Prices as of April 15, 2015. Check Web site for most current prices.

What is a Programmable Controller?
What are programmablecontrollers and how dothey work?
Programmable controllers are often
defined as miniature industrial computersthat contain hardware and software used
to perform control functions. A controller
consists of two basic sections: the central
processing unit (CPU) and the input/
output interface system. The CPU, which
controls all system activity, can further
be broken down into the processor andmemory system. The input/output system isphysically connected to field devices (e.g.,switches, sensors, etc.) and provides theinterface between the CPU and the information providers (inputs) and controllable
devices (outputs).
To operate, the CPU “reads” input datafrom connected field devices throughthe use of its input interfaces, and then“executes” or performs the control programthat has been stored in its memory system.
Programs are typically created in ladderlogic, a language that closely resembles
a relay-based wiring schematic, and areentered into the CPU’s memory prior tooperation. Finally, based on the program,the PLC “writes” or updates output devices
via the output interfaces. This process, also
known as scanning, typically continues inthe same sequence without interruption,and changes only when a change is madeto the control program.

Discrete applications

Today’s controllers

Programmable controllers are often used
to control machines or processes that aresequential in nature, using “discrete” inputs
and outputs that have defined states. For
example, if a limit switch detects the presence of an object, it provides an “ON”
signal to the PLC; if no object is detected,
it provides an “OFF” signal. The machineor device typically performs actions basedon time or events in a pre-defined order.
The expected sequence is typically interrupted only when an abnormal condition
occurs.

Initially, devices that exhibited the attributes discussed here were known as
Programmable Logic Controllers (PLCs).
This tended to emphasize that the mainfunctionality of these systems was LOGIC
operations. As technology has advanced,
so have programming languages andcommunications capabilities, along withmany other important features. Thesedevelopments seemed to demand thedefinition of a new class of controller, theProgrammable Automation Controller(PAC), which combines features of
traditional PLCs with those of personal
computers.

Process control
applications
Programmable controllers can also
control continuous processes that use
analog I/O. For example, a temperature
sensor may provide a variable signal, suchas 0-10 volts, based on the measurementof an actual temperature. The controller
program monitors the sensed values
continuously and operates devices that
may also be analog in nature. This could
include setting the position of a valve
between 0-100% open, or controlling the
speed of a motor. Continuous applications are so called because they typicallyhave no defined start or end once they
are initiated; they maintain a process in a
“steady” operating state.

In the past, size was typically used tocategorize controllers, and was often
an indication of the features and types
of applications it would accommodate.
Small, non-modular PLCs (also known
as fixed I/O PLCs) generally have lessmemory and accommodate a small
number of inputs and outputs in fixed
configurations. Modular PLCs have bases
or racks that allow installation of multiple
I/O modules, and will accommodate more
complex applications. With the emergenceof PACs, functionality is the determining
factor in categorizing controllers.

Which programmablecontroller is right for you?
Choosing the most effective controller foryour application depends on a number offactors. To begin the selection process,a drawing of the machine or process isa good start. This can help identify fielddevices 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 andhardware locations are defined, you canreview controllers that will meet yourrequirements. See the Controller Selection
Worksheet in this section that will help you
work through the considerations for determining the type of controller you will need,regardless of which manufacturers you areevaluating.

Book 1 (14.3)

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Control Systems Overview

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Prices as of April 15, 2015. Check Web site for most current prices.

PLC vs. PAC vs. PC-based Control
The most common control systems today
are the Programmable Logic Controller(PLC), PC-based control, and the mostrecent addition, the Programmable
Automation Controller (PAC). While theyeach share a few attributes with the others, their differences lie mainly in form
factor and functionality.

•	Data exchange with businessapplications (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 ofdata• 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 theprocess

Programmable Logic Controller
The Farlex Dictionary defines a PLC
as follows: “A programmable microprocessor-based device that is used in discrete manufacturing to control assemblylines and machinery on the shop floor
as well as many other types of mechanical, electrical and electronic equipment
in a plant. Typically RISC based andprogrammed in a specific-purpose
programming language, a PLC isdesigned for realtime use in rugged,
industrial environments. Connected
to sensors and actuators, PLCs are
categorized by the number and type of
I/O ports they provide and by their I/Oscan rate.”

PLCs excel at sequential logic and basic
analog control. Their modularity andruggedness make them suitable for awide variety of automation applications.
PC-based Control
With Personal Computer technology
booming in the 1980s and 1990s, there
was a natural progression to consider
using the processing power in these units
to solve more complicated applications
that extended well beyond the realmof digital and analog I/O manipulation. These more advanced capabilites
could be performed far more efficiently
by hardware and software native tothe commercial personal computer.
Examples of these requirements include:

Company
Information

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 pounding that PLCs have been subjected to formany years.
Ideally, a PAC encompasses the following
features:
PLC Feel• Modular footprint• Industrial reliability•W ide array of I/O modules
and system configurations
PC Power• L arge memory andfast processing•H igh-level data handlingand enterprise connectivity• E xtensive communications
capability, multiple protocols andfield networks
PACs are most often used foradvanced machine control, processcontrol, data acquisition and equipment
monitoring.

In a PC-based control system, a standard operating system such as Windows
NT supports HMI and control software
running on a PC platform, either areadily available commerical model oran industrially hardened unit. PC architecture allows the system to seamlessly
support a variety of third-party I/O,
specialty motion and vision systems, andfield networks.
Programmable Automation Controller
A programmable automation controller
is a compact controller that combines thefeatures and capabilities of a PC-based
control system with that of a typical programmable logic controller (PLC).

Although each PAC vendor uses theirown development environment (IDE) andprogramming language, PAC networking
is typically based on IP and Ethernet.
This class of controller provides morememory capacity and processing power
which allows for better data processing
capabilities, and connectivity to enterprisebusiness systems from the plant floor.
Additionally, PACs offer the benefitof easy integration for multi-domain
systems comprising Human MachineInterface (HMI), discrete control andprocess control.

•	The need for a Human MachineInterface (HMI) as well as control•	Advanced data manipulation andadvanced math functions
Book 1 (14.3)

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Control Systems Overview

eCS-3

Control Systems
Overview
CLICK PLC
Do-MorePLCs Overview
Do-More H2
PLC
Do-More T1H
PLC
DirectLOGIC
PLCs Overview
DirectLOGIC
DL05/06
DirectLOGIC
DL105
DirectLOGIC
DL205
DirectLOGIC
DL305
DirectLOGIC
DL405
Productivity
Controller
Overview
Productivity
3000
Universal
Field I/O
Software
C-MoreHMI
C-More Micro
HMI
ViewMarq
Industrial
Marquees
Other HMI
Communications
AppendixBook 1
Terms andConditions

Prices as of April 15, 2015. Check Web site for most current prices.

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 asystem, and provides space for recording determinations of your system needs.

Consideration

Information to Record1.
____ New system
Proposed System_____ Existing
systemWhy this is important
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 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.).

2.
Environmental
Issues____ No codes or____environmental
Codes/environmental
issues to conissues to consider
sider

Why this is important: Certain environments may affect the operation of a controller. For example, typical controllers have an operating temperature of 0-55 degrees Celsius (32-130 degrees F).
If your application will include any extreme environmental conditions, or you have specific codes at your facility that must be met,
you will need to either research products that meet those specifications or design the installation to meet requirements. Checkappropriate entry.
Determine how many discrete devices your system will have. Whichtypes (AC, DC, etc.) are needed?

_____ Total inputs:

3.
Discrete Devices_____ AC_____ DC_____ Total inputs:____ Voltage

4.
Analog Devices____ Current____ Thermo____ RTD_____ Total outputs: Why this is important: The number and type of devices your system
will include is directly linked to the amount of I/O that will be_____ ACnecessary for your system. You will need to choose a controller_____ DC
that supports your I/O count requirements and has modules that
support your signal types. Enter quantities and type based on corresponding field devices.
Determine how many analog devices your system will have.
_____ Total outputs: Which types (voltage, current, temperature, etc.) are needed?
____ Voltage Why this is important: The number and type of devices your system
will include is directly linked to the amount of I/O that will be____ Current necessary for your system. You will need to choose a controllerthat supports your I/O count requirements and has modules that
support your signal types. Enter quantities and type based on corresponding field devices.

_____ High speed counter

5.
Specialty
Modules or
Features(applicationspecific)_____ 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
available in a controller CPU or in standard I/O modules.
Understanding the special functions your system may perform will
help you determine whether or not you will need to purchase additional specialty modules. Check all features required.

Table continued on the following page

Book 1 (14.3)

eCS-4

Control Systems Overview

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Prices as of April 15, 2015. Check Web site for most current prices.

Considerations for Choosing a Controller

Company
Information
Control Systems
Overview

Consideration

Information to Record
Hardware requirements:________ K program memory
required(estimated)________ K data memory required(estimated)______ Fast scan time required?

6.
CPU Required______ Battery backup required?

Software/special function
requirements:

Why this is important

CLICK PLC

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

Do-MorePLCs Overview

Why this is important: Data memory refers to the amount of memory
needed for 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
historical data retention, such as measured device values over a long periodof time, the size of the data tables required may determine the CPU model
you choose. 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 program
memory, typically defined in a programming manual. Applications thatare basically sequential in nature can rely on the I/O device rule of thumbto estimate program memory (five words of memory for each I/O device);complex applications will be more difficult to judge.
If scan time is important in your application, consider the CPU processor
speed as well as instruction execution speed. Some CPUs are faster atboolean logic but slower with data handling instructions.

____ PID____ Floating Point MathOthers (see Programming section
below)

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 ofprogram memory for each discrete device and 25 words for each analog
device. Check or calculate all requirements that apply.
Determine where your I/O will be located: Will your system require only
local I/O, or both local and remote I/O locations?

7.
I/O Locations_______
Local …
only_______ Remote 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
also have to determine if the remote distances and speeds supported will
Specific remote I/O protobe adequate for your application. Serial and Ethernet-based I/O hardcol required? Which one?
ware 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 as Modbus.
Enter number of physical locations needed, and if/what specific protocol
may be required.

_____ Ethernet_____ PLC to PLC_____ Modbus RTU
8.
Communications_____ ASCII (interface to serial devices)_____ Other_____ PID loops

9.
Programming__________ number of loops
Floating
neededpoint math
_____
Drum
sequencer_____ Subroutines_____ Direct interrupts_____ Others (list)

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 programming port) are not always included with a controller. Knowing your systemcommunication requirements will help you choose a CPU that supports
your communication requirements, or additional communication modules
if necessary. Check any/all communications functions required.
Determine your programming requirements: Does your application require
only traditional programming instructions, or are special instructions necessary?
Why this is important: Certain controllers may not support every type of
instruction. You will need to choose a model that supports all instructions thatyou may need for a specific application. For example, built-in PID functions
are much easier to use than writing your own code to perform closed-loop
process control. Typical instructions such as timers, counters, etc. are available in most controllers; note any other special instructions required here.
Check any/all programming functions required.
Book 1 (14.3)

www.automationdirect.com

Control Systems Overview

eCS-5

Do-More H2
PLC
Do-More T1H
PLC
DirectLOGIC
PLCs Overview
DirectLOGIC
DL05/06
DirectLOGIC
DL105
DirectLOGIC
DL205
DirectLOGIC
DL305
DirectLOGIC
DL405
Productivity
Controller
Overview
Productivity
3000
Universal
Field I/O
Software
C-MoreHMI
C-More Micro
HMI
ViewMarq
Industrial
Marquees
Other HMI
Communications
AppendixBook 1
Terms andConditions

Prices as of April 15, 2015. Check Web site for most current prices.

Programmable Controller Summary
Those making the buying decisions for Programmable Controller
applications can have very different needs. We offer a selection of controller families that can fit a variety of applications.
Regardless if you are a newcomer to programmable controllers or if you

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

CLICK: Our best value PLC

Easy for new user

The CLICK PLC is becoming one of
the industry’s favorite control systems in the
142 I/O or less category.

Basicmachine control
Lowest cost
Simple analog

Basic PLCs:• 8 DC In / 6 DC Out (sinking)• 8 DC In / 6 DC Out (sourcing)• 8 DC In / 6 Relay Out• 8 AC In / 6 Relay Out

Analog PLCs:

FREE Software• 4 DC In / 4 DC Out (sinking),
2 Analog In, 2 Analog Out(current/voltage selectable)• 4 DC In / 4 DC Out (sourcing),
2 Analog In, 2 Analog Out(current/voltage selectable)

Do-more H2 and T1H Series CPUs: Spend Less, Do More!

Fast CPUCPU
w/ built-in Ethernet

Do-more is a micro-modular PLC that leverages our mostflexible I/O systems to create an incredibly powerful PLC
at a fraction of the cost of comparable controllers.

H2 works with most
DL205 I/O modules.
T1H works with mostTerminator I/O.

• Cost effective hardware• Documentation can be stored onboard• Built-in communications include
USB programming, serial, and(optional) Ethernet• Practical counting/pulse• Ethernet-connected expansion I/O• High-performance processors

Advanced discrete
Process control
Expandability
FREE Software• FREE programming software(with built-in simulator)• Powerful control over program
execution• Enhanced troubleshooting tools• FREE online training with coupon• Starter kits available

Productivity Series: Premium features at a value price

Advanced discreteand process

The Productivity controllers shatter the price per feature paradigm in every category,with prices that can’t be beat and a two-year warranty on all modules.

Data collection
Extensivecommunication
Built-in data
displays
Web Server
FREE Software

Advanced discrete• Built-in communication ports (two in Basic
PLC units, three in Standard and Analog PLC units)• Optional battery backup
Standard PLCs:(Standard and Analog PLCs units only)• 8 DC In / 6 DC Out (sinking)• 8 DC In / 6 DC Out (sourcing) • Real time clock/calendar(Standard and Analog PLCs units only)• 8 DC In / 6 Relay Out• 8 AC In / 6 Relay Out• Removable terminal blocks for easy wiring• Stackable discrete and analog I/O option
modules (DIN-rail or panel mountable)• 4 DC In / 4 Relay Out,• Program AND documentation stored in PLC unit
2 Analog In, 2 Analog Out(current/voltage selectable)• Decimal memory addressing• 21 easy-to-use instructions• 8,000 steps of program memory

DirectLOGIC: Long-running PLCs

• Auto discovery of hardware, including remote
I/O bases (P3000 only) and GS drives whenconnected 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• FREE Productivity Suite software

Six PLC platforms to choose from in the DirectLOGIC family:• DL05 stand-alone brick with one option slot (30 I/O max)
• DL06 stand-alone brick with 4 option slots (100 I/O max)
• DL105 stand-alone brick with high amp relays (18 I/O max)
Expandability
All platforms use the same DirectSOFT programming software, so• DL205 powerful modular PLC with the most available option modules
your investment is protected.
Ethernet(up to 16,384 I/O max)
• DL305 time tested, legacy control platform (up to 368 I/O max)
FREE Software**100-word program limitation,• DL405 time tested, legacy control platform (up to 16,384 I/O max)
Basicprocess control

DirectLOGIC PLCs (nano fixed I/O to modular units) are industry
workhorses, time-tested in some of the toughest industrial settings.

$395 for unlimited program sizes

Book 1 (14.3)

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Control Systems Overview

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Prices as of April 15, 2015. Check Web site for most current prices.

Application Briefs

Company
Information

DL06 PLC puts heaters to
the test

Semi cab sheetingproduction improved

Pyromatics Automation Systems of Crystal
Lake, Il. was contracted by a customer todevelop a Life Cycle Test Station for its
electric heating elements.

ITS, a design build firm in Columbus, Ohio
specializes in industrial automation. The
company was contacted by a division ofInternational Harvester responsible for the
manufacturing of semi cabs. International
Harvester uses automated machines toplace aluminum rivets on sheeting that is
attached to the frame of the semi cabs. The
original CNC machines were becoming
antiquated and needed to be upgraded.

This test station needed a user-friendly
graphical interface to give operators theability to select multiple ramp/soak parameters, output voltages, temperature sensor
types, amperage ratings and total cycle
counts on tests for the cast-in electric heater platens. The system also needed torecord temperature, volts, and current draw
throughout the test for use in quality reports.
Also, a failure of the heater required a safe
shutdown of the test while alerting the quality department of the alarm condition.

The completed system allows users to quickly connect the heater to be tested, enter test
parameters, 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 automatically 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.

Lockhart Power Company owns andoperates a hydroelectric plant located on
the Broad River in upstate South Carolina.

CLICK PLC
Do-MorePLCs Overview
Do-More H2
PLC
Do-More T1H
PLC
DirectLOGIC
PLCs Overview
DirectLOGIC
DL05/06
DirectLOGIC
DL105
DirectLOGIC
DL205

The plant includes an 8-gate dam feedinga canal that channels the water flow to thepowerhouse. The powerhouse contains
five turbine generators with a combined
power capacity of over 17 MW. The
dam and turbine control system receives
data from power, flow, and level sensing
devices to perform monitoring and control of the dam, generators, and associated equipment.

Pyromatics selected the cost-effective
DirectLOGIC® DL06 PLC as the heart ofthe system because of its ability to control
up to eight PID loops and the multiple
expansion slots available for thermocouple
cards and analog input modules. It also
controls two heaters, two chillers and anarray of panel indicators, buttons, switches
and relays.
A C-more 10-inch TFT touch-screen operator interface was used to provide operatorswith the necessary interface to operate andmonitor the tests.

Cost-effective I/O
simplifies hydroelectric
plant controls upgrade

Control Systems
Overview

ITS chose a DL205 PLC as the new controller for the machines, along with discrete
I/O and an H2-CTRIO high-speed countermodule that drives a dual axis servo. An
H2-ECOM Ethernet Communications card
links the machines back to an office for dataacquisition. ITS also added a 15-inch touch
screen for diagnostics.
In the new system, an operator stamps
sheets of aluminum to welded frameworkwith a handful of hand rivets and thenplaces the product onto a dual axis servo
table. After the operator selects one of fivedifferent parts programs, the machine will
navigate the panel under the head assembly, which is responsible for the drilling
and riveting, with a tolerance of 1/10 of amillimeter. The panel is drilled and a rivet
is installed and squeezed to approximately
1200 PSI, producing a rivet consistency
within .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 easy
way to run and maintain the machines.

Lockhart Power contracted North Fork
Electric in Crumpler, NC, to lend theirexpertise to a renovation of the conrtol
system.
The system consists of seven DirectLOGIC
DL205 micro-modular PLCs with built in
PID functionality. Each of the five systems
for generator control includes discrete
and analog I/O, and an Ethernet communications module. The remaining two
PLCs are configured in a master/slavearrangement and control the dam gates,
located upriver from the powerhouse,
via radio modems. Operator interfaces
include two 6-inch color touch screen
panels and a Windows NT-based PC
running the LookoutDirect SCADA/HMI
software package.
In the automatic mode, the PLC can start,stop, and operate the generator, andcontrol startup and synchronization of
the turbine. Changing the generator gate
position varies the flow of water to theturbine.
The dam control system controls the eightcanal gates located at the dam, which
regulate the flow of water downstream tothe turbines.
Book 1 (14.3)

www.automationdirect.com

Control Systems Overview

eCS-7

DirectLOGIC
DL305
DirectLOGIC
DL405
Productivity
Controller
Overview
Productivity
3000
Universal
Field I/O
Software
C-MoreHMI
C-More Micro
HMI
ViewMarq
Industrial
Marquees
Other HMI
Communications
AppendixBook 1
Terms andConditions

Prices as of April 15, 2015. Check Web site for most current prices.

Programmable Controller Selection Guide

44Standard CPU 8 In/6 Out

142

142

4

4

4

4

Analog CPU

140

140

4

4

4

4

H2-DM1

256

65,536

4

4

4

4

4

H2-DM1E

256

65,536

4

4

4

4

4

T1H-DM1

256

65,536

4

4

4

4

4

T1H-DM1E

256

65,536

4

4

4

4

4

4

4 4

P2-550 CPU

240

240

4

4

4

4

4

4p 4

4

4

4

P3-550 CPU

3520 59,840

4

4

4

4

4 4 4 44

4

4

P3-530 CPU

3520

4

4

4

4

4 4

4

4

4 In/4 Out 2 In/2 Out

3520

Built-In Remote I/O

4

AnalogIn & Out142

AC, DC,
Relay I/O

142

Series / CPU

8 In/6 Out

Basic CPU

4
4

4 4

4

4

4

4

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

j Scan time is based on type and amount of ladder logic instructions andtotal system I/O
k Scan times may vary during Run-Time Transfersm High Speed inputs available on DC input models / Pulse output available on
DC output models

n RS-485 for Modbus protocol only The Ethernet ports on the H2-DM1E and T1H-DM1E allow expansion beyond the
local base.

p GS Drives only
Book 1 (14.3)

eCS-8

Modbus TCP Ethernet Protocol

Built-In RS-485 Multi-drop port

Built-In RS-422 Multi-drop port

Built-In RS-232 Serial port

Built-In Local I/O Expansion Ports

Built-In Ethernet & USB

High-speed I/O modules with
Motion Control

16 PID loops, Complex Math formulas &/or Array Manipulation

Analog I/O, Simple Mathand data manipulation

CPU Communications

Digital I/O & Simple
Logic Requirements

Stage Programming(State Machine Control)

Process High-Speed
Control and Motion

Total Possible I/O

Built-In I/O

I/O Capacity

Local I/O
(with Expansion)

Productivity

Do-more

CLICK PLC

Controller Family

Selection Criteria

Basic
MachineControl

Control Systems Overview

1-800-633-0405

4Programmable Controller Selection Guide

Company
Information
Control Systems
Overview
CLICK PLC

Communications andSpecialty Modues

Ports & Protocols

Programmability

Do-MorePLCs Overview

4

4

4 4
8k steps

Sub-Divided Program Tasks

Email Instruction

Drum Sequencer

Freeform Expressions in Math

Floating point Math

Built-in High Speed Counter& Pulse Output

Run-Time Transfer(Scan updates during transfer)

Run Mode Edits(Outputs pause during transfer)

Stage Programming

Battery Backed Memory
Clock / Calendar

Total Memory

DeviceNet/Profibus Slaves

Ethernet or Serial Remote I/O

Basic Coprocessor

Serial RS-232 & RS-485

Ethernet (10/100 Mb)

ASCII IN

ASCII Out

DirectNet Master

DirectNet Slave

K-Sequence Slave

Modbus RTU Master

Do-More H2
PLC

Modbus RTU Slave

EtherNet/IP

4Prices as of April 15, 2015. Check Web site for most current prices.

4 4 4

4

4

4 4 4

4

4

4 4 4

4

4

4 4

4

4

4 4

4

4

4

4 4 4 4

4

262kb

4

4

4

4

4 4 4 4 4444

4 4 4 4

4

262kb

4

4

4

4

4 4 4 4 4444

4 4 4 4

4

262kb

4

4

4

4

4 4 4 4 4444

4 4 4 4

4

262kb

4

4

4

4

4 4 4 4 4

4

4

50Mb

4

4k

4 4 4 4 4

4

DirectLOGIC
PLCs Overview
DirectLOGIC
DL05/06
DirectLOGIC
DL105
DirectLOGIC
DL205

4

4 4

Do-More T1H
PLC

DirectLOGIC
DL305
DirectLOGIC
DL405
Productivity
Controller
Overview
Productivity
3000
Universal
Field I/O
Software
C-MoreHMI
C-More Micro
HMI
ViewMarq
Industrial
Marquees

4

4

4 4

4

4

50Mb

4

4k

4 4 4 4 4

Other HMI
Communications

4

4

4 4

4

25Mb

4

4k

4 4 4 4 4AppendixBook 1
Terms andConditions

Book 1 (14.3)

www.automationdirect.com

Control Systems Overview

eCS-9Prices as of April 15, 2015. Check Web site for most current prices.

Programmable Controller Selection Guide

4

4

4

4

4

All CPUs

20 In/
16 Out

100

100

4

4

4

4

4 4 4

All CPUs

10 In/
8 Out

n/a

18

4

4

D2-230256

256

D2-240256

896

D2-250-1

768

16,384*

D2-2601280

16,384*

4
4
4
4

4
4
4
4

D3-330

176

176

4

4

D3-340

184

184

4

4

D3-350

368

368

4

4

640

1664

4

4

4

D4-440640

2688

D4-4502048

16,384*

4
4

4
4

4
4 4
4 4 4 4

AnalogIn & OutAC, DC,
Relay I/O

Series / CPU

DL205
DL305
DL405

D4-430

4

4
4

4
4
4

4

4 4 4 4

4

4

4
4
4 4 4
4 4 4 4n

44* 16384 (fully expanded H4-EBC slave bases, using V-memory & bit of word
instructions)l DeviceNet & ProfiBus Slave modules for the DL205 series are installed in place ofj Scan time is based on type and amount of ladder logic instructions andm High Speed inputs available on DC input models / Pulse output available on

total system I/O

k Scan times may vary during Run-Time Transfers

Modbus TCP Ethernet Protocol

Built-In RS-485 Multi-drop port

Built-In RS-422 Multi-drop port

Analog I/O, Simple Mathand data manipulation

Built-In RS-232 Serial port

Stage Programming(State Machine Control)

30

Built-In Remote I/O

Digital I/O & Simple
Logic Requirements

Built-In Local I/O Expansion Ports

Total Possible I/O

30

Built-In Ethernet & USB

Local I/O
(with Expansion)

8 In/6 Out

Built-In I/O

DL05

High-speed I/O modules with
Motion Control

CPU Communications

DL06>16 PID loops, Complex Math formulas &/or Array Manipulation

Process High-Speed
Control and Motion

All CPUs

Controller Family
DirectLOGICI/O Capacity

DL105

Selection Criteria

Basic
MachineControl

the CPU in the CPU slot
DC output models

n RS-485 for Modbus protocol only The Ethernet ports on the H2-DM1E and T1H-DM1E allow expansion beyond the
local base.

Book 1 (14.3)

eCS-10Control Systems Overview

1-800-633-0405

Prices as of April 15, 2015. Check Web site for most current prices.

Programmable Controller Selection Guide

Company
Information
Control Systems
Overview
CLICK PLC

Sub-Divided Program Tasks

Email Instruction

Drum Sequencer

Do-MorePLCs Overview

Freeform Expressions in Math

Floating point Math

Built-in High Speed Counter& Pulse Output

Run-Time Transfer(Scan updates during transfer)

Run Mode Edits(Outputs pause during transfer)

Stage Programming

Battery Backed Memory
Clock / Calendar

Programmability

Total Memory

DeviceNet/Profibus Slaves

Ethernet or Serial Remote I/O

Basic Coprocessor

Serial RS-232 & RS-485

ASCII IN

ASCII Out

DirectNet Master

DirectNet Slave

K-Sequence Slave

Modbus RTU Master

Modbus RTU Slave

Ethernet (10/100 Mb)

Communications andSpecialty Modues

Ports & Protocols

Do-More H2
PLC
Do-More T1H
PLC
DirectLOGIC
PLCs Overview
DirectLOGIC
DL05/06
DirectLOGIC
DL105
DirectLOGIC
DL205

4

4

4 4 4 4

4 4 4

4

6.0k

4

4

4 4 4 4 4 4 4 4

4

14.8k

4

4
4

4
4

4
4

4

4

4

4
4 4
4 4 4
4 4 4 44 4 4
4 4 4 4 4 4 4 4

4l

4
4
4

4

4

4m

4

4

4m 4 4 4 4

2.4k

4

4

4m

2.4k

4
4
4
4

4
4
4
4

4l 3.8k
4l 14.8k
4l 30.4k

4

4
4
4

4 4 4

4

DirectLOGIC
DL305
DirectLOGIC
DL405
Productivity
Controller
Overview
Productivity
3000

4 4 4 44 4 4 4

Universal
Field I/O
Software

4 4

3.8k

C-More
HMI

4

3.9k

C-More Micro
HMI

4 4 4 4

4

14.8k

4

4

4

4 4

4 4 4

4

6.5k

4

4

4

4 4
4 4 4 4

4 4 4

4
4

22.5k

4

4

4

30.8k

4

4

4

4 4 4

4

4
4

4 4 4 4

ViewMarq
Industrial
Marquees
Other HMI
Communications
AppendixBook 1
Terms andConditions

Book 1 (14.3)

www.automationdirect.com

Control Systems Overview

eCS-11

Prices as of April 15, 2015. Check Web site for most current prices.

Get The Training You Need,
When And Where You Need It
Doug Bell andInterConnecting
Automation, Inc.
Interested in a PLC training course focused entirely
on AUTOMATIONDIRECT’s products, taught bysomeone who has used most of our products inreal-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)
covering advanced programming anddebugging, with remote I/O, networking,modems and more
• PID training course (two days) covering
PID loop setup, tuning and troubleshooting,as well as shortcuts and tools the experts use
Go online to:www.interconnectingautomation.com
for a complete schedule.

Training sets
Available on DVD and in Spanish
Want to learn how to program our PLCs in
the comfort of your own office? Doug Bellhas created two hands-on training kits, one
based on his world-famous basic PLC trainingclass, the other focusing on PLC analog principles. The basic PLC training kit includes twovideotapes or one DVD, a pre-wired trainer
containing a DL05 PLC, and the DL05 User
Manual.
The analog training kit includes two videotapes or one DVD, a pre-wired trainer withpotentiometers and meters, a DL05 analog
input/output module, I/O cable and 24 VDC
power supply. Each kit can be ordered directlyfrom ICA.

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

“PLC analog I/O” training video
or DVD and hardware
Learn the ins and outs of using analog I/Owith PLCs in this step-by-step training set.
Check the Appendix for complete descriptions of the training kits and course contents.

Online training at www.interconnectingautomation.com
View 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 monthly
basis. Get unlimited access anytime during the 30 days; videos can be viewed as
many 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)• Do-More series PLC Training (includes Introduction to PLCs library)(DirectSOFT programming software must bepurchased separately.)• Productivity2000 series PLC Training (includes Introduction to PLCs library)

Online training• Productivity3000 series Controller 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.

• CLICK series PLC Training (includes Introduction to PLCs library)
Libraries will be added on a continuing basis.

Interconnecting Automation
1-414-425-8348
www.interconnectingautomation.com

Book 1 (14.3)

eCS-12Control Systems Overview

1-800-633-0405