Precision PLC Wiring
Wiring Diagrams
With a firm understanding of many electrical components found in PLC panels, Champion employees are able to read symbols that represent them in a wiring diagram. Our wiring diagrams are cad images that represent circuit components.
Many of the control panels we work on consist of power and control components. This work defines us as a company. We devote the highest concentration and precision to this step of the operation. Our team of wiring technicians is fully trained to handle any power or control device within the industry. For a list of components we have installed in the past see below.
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PLC Panel Power Components
- Rotary Disconnect: It is used for connecting incoming power lines/wires. It can include fuses or not. To turn the power ON or OFF, it is usually rotated using the black or yellow PLC panel door handle.
- Power Distribution Block: It is mainly made of machined aluminum. The top of this block has a couple of holes for larger connecting wires, while its bottom has multiple holes for smaller connecting wires. The power distribution block is used to split a large connecting wire into smaller wires to be used with many other different electrical components in the PLC panel.
- Relays and Contactors: These are ON/OFF switches that control mechanized functions based on control commands from the PLC controller. Smaller relays control simple functions such as fans and lights. The larger relays are known as contactors, and they control more advanced functions like three-phase motors.
- Main Circuit Breaker: We are all familiar with the main disconnect of electric circuits in our homes or offices. Well, the main circuit breaker in a PLC panel is similar to such an electrical disconnect. In most industrial control applications, the main circuit breakers in PLC panels handle between 120V to 480V.
- Branch Circuit Breakers: These provide short circuit protection and in some cases, they prevent overload conditions for each type of load controlled by the PLC, such as a heater, motor, etc.
- Surge arresters: They are used to prevent utility power surges or lightning strikes from damaging the electrical components inside a PLC panel due to overvoltage.
- Transformer: Normally, a step-down transformer is used to reduce the incoming AC voltage to 120V for various components while in other cases it is used to step down the incoming voltage to 24V. This is applicable in instances where the PLC panel is connected to a 120V AC power line.
- Power Supply: This is used to convert high power AC voltage, normally 120V or 240V AC to a lower and safe control DC voltage (24V DC) for the various control components in the PLC panel like HMI, or PLC controller.
- Power Contacts: These are used to manually disable/enable power flow to a machine using e-stop buttons.
- Motor Starter: Also known as a motor contactor, it turns ON motors at full speed and full voltage.
- Variable Frequency Drive (VFD): This is a type of motor controller which is used to adjust the motor speed as well as monitor other motor data.
- Motor Soft Starter: This is also a type of motor controller which is used to start a motor gradually over time, then ramp up to full motor speed.
- Grounding: This connection is necessary as it provides a current flow pathway in the event of an electrical fault.
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PLC Panel Control Components
- Supplementary Circuit Breaker: It is used to protect high-end and expensive control devices and components of the PLC panel.
- Master Control Relay (MCR): It is used to implement a safety circuit that transfers power from all output devices in case of an emergency. In most cases, the MCR will be paired mushroom-head Stop pushbutton.
- Network Switches: They make up the communication hub of the PLC panel. They facilitate communication between the PLC system and a variety of other network-compatible devices on the assembly line. An example of a network switch is the Ethernet switch which is used for network communications between the PLC, the HMI, and other smart devices.
- Programmable Logic Controller (PLC): This is essentially the CPU of the PLC contained inside the panel. This unit has the Arithmetic and Logic Unit (ALU) which is responsible for data manipulation, arithmetic functions, and logic operations. A control unit is also included to regulate the timing of the PLC control operations.
- Human Machine Interface (HMI): HMIs provide a Graphical User Interface (GUI) that enables operators to interact with the PLC control system. So an operator can use an HMI graphical display to monitor and review real-time input and operational data or configure and control certain functions of machinery or process. Examples of HMIs include keypads, text-readouts, joysticks, video monitors, or large touch screen panels like Liquid Crystal Displays (LCDs).
- Input/Output Module: I/O modules provide an interface from the PLC to the input field devices and the components or devices being controlled. The output module connects the PLC to the input devices such as sensors, start/stop pushbuttons, and switches. On the other hand, the output module is used by the PLC to control output field devices like relays, solenoid valves, motors, pumps, and electric heaters. You can have either analog or Digital Input/Output modules.
- Operator Pushbutton: This is located on the front of the PLC panel and is used by the operator to control the process or machine.
- Terminal Blocks: They are used to connect and splice field device wiring and internal PLC panel wiring. They also assist in organizing and distributing the array of wires emanating from various sources to different electrical devices.
Order In
Once your order is in and processed, we begin the task of converting it into a control Panel. We create a reasonable lead time that fits within your project life cycle and meets your delivery schedule. A new job order is added to our database and is updated periodically with your design plans, component requests, and specifications.
Order In
Once your order is in and processed, we begin the task of converting it into a control Panel. We create a reasonable lead time that fits within your project life cycle and meets your delivery schedule. A new job order is added to our database and is updated periodically with your design plans, component requests, and specifications.
Order In
Once your order is in and processed, we begin the task of converting it into a control Panel. We create a reasonable lead time that fits within your project life cycle and meets your delivery schedule. A new job order is added to our database and is updated periodically with your design plans, component requests, and specifications.
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