔3✔3✔3✔3✔32.4k3.8k14.8k30.4k✔✔✔✔✔✔✔✔✔✔✔✔✔✔✔✔✔✔✔✔ ✔✔✔✔✔✔ ✔ ✔3.8k3.9k14.8k ✔ ✔ ✔ ✔ ✔✔✔✔✔✔✔✔ ✔ ✔✔✔✔✔✔✔✔✔✔✔✔✔✔✔✔6.5k22.5k30.8k✔✔✔✔✔✔✔✔✔ ✔ ✔✔✔ ✔✔ ✔ ✔ ✔ 50Mb ✔ ✔2 ✔ ✔ ✔ ✔ ✔Ports & ProtocolsCommunications andSpecialty ModuesProgrammability
  11. 11. 1 - 8 0 0 - 6 3 3 - 0 4 0 5eCS-12 Control Systems OverviewVolume 13Get 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 limitedcontrols knowledge)• CLICK series PLC Training (includes Introduction to PLCs library)• Productivity3000 series Controller TrainingLibraries 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 operationincluding CPU, bases, discrete I/O,analog I/O, and communications• Advanced PLC training course (three days)covering advanced programming anddebugging, 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 useCheck Appendix for a complete schedule ofclasses for 2010-11 in cities across the U.S.Training setsAvailableonDVDandinSpanishWant 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 Automation1-414-425-8348www.interconnectingautomation.com