Check out the Click PLC trainer I assembled for my Industrial Electric Control's class with my Applied Engineering Technology (AAS) program with Colorado Mountain College!

1. 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

2. 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.

3. 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.

4. 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
rr
On
/
Off

5. Wiring Diagram:
7 U

6. 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 +

7. 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.

8. Pictures:

17. Conclusion:
The Click PLC was successfully assembled, able to be programmed
with ladder logic and able to perform closed-loop industrial control
process.