What is a Programmable Controller?

What are programmable Discrete applications Today’s controllers

controllers and how do Programmable controllers are often used Initially, devices that exhibited the attrib-
they work? to control machines or processes that are utes discussed here were known as
sequential in nature, using “discrete” Programmable Logic Controllers (PLCs).
Programmable controllers are often inputs and outputs that have defined This tended to emphasize that the main
defined as miniature industrial computers states. For example, if a limit switch detects functionality of these systems was LOGIC
that contain hardware and software used the presence of an object, it provides an operations. As technology has advanced,
to perform control functions. A controller “ON” signal to the PLC; if no object is so have programming languages and
consists of two basic sections: the central detected, it provides an “OFF” signal. The communications capabilities, along with
processing unit (CPU) and the input/output machine or device typically performs many other important features. These
interface system. The CPU, which controls actions based on time or events in a pre- developments seemed to demand the defi-
all system activity, can further be broken defined order. The expected sequence is nition of a new class of controller, the
down into the processor and memory typically interrupted only when an Programmable Automation Controller
system. The input/output system is physi- abnormal condition occurs. (PAC), which combines features of tradi-
cally connected to field devices (e.g., tional PLCs with those of personal
switches, sensors, etc.) and provides the computers.
interface between the CPU and the infor- Process control
In the past, size was typically used to cate-
mation providers (inputs) and controllable applications gorize controllers, and was often an indi-
devices (outputs).
Programmable controllers can also control cation of the features and types of
To operate, the CPU “reads” input data continuous processes that use analog I/O. applications it would accommodate.
from connected field devices through the For example, a temperature sensor may Small, non-modular PLCs (also known as
use of its input interfaces, and then provide a variable signal, such as 0-10 fixed I/O PLCs) generally have less
“executes” or performs the control volts, based on the measurement of an memory and accommodate a small
program that has been stored in its actual temperature. The controller number of inputs and outputs in fixed
memory system. Programs are typically program monitors the sensed values configurations. Modular PLCs have bases
created in ladder logic, a language that continuously and operates devices that or racks that allow installation of multiple
closely resembles a relay-based wiring may also be analog in nature. This could I/O modules, and will accommodate
schematic, and are entered into the CPU’s include setting the position of a valve more complex applications. With the
memory prior to operation. Finally, based between 0-100% open, or controlling the emergence of PACs, functionality is the
on the program, the PLC “writes” or speed of a motor. Continuous applications determining factor in categorizing
updates output devices via the output are so called because they typically have controllers.
interfaces. This process, also known as no defined start or end once they are initi-
scanning, typically continues in the same ated; they maintain a process in a “steady”
sequence without interruption, and operating state.
Which programmable
changes only when a change is made to controller is right for you?
the control program.
Choosing the most effective controller for
your application depends on a number of
factors. To begin the selection process, a
drawing of the machine or process is a
good start. This can help identify field
devices and physical requirements for
hardware locations. From the drawing, you
can determine how many analog and/or
discrete devices you will have.
Once the field device requirements and
hardware locations are defined, you can
review controllers that will meet your
requirements. See the Controller Selection
Worksheet in this section that will help you
work through the considerations for deter-
mining the type of controller you will need,
regardless of which manufacturers you are
evaluating.

Volume 13
eCS-2 Control Systems Overview 1 - 80 0 - 633 - 0405
PLC vs. PAC vs. PC-based Control Company
Information

Systems
The most common control systems today • Data exchange with business This hybrid arose not only to solve Overview

are the Programmable Logic Controller applications (spreadsheets, complex applications with the speed and Programmable
(PLC), PC-based control, and the most ERP systems) processing power of a PC-based system, Controllers
recent addition, the Programmable • One or more third-party PC cards, such but to do it on a platform capable of
Automation Controller (PAC). While they as those for motion control or vision withstanding the environmental pounding Field I/O
each share a few attributes with the oth- systems that PLCs have been subjected to for
ers, their differences lie mainly in form • Communication with serial or many years. Software
factor and functionality. networked field devices
C-more &
• Storage or access to large amounts of other HMI
Programmable Logic Controller data Ideally, a PAC encompasses the following
The Farlex Dictionary defines a PLC • Large number of PID loops (64 or more) features: Drives
as follows: “A programmable micro- • Open architecture for C/C++ or
processor-based device that is used in VisualBasic systems PLC Feel
Soft
Starters
discrete manufacturing to control assem- • Online productivity tools to analyze and • Modular footprint
bly lines and machinery on the shop floor improve performance of the process Motors &
• Industrial reliability Gearbox
as well as many other types of mechani-
cal, electrical and electronic equipment • Wide array of I/O modules Steppers/
in a plant. Typically RISC based and and system configurations Servos

programmed in a specific-purpose
Motor
programming language, a PLC is PC Power Controls
designed for realtime use in rugged, • Large memory and
Proximity
industrial environments. Connected to fast processing Sensors
sensors and actuators, PLCs are • High-level data handling
categorized by the number and type of and enterprise connectivity Photo
Sensors
I/O ports they provide and by their I/O
• Extensive communications
scan rate.” Limit
capability, multiple protocols and Switches
field networks
Encoders

PACs are most often used for

Current
advanced machine control, process Sensors
control, data acquisition and equipment
monitoring. Pressure
Sensors

In a PC-based control system, a stan- Although each PAC vendor uses their Temperature
Sensors
dard operating system such as Windows own development environment (IDE) and
NT supports HMI and control software programming language, PAC networking Pushbuttons/
running on a PC platform, either a is typically based on IP and Ethernet. Lights
PLCs excel at sequential logic and basic
readily available commerical model or an Process
analog control. Their modularity and This class of controller provides more mem-
industrially hardened unit. PC architecture
ruggedness make them suitable for a ory capacity and processing power which
allows the system to seamlessly support a Relays/
wide variety of automation applications. allows for better data processing capabili- Timers
variety of third-party I/O, specialty motion
and vision systems, and field networks. ties, and connectivity to enterprise business Comm.
PC-based Control systems from the plant floor.
With Personal Computer technology Terminal
booming in the 1980s and 1990s, there Programmable Automation Controller Additionally, PACs offer the benefit of
Blocks &
Wiring
was a natural progression to consider A programmable automation controller is
easy integration for multi-domain
using the processing power in these units a compact controller that combines the
systems comprising Human Machine Power
to solve more complicated applications features and capabilities of a PC-based
control system with that of a typical pro- Interface (HMI), discrete control and Circuit
that extended well beyond the realm of process control. Protection
grammable logic controller (PLC).
digital and analog I/O manipulation.
These more advanced capabilites could Enclosures

be performed far more efficiently by

Tools
hardware and software native to the
commercial personal computer. Pneumatics
Examples of these requirements include:
Appendix

• The need for a Human Machine Product

Interface (HMI) as well as control Index
• Advanced data manipulation and
Part #
advanced math functions Index

Volume 13
w w w. a u to m at i o n d i re c t . c o m Control Systems Overview eCS-3
 Considerations for Choosing a Controller
Use the worksheet on the following pages as a checklist of the things to consider when determining
programmable controller requirements. It lists the most important areas to consider when choosing
a system, and provides space for recording determinations of your system needs.

Consideration Information to Record Why this is important

Determine whether your system is new or existing: Will your system
be installed from scratch or are there existing products already
installed? The rest of your system will need to be compatible with
1. _____ Existing new components.
Proposed System ____ New system system Why this is important: Certain controller products may not be
compatible with others. Making sure your existing products are
compatible with any new products you are researching will save
you time and money. Check appropriate entry.
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-
____ No codes or tion of a controller. For example, typical controllers have an oper-
2. ____
environmental ating temperature of 0-55 degrees Celsius (32-130 degrees F). If
Environmental Codes/environmental
issues to con-
Issues issues to consider your application will include any extreme environmental condi-
sider 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. Check
appropriate entry.
Determine how many discrete devices your system will have. Which
types (AC, DC, etc.) are needed?
_____ Total inputs: _____ Total outputs: Why this is important: The number and type of devices your system
3. _____ AC _____ AC will include is directly linked to the amount of I/O that will be
Discrete Devices necessary for your system. You will need to choose a controller
_____ DC _____ DC that supports your I/O count requirements and has modules that
support your signal types.Enter quantities and type based on corre-
sponding field devices.

Determine how many analog devices your system will have.

_____ Total inputs: Which types (voltage, current, temperature, etc.) are needed?
_____ Total outputs:
____ Voltage Why this is important: The number and type of devices your system
4. ____ Voltage will include is directly linked to the amount of I/O that will be
____ Current
Analog Devices ____ Current necessary for your system. You will need to choose a controller that
____ Thermo supports your I/O count requirements and has modules that
____ RTD support your signal types. Enter quantities and type based on corre-
sponding field devices.
_____ High speed counter Determine whether your system will require any specialty features:
_____ Positioning Will your application require high-speed counting or positioning?
5. What about a real-time clock or other specialty feature?
Specialty _____ Servo/stepper
Modules or _____ BASIC programming
Why this is important: Specialty functions are not necessarily avail-
Features able in a controller CPU or in standard I/O modules.
(application- _____ Real-time clock Understanding the special functions your system may perform will
specific)
help you determine whether or not you will need to purchase addi-
_____ Others (list) tional specialty modules. Check all features required.

Table continued on the following page

Volume 13
eCS-4 Control Systems Overview 1 - 80 0 - 633 - 0405
Considerations for Choosing a Controller Company
Information

Systems
Overview

Programmable
Controllers
Consideration Information to Record Why this is important
Determine the type of CPU you will need: How much memory will your Field I/O

Hardware requirements: system require? How many devices will your system have (determines data
Software
memory)? How large is your program, and what types of instructions will your
program include (determines program memory)? How fast a scan time do C-more &
________ K program memory required you need? other HMI
(estimated) Why this is important: Data memory refers to the amount of memory needed Drives
for dynamic data manipulation and storage in the system. For example,
________ K data memory required counter and timer instructions typically use data memory to store setpoints, Soft
Starters
(estimated) current values, and other internal flags. If the application requires historical
data retention, such as measured device values over a long period of time, Motors &
the size of the data tables required may determine the CPU model you Gearbox
______ Fast scan time required? choose. Program memory is the amount of memory needed to store the Steppers/
6. sequence of program instructions that have been selected to perform the Servos

CPU Required ______ Battery backup required? application. Each type of instruction requires a specific amount of program
Motor
memory, typically defined in a programming manual. Applications that are Controls
basically sequential in nature can rely on the I/O device rule of thumb to esti-
Software/special function mate program memory (five words of memory for each I/O device); complex Proximity
Sensors
requirements: applications will be more difficult to judge.
If scan time is important in your application, consider the CPU processor Photo
Sensors
____ PID speed as well as instruction execution speed. Some CPUs are faster at
boolean logic but slower with data handling instructions. Limit
Switches
If special functions such as PID are required, the CPU you select may make
____ Floating Point Math
those functions easier to perform. Encoders

For program memory required, follow this rule of thumb: 5 words of pro- Current
Others (see Programming section below) gram memory for each discrete device and 25 words for each analog Sensors
device. Check or calculate all requirements that apply.
Pressure
Determine where your I/O will be located: Will your system require only Sensors

local I/O, or both local and remote I/O locations?

Temperature
_______ _______ Remote Locations Why this is important: If subsystems will be needed at long distances from Sensors

Local . . . the CPU, you will need a controller that supports remote I/O. You will also
Pushbuttons/
only have to determine if the remote distances and speeds supported will be Lights
7. Specific remote I/O protocol
I/O Locations adequate for your application. Serial and Ethernet-based I/O hardware
required? Which one? Process
are two typical choices available for most systems. This I/O may also be
referred to as distributed I/O, and may require a particular protocol, such Relays/
____________________ as Modbus. Timers

Enter number of physical locations needed, and if/what specific protocol Comm.
may be required.
_____ Ethernet Determine your communication requirements: Will your system Terminal
Blocks &
_____ PLC to PLC be communicating to other networks, systems or field devices? Wiring

_____ Modbus RTU Why this is important: Communication ports (other than the programming Power
8.
Commuications port) are not always included with a controller. Knowing your system
_____ ASCII (interface to serial devices)
communication requirements will help you choose a CPU that supports Circuit
Protection
_____ Other your communication requirements, or additional communication modules
if necessary. Check any/all communications functions required. Enclosures

Determine your programming requirements: Does your application require Tools

_____ PID loops
only traditional programming instructions, or are special instructions neces-
_____
Floating sary? Pneumatics
_____ number of loops needed
point math Why this is important: Certain controllers may not support every type of instruc- Appendix
9. _____ Subroutines tion. You will need to choose a model that supports all instructions that you
Programming _____ may need for a specific application. For example, built-in PID functions are Product
Index
Drum much easier to use than writing your own code to perform closed-loop
sequencer _____ Direct interrupts
process control. Typical instructions such as timers, counters, etc. are available Part #
Index
_____ Others (list)
in most controllers; note any other special instructions required here. Check
any/all programming functions required.

w w w. a u to m at i o n d i re c t . c o m Control Systems Overview eCS-5

 Programmable Controller Summary
Those making the buying decisions for Programmable Controller controllers or if you are a seasoned veteran; whether you need
applications can have very different needs. Our goal is to offer a simple discrete control or if you need to calculate complex
selection of controller families that best fit your specific application algorithms lightning fast, we have a controller family that is perfect
needs. Regardless if you are a newcomer to programmable for you.

CLICK DirectLOGIC Productivity3000

Our best value PLC The most practical PLCs PAC features
for a PLC price
The CLICK PLC is rapidly becoming DirectLOGIC PLCs (nano fixed I/O to
one of the industry's favorite control modular units) are industry workhorses, The Productivity 3000 shatters the
systems in the 142 I/O or less category. time-tested in some of the toughest indus- price per feature paradigm in every
trial settings. Installed in thousands of category.
Get standard PLC features (discrete
and analog) in a compact yet expand- applications, their wide range of I/O and Once again, AutomationDirect chal-
able design. The FREE software offers communication options ensure you’ve lenges the status quo to remain the
an extremely easy to use programming got the tools you need to do the job. #1 Value in Automation, with prices
experience with powerful features From simple machine sequencing to that can't be beat and a two-year
commonly found in programs costing process control, you will find a quality warranty on all modules.
several hundred dollars. programmable controller to suit your
application at a fraction of the price • Auto discovery of hardware, including
you'd normally expect to pay. remote I/O bases & GSDrives when
• Select from a variety of Stand-alone
connected to the Ethernet remote I/O
CPU combinations with AC / DC / Relay
network
& Analog I/O available • 6 PLC platforms to chose from within the
• Tag name database programming
• Built-in communications ports DirectLOGIC family
• Task management
(two in the Basic CPUs, three in the • DL05 stand-alone brick PLC with one
• Advanced “fill-in-the-blank” instructions
Analog CPUs) available option slot (30 I/O max)
• Seamless Corporate Database
• Eleven stackable, discrete I/O modules • DL06 stand-alone brick PLC with 4
connectivity
• 21 Intuitive and easy to use instructions available option slots (100 I/O max)
• Run-time Editing and project transfer
• 8000 step program memory • DL105 stand-alone brick PLC with high
• Project file, tag database and ladder
• Store your program and ladder amp relays (18 I/O max)
documentation stored in the CPU
documentation in the CPU • DL205 powerful modular PLC with the
• Much more
• PLCs start at $69.00 (stand-alone, DC most available option modules
powered CPU with 8DC in & 6DC out) (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 FREE SOFTWARE* FREE SOFTWARE

*100 word limited version. Full version cost is $395.00
Volume 13
eCS-6 Control Systems Overview 1 - 80 0 - 633 - 0405
Application Briefs Company
Information

Systems
Overview
DL06 PLC puts heaters to Semi cab sheeting Cost-effective I/O
Programmable
the test production improved simplifies hydroelectric Controllers

Pyromatics Automation Systems of Crystal ITS, a design build firm in Columbus, Ohio plant controls upgrade
Lake, Il. was contracted by a customer to specializes in industrial automation. The Field I/O
Lockhart Power Company owns and
develop a Life Cycle Test Station for its company was contacted by a division of
operates a hydroelectric plant located on Software
electric heating elements. International Harvester responsible for the
the Broad River in upstate South Carolina.
manufacturing of semi cabs. International C-more &
This test station needed a user-friendly Harvester uses automated machines to other HMI
graphical interface to give operators the place aluminum rivets on sheeting that is
ability to select multiple ramp/soak parame- attached to the frame of the semi cabs. The
Drives

ters, output voltages, temperature sensor original CNC machines were becoming Soft
types, amperage ratings and total cycle antiquated and needed to be upgraded. Starters
counts on tests for the cast-in electric heater
Motors &
platens. The system also needed to record Gearbox
temperature, volts, and current draw
throughout the test for use in quality reports. Steppers/
Servos
Also, a failure of the heater required a safe
shutdown of the test while alerting the qual- Motor
Controls
ity department of the alarm condition.
The plant includes an 8-gate dam feeding
Proximity
Pyromatics selected the cost-effective a canal that channels the water flow to the Sensors
DirectLOGIC® DL06 PLC as the heart of powerhouse. The powerhouse contains
the system because of its ability to control up five turbine generators with a combined Photo
Sensors
to eight PID loops and the multiple expan- power capacity of over 17 MW. The dam
sion slots available for thermocouple cards and turbine control system receives data Limit
Switches
and analog input modules. It also controls from power, flow, and level sensing
two heaters, two chillers and an array of devices to perform monitoring and control Encoders
panel indicators, buttons, switches and of the dam, generators, and associated
relays. equipment. Current
Sensors

A C-more 10-inch TFT touch-screen opera- Lockhart Power contracted North Fork Pressure
tor interface was used to provide operators Electric in Crumpler, NC, to lend their Sensors
with the necessary interface to operate and expertise to a renovation of the conrtol
monitor the tests. ITS chose a DL205 PLC as the new con- Temperature
system. Sensors
troller for the machines, along with discrete
I/O and an H2-CTRIO high-speed counter The system consists of seven DirectLOGIC Pushbuttons/
module that drives a dual axis servo. An H2- DL205 micro-modular PLCs with built in Lights

ECOM Ethernet Communications card links PID functionality. Each of the five systems Process
the machines back to an office for data for generator control includes discrete and
acquisition. ITS also added a 15-inch touch analog I/O, and an Ethernet communica- Relays/
Timers
screen for diagnostics. tions module. The remaining two PLCs are
configured in a master/slave arrangement Comm.
In the new system, an operator stamps
and control the dam gates, located upriv-
sheets of aluminum to welded framework Terminal
er from the powerhouse, via radio
with a handful of hand rivets and then Blocks &
modems. Operator interfaces include two Wiring
places the product onto a dual axis servo
6-inch color touch screen panels and a
table. After the operator selects one of five Power
Windows NT-based PC running the
The completed system allows users to quick- different parts programs, the machine will
LookoutDirect SCADA/HMI software Circuit
ly connect the heater to be tested, enter test navigate the panel under the head assem-
package. Protection

parameters, and run the test. Trend charts bly, which is responsible for the drilling and
on the C-more panel track test parameters riveting, with a tolerance of 1/10 of a In the automatic mode, the PLC can start, Enclosures

and quickly identify potential issues such as millimeter. The panel is drilled and a rivet is stop, and operate the generator, and Tools
sudden drops in current or temperature. installed and squeezed to approximately control startup and synchronization of the
1200 PSI, producing a rivet consistency turbine. Changing the generator gate Pneumatics
Alarm reporting and history are also auto- within .003 in. After completion of the panel position varies the flow of water to the
Appendix
matically recorded, allowing the operator to (between 64 and 138 rivet locations), the turbine.
determine causes of failure. Data from the machine will return to its home position and Product
test can be easily uploaded to a USB thumb await the next product. The dam control system controls the eight Index

drive from the C-more panel. The data can canal gates located at the dam, which
then be imported into the user’s choice of The solution increased productivity by regulate the flow of water downstream to Part #
Index
word processor or spreadsheet. approximately 30% and provides an easy the turbines.
way to run and maintain the machines.
Volume 13
w w w. a u to m at i o n d i re c t . c o m Control Systems Overview eCS-7
 Programmable Controller Overview
CLICK: Brick PLC with expandable
I/O and easy-to-use instructions
The 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 combinations
of AC, DC, relay and analog I/O, and advanced programming functions such as drum
sequencing.
• 8 discrete inputs and 6 discrete outputs • 8 K program / 8 K data memory
for discrete units • Two built-in communication ports
• 4 discrete inputs / 4 discrete outputs / • 21 instructions
2 analog inputs / 2 analog outputs for • Removable terminal block
analog units • 24 VDC powered

starts on page 1-1

DL05: Offers incredible features
with an expansion slot
The DL05 series is a fixed I/O PLC with eight inputs and six outputs with one option
card 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.
• Eight inputs and six outputs • Thermocouple and RTD modules
• 2 K program memory • Ethernet and serial communications
• 4 K data memory modules
• Two built-in communication ports • 1-channel high-speed
• Over 250 instructions, including four input/pulse output module
PID loops • Memory cartridge/real-time
• Removable terminal block clock module
starts on page 2-1 • 12/24 VDC powered versions • DeviceNet™ / Profibus slave modules
• Discrete and analog I/O modules • Basic CoProcessor module

DL06: Mighty micro PLC

with 36 I/O and four expansion slots
The DL06 series combines its fixed I/O of 20 inputs and 16 outputs with four
option card slots for expansion all in the same package. With the DL06, you can
use the same PLC panel layout for all applications from 36 to 100 I/O.
• 20 inputs and 16 outputs • 12/24 VDC powered versions
• 7.5 K program memory • Built-in real-time clock/calendar
• 7.3 K data memory • Discrete and analog I/O modules
• Two built-in communication • Thermocouple and RTD modules
ports - one RS232 and one • Ethernet and serial communications
RS232/422/485 port modules
• Over 275 instructions, including • High speed input/pulse output module
starts on page 2-1 eight PID loops and ASCII • DeviceNet™ and Profibus slave
• Removable terminal blocks modules
• Built-in 300 mA 24 VDC • Basic CoProcessor module
auxiliary power supply • Optional plug-in LCD display

DL105:Fixed-I/O Micro PLC

The DL105 series is a fixed-I/O micro PLC with 10 inputs and eight outputs. Eight
configurations are available in combinations of AC, DC and relay I/O.
• 10 inputs and eight outputs • One RS-232 communication port
• 2 K program memory • Heavy-duty seven amp relays with
• 384 words data memory built-in surge suppression on
• 110/220 VAC or 24 VDC power models with relay outputs
supply versions
• Built-in 0.5A, 24 VDC
starts on page 3-1 auxiliary power supply
Volume 13
eCS-8 Control Systems Overview 1 - 80 0 - 633 - 0405
Programmable Controller Overview Company
Information

DL205:
Systems
The most practical micro-modular PLC Overview

with a wide range of I/O and communications modules Programmable

Controllers

If your application requires the flexibility of a modular system, a DL205 PLC is a low Field I/O
cost, yet extremely versatile solution.
Software
• Four CPUs, up to 30.4K memory and 16,384 I/O • Ethernet and serial remote I/O
• Four base sizes available • High-speed counter/pulse C-more &
other HMI
• 16 buit-in PID loops using D2-260 CPU output module
• AC/DC input/output modules • Counter input/pulse output module Drives
• Up to 10 A relay outputs • Basic CoProcessor module
• 12-bit and 16-bit analog I/O modules • Ethernet, DeviceNet™ and Profibus slave Soft
Starters
• Thermocouple and RTD input modules controller modules
• Ethernet and serial communications modules • Triple port serial module for WinPLCs and EBCs Motors &
starts on page 4-1 Gearbox

Steppers/
Servos

DL305: We’ve still got it! Motor

Controls

The DL305 series is a small modular PLC that has been marketed by various
Proximity
name brand PLC manufacturers for over 27 years. This Koyo design revolution- Sensors
ized the small PLC market, and you can keep your DL305 system operating with
Photo
these compatible components. Sensors
• Three CPUs, including the D3-350 with PID • AC, DC inputs
Limit
control and two communication ports • AC, DC and relay outputs Switches
• Five, eight and 10 slot bases • Analog input/output
• 110/220 VAC or 24 VDC power supply Encoders
starts on page 5-1
Current
Sensors

DL405: Specialty modules Pressure

Sensors

for complex applications Temperature

Sensors
The DL405 PLC product line has a wide choice of specialty I/O modules,
Pushbuttons/
including high-speed counting, temperature controller, and magnetic pulse input. Lights

• Three CPUs, up to 30.8K memory and • 10 A relay outputs Process

16,384 I/O • 12-bit and 16-bit analog I/O modules
• Three base sizes with built-in power supply • Thermocouple and RTD input modules Relays/
Timers
• 16 built-in PID loops (D4-450 CPU), • Ethernet and serial communications modules
up to 96 loops using PID modules • Ethernet and serial remote I/O master and Comm.
• AC/DC input/output modules slave modules starts on page 6-1
Terminal
Blocks &
Wiring

Productivity3000 PAC: Power

PAC features at a PLC price Circuit

Protection
Productivity3000 is a compact controller that combines the features and
capabilities of a PC-based control system with that of a typical programmable Enclosures
logic controller (PLC).
Tools
• High-performance CPU with 50Mb • Unmatched built-in communications
memory, fast scan time, and USB capabilities, including local and remote Pneumatics
& Ethernet programming ports for I/O ports and networking Appendix
quick and easy connectivity • Integrated drive communications
• Modular rack-based footprint with over Ethernet Product
36 discrete and analog I/O option Index
• System hardware Auto Discovery
modules, up to 115,000 I/O • Tag name database programming Part #
• Hot-Swappable I/O for advanced • Advanced “fill-in-the-blank” Index
troubleshooting and system repair instructions starts on page 7-1
Volume 13
w w w. a u to m at i o n d i re c t . c o m Control Systems Overview eCS-9
 Programmable Controller Selection Guide
Basic Test &
Process
Selection Criteria I/O Capacity Machine Data CPU Communications
Control
Control Acquisition

Analog I/O, limited PID, Simple

Built-In Local I/O Expansion Ports

Built-In RS-485 Multi-drop port

formulas & Array Manipulation

Logging & Corporate database

Modbus TCP Ethernet Protocol

>16 PID loops, Complex Math
Math and data manipulation

Sub-millisecond Scan, Data

Built-In RS-232 Serial port

(State Machine Control)

Built-In Ethernet & USB

Built-In I/O

Digital I/O & Simple

Logic Requirements
Stage Programming

Built-In Remote I/O

Modbus RTU Salve

Total Possible I/O
Controller Family

(with Expansion)
Series / CPU

connectivity
Local I/O
Relay I/O

In & Out
AC, DC,

Analog

✔
Basic CPU 8 In/6 Out 142 142 ✔ ✔
Click PLC

✔
Analog CPU 4 In/4 Out 2 In/2 Out 140 140 ✔ ✔ ✔ ✔
✔
DL05

All CPUs 8 In/6 Out 30 30 ✔ ✔ ✔ ✔

✔
DL105 DL06

20 In/
All CPUs
16 Out
100 100 ✔ ✔ ✔ ✔ ✔
10 In/
All CPUs
8 Out
n/a 18 ✔ ✔ ✔
D2-230 256 256
✔ ✔ ✔
D2-240 256 896 ✔ ✔ ✔
DL205
DiectLogic

D2-250-1 768 16,384* ✔ ✔ ✔ ✔ ✔ ✔ ✔

✔ ✔ ✔ ✔ ✔ ✔
D2-260 1280 16,384* ✔
D3-330 176 176
✔ ✔
✔
DL305

D3-340 184 184 ✔ ✔ ✔

D3-350 368 368 ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔
D4-430 640 1664 ✔ ✔ ✔ ✔
DL405

D4-440 640 2688 ✔ ✔ ✔ ✔

D4-450 2048 16,384* ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔
Productivity 3000

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

* 16384 (fully expanded H4-EBC slave bases, using V-memory & bit of word 3 DeviceNet & ProfiBus Slave modules for the DL205 series are installed in place of
instructions) the CPU in the CPU slot
1 Scan time is based on type and amount of ladder logic instructions and 4 High Speed inputs available on DC input models / Pulse output available on
total system I/O DC output models
2 Scan times may vary during Run-Time Transfers

Volume 13
eCS-10 Control Systems Overview 1 - 80 0 - 633 - 0405
 Programmable Controller Selection Guide Company
Information

Systems
Overview

Programmable
Controllers
Communications and
Ports & Protocols Programmability
Specialty Modues Field I/O

Software

Freeform Expressions in Math

(Outputs pause during transfer)

(Scan updates during transfer)

Built-in High Speed Counter

Sub-Divided Program Tasks

Serial RS-232 & RS-485

Battery Backed Memory

C-more &
Ethernet (10/100 Mb)
Modbus RTU Master

Ethernet Remote I/O

Stage Programming

Floating point Math

Run-Time Transfer
Basic Coprocessor
K-Sequence Slave

Serial Remote I/O

other HMI
DirectNet Master

Email Instruction
Drum Sequencer
DeviceNet Slave

Clock / Calendar

Run Mode Edits

DirectNet Slave

& Pulse Output

Profibus Slave

Total Memory
ASCII Out

ASCII IN

Drives

Soft
Starters

Motors &
Gearbox

Steppers/
Servos

8k
✔ ✔ ✔ steps ✔ ✔ ✔ ✔ Motor
Controls

8k Proximity
✔ ✔ ✔ steps ✔ ✔ ✔ ✔ ✔ Sensors

Photo

✔4
Sensors
✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ 6.0k ✔ ✔ ✔ ✔ ✔
Limit
Switches

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

Current
✔ 2.4k ✔ ✔ ✔4 ✔ Sensors

Pressure
✔ ✔3 ✔3 2.4k ✔ ✔ Sensors

✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔3 ✔3 3.8k ✔ ✔ ✔ Temperature
Sensors

✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔3 ✔3 14.8k ✔ ✔ ✔ ✔ ✔ ✔ ✔ Pushbuttons/
Lights
✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔3 ✔3 30.4k ✔ ✔ ✔ ✔ ✔ ✔ ✔
Process

✔ ✔ 3.8k
Relays/

✔
Timers
3.9k

✔ ✔ ✔ ✔ ✔ ✔ 14.8k ✔ ✔ ✔ ✔ ✔
Comm.

Terminal
✔ ✔ ✔ ✔ ✔ ✔ ✔ 6.5k ✔ ✔ ✔ Blocks &
Wiring

✔ ✔ ✔ ✔ ✔ ✔ ✔ 22.5k ✔ ✔ ✔ ✔ Power

✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ 30.8k ✔ ✔ ✔ ✔ ✔ ✔ ✔ Circuit
Protection

Enclosures

✔ ✔ ✔ ✔ 50Mb ✔ ✔2 ✔ ✔ ✔ ✔ ✔
Tools

Pneumatics

Appendix

Product
Index

Part #
Index

Volume 13
w w w. a u to m at i o n d i re c t . c o m Control Systems Overview eCS-11
 Get The Training You Need,
When And Where You Need It
Doug Bell and
InterConnecting
Automation, Inc.
Interested in a PLC or drives training course
focused entirely on AUTOMATIONDIRECT’s prod-
ucts, taught by someone who has used most of our
products in real-world applications? Would it be
extra convenient if the training was held in a city
near you? We thought so! Doug’s offering
includes:
• 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) “Introduction to PLC Logic and
covering advanced programming and Principles” video or DVD and
debugging, with remote I/O, networking, training kit
modems and more
Get the most important lessons from the
• PID training course (two days) covering PID three-day basic PLC seminar in a step-by-
loop setup, tuning and troubleshooting, as well step two-video or DVD set.
as shortcuts and tools the experts use
Check Appendix for a complete schedule of
classes for 2010-11 in cities across the U.S. “PLC analog I/O” training video
or DVD and hardware
Learn the ins and outs of using analog I/O
Training sets with PLCs in this step-by-step training set.
Available on DVD and in Spanish
Want to learn how to program our PLCs in the Check the Appendix for complete descrip-
comfort of your own office? Doug Bell has tions of the training kits and course contents.
created two hands-on training kits, one based
on his world-famous basic PLC training class,
the other focusing on PLC analog principles. Online training at www.interconnectingautomation.com
The basic PLC training kit includes two video-
View the complete list of videos in each "library" as well as watch sample videos;
tapes or one DVD, a pre-wired trainer
when ready to purchase, register and pay for your selected libraries on a monthly
containing a DL05 PLC, and the DL05 User
basis. Get unlimited access anytime during the 30 days; videos can be viewed as
Manual.
many times as needed. Most libraries range from $29.95 - $39.95 per month.
The analog training kit includes two videotapes Typical libraries include:
or one DVD, a pre-wired trainer with poten- • Introduction to PLC Principles (for the novice non-user with limited
tiometers and meters, a DL05 analog controls knowledge)
input/output module, I/O cable and 24 VDC
• CLICK series PLC Training (includes Introduction to PLCs library)
power supply. Each kit can be ordered directly
• Productivity3000 series Controller Training
from ICA.
(DirectSOFT programming software must be Libraries will be added on a continuing basis.
purchased separately.)

Online training
If you can’t travel and can’t justify a training kit, how
about inexpensive online training? Check out
Doug’s online training videos for PLCs and HMI.
Interconnecting Automation
1-414-425-8348
www.interconnectingautomation.com

Volume 13
eCS-12 Control Systems Overview 1 - 80 0 - 633 - 0405