How to Wire Sensors to a PLC - Part 1

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Have you ever wondered how the digital and analog signals, coming from devices such as valves or sensors, are connected to the PLC's input and output modules? In this video, using a practical example, you're going to learn exactly how these field devices are wired and connected to the PLC's input and output modules.
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How to Wire Sensors to a PLC - Part 2:
• How to Wire Sensors to...
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A special thanks to Frederico Duarte Fagundes for translating this video.
#RealPars #PLCSensors #PLCWiring

[@harunplasto3590]

You got me at: "And that's where you'll say: What the heck!?" :D :D

[@texas4434]

Great video Im near to graduating with an I&E degree and my studies were a bit vague This page's videos are a great summary to some of the classes that were required A great refresher and boost of confidence heading into the interviews phase Greatly appreciated

[@rmrieee9748]

What courses other than Electrical engineering?

[@brettwashburn9611]

This served as a good reminder for me to make sure I have speced out and ordered every part I'll need to actually land wire from the field to the PLC card. Love the videos, keep it going guys!

[@realpars]

Glad you like the video. Thanks for watching!

[@baconsledge]

All your videos are valuable and top-notch quality. So impressive!

[@realpars]

Great to hear! Thanks a lot!

[@Khosrov13]

Can you please make a video about Emerson I/O modules and VIM? Your videos are very helpful. The only drawback I could see is that it is solely based on Siemens PLC hardware.

[@realpars]

Hi Elshad! Thanks for your comment and your suggestion. I will pass this on to our course developers! Thanks for sharing and happy learning!

[@kedam22]

Very nice and clear videos for a good understanding about all kinds of engineering subjects, subscribed!

[@SuperPrince424]

I learned how physical wiring is done on a compact plc.

[@roseelectronics4582]

The third part of this series just came out.

[@MrGrzegorz22crewe]

Amazing videos ! I have electronic background but not much field experience, thanks to your videos I'm finally not scared of controll panels and started to understand how things are working.Love your videos, please keep up with great work👏💪💪💪

[@realpars]

That's amazing to hear, Grzegorz! If you have any questions in the meantime, please do not hesitate to contact us at any time - we're more than happy to help!

[@johnc5258]

do you have videos on different PLCs? Schneider Modicon?

[@ashiqmumtaz8726]

I love your videos. This video is really helpful.

[@realpars]

Glad you found the video helpful!

[@Blades-fm6ck]

Those front connectors look great! So much easier to connect the wires compared to some other PLC modules, where wiring is awkward and fiddly.

[@realpars]

Very true!

[@ranakamran8947]

very good and help ful

[@mintahtaylor4993]

Very good video I like it

[@pietermuller9535]

How to Use PLC In Home Automation

[@jacobzindel987]

Interesting question, I think it would depend on what you want to automate in your home, though. The principles would be similar.

[@geppeto]

You're teaching skills are remarcable! simple and useful for everybody to understand. good job! keep it that way!

[@realpars]

Hi Costin, we’re stoked to hear that you found our videos helpful. Thanks for the feedback! :)

[@ecosysefficiencies5164]

I did not know that an additional accessory namely the Front Connector would have to be purchased with the modules. Watching this video has definitely saved me some trouble. Thank you!

[@realpars]

Great to hear your positive feedback.

[@lordydaddy]

@ 2.25 ----> good practice is to Use INSULATED screwdriver . otherwise Great video.

[@miguelmartinriveracolorado8226]

I'm trying to acquire more knowledge about controls and electrical stuff, I find you videos really helpful and interesting , thank you for sharing your experience!!

[@realpars]

Glad you like them, Miguel! Glad to hear that.

[@therobloxgirl4221]

Great video. Very useful.

[@realpars]

Glad to hear that!

[@vasudevasubramaniam6620]

Getting to learn the basics of PLCs. Excellent video for the same

[@ZahidHussain-wk1zl]

Very impressive... easy to learn... please suggest me... programs for beginners ?

[@CesarEscobar74]

I'm recently getting into the field of PLC's and Automation due to my job that is in Renewable Energy realm. As a young professional I don't know how majority of this stuff works and I find automation and PLCs extremely intriguing so I want to learn more. I Googled/KZbind a bunch and finally found a good step-by-step video! Thank you.

[@realpars]

Thanks for sharing your positive feedback with us, Cesar! Great to hear. Happy learning :)

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Really useful I will be keep on following you to get great information from you.

[@syedjawadable]

really knowledgeable videos. please upload a video for programming and details of encoder with PLC ☺ .and which type of module is used for interfacing.

[@toufikmouloud5966]

thank you the videos are helpfule but what i wont exactly how we wired the device to JB than to rackroom (rear side /front side ).

[@oiejrhoingv]

great video, this little techical information is unique in KZbin

[@realpars]

Thanks for your input.

[@JahanZeb1976]

This was an excellent video which came after a long waiting time of more than a month. Hope the other part will come soon. Please upload frequently your excellent and lovely work as we all are looking forward for your uploads. The learning point for me here of using ferrules even though it is basic but important to use in such situation to avoid shorting to the surrounding. Regards,

[@realpars]

Creating high quality videos take time but we're trying to upload more frequently here! Thanks for your input and sharing what you learned.

[@JahanZeb1976]

That is true dear sir. Same is the case with me. It take a lot of time to shoot and edit a video with quality. Anyhow your videos are great and helping a lot. Thanks for your reply.

[@heshamelsaadany7663]

Thank you so much. Your video is very helpful.

[@realpars]

You're very welcome! Thanks for watching.

[@MohammedAslam-ni4vf]

I learn how an input module looks like and what additional components are required for wiring it.

[@engcaiobarros]

Thank you so much! Please continue sharing you knowledge with us.

[@ohnoesgoes]

I learned about front connectors and how they're used with modules to get all terminal connections out to the field. This was very helpful to see physically, thank you!

[@realpars]

Glad to hear that!

[@sofarleftturnigright]

Hey can you tell me what the make and models are of the wire stripper and crimper are? Thanks

[@vishveshpatel3932]

Fabulous video Good content Great lecture delivery Easiest language No extra talk in starting Live demonstration

[@realpars]

Happy to hear that you benefit from our courses!

[@kiykio4299]

You are great. Thank you very much. I would like to explain module EM 231 s7- 200 connection and scale

[@realpars]

Hey! Thanks for your comment and your suggestion. I will pass this on to our course developers! Thanks for sharing and happy learning!

[@averycox1429]

Is there a way to test the devices that are connected to the i/o module without using the plc. Example we have a removable tool that has some i/o for a couple of valves and some prox switches. We rebuild the tool I would like to test all of the components before we reinstall the tool. Can you force an i/o controller with something like an arduino with a relay modul?

[@davidrichardson977]

Hey, Avery - Dave from RealPars. As a general answer, most PLCs have indicator lights on the input modules, so that you can power up the PLC and the attached circuitry, and the lights will come on without having any program in the PLC. To test the outputs from the PLC to your circuitry, you can either force the outputs using an attached PC with the programming software on it, or disconnect the outputs and use a jumper wire to test your attached circuitry. The specifics of how to force the outputs are different for different brands of PLCs, so if you want a more specific answer, please tell us what kind of PLC you have. Some PLCs may not even have a method to do this, but in those cases I usually ended up writing special test programs to cycle the outputs. A test program often is useful as you debug the attached circuitry anyway. Please feel free to ask more questions in here - we are happy to answer what we can, and a good question might even turn into a video, you never know!

[@denisl2760]

2:04 I learned that someone doesn't flush cut their zip ties!

[@arshu333]

OMG :: Amazing content. Thank you for creating the channel and creating these amazing videos that show the real life devices as well as simulations. Thank you.

[@realpars]

Glad you like them! You're very welcome

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Hi RealPars .. Your Explanations are crystal clear n amazing.. did a great job.. Thanks

[@realpars]

Amazing, I'm very happy to hear that!

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Just started my first PLC class in college, your videos are great training aid to help get ahead in class

[@realpars]

Thanks for your positive feedback. Feel free to reach out with any questions!

[@omine2000]

yes,I learn how to connect field sensor to plc using word and ferrule

[@chrisatronx]

why don't PLCs come with front connecters already installed? why do I have to buy that separately? Do microwave doors come separate to microwaves?

[@realpars]

Hi there, Great question! Front connectors from Siemens or other PLC manufacturers will only sell you the board and not the connector, as we stated in our video. The reason is mainly that you can get the front connector with screw-type terminals or push-pin terminals. You can purchase the front connector from a manufacturer like Siemens or a third-party company that will fit your needs at a better price. If you are designing your system within a set budget, you must stay within it. Here is a link you might find useful to review the different possibilities. public.eandm.com/Public_Docs/S7ConnectionTypes.pdf Happy learning!

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very helpful information, keep up the good work, it is very nice to have this useful information avialable on youtube.

[@realpars]

It's great to have people on KZbin who know the true value of practical info! :)

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You guys are doing a great job and thanks for sharing 👍

[@realpars]

Amazing! Thanks for your support.

[@randyhandy6437]

Yes always better to use the correct size feral great video thanks

[@unclefrankindia]

nice video now please show to program the input❤

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Very helpful and easy to understand.

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I strongly agree on that

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[@realpars]

Sounds great!

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[@JaykeSapalaran-iq3qs]

Please make a video information on letters and number in plc module. And how to wire install AI/0 DI/0

[@realpars]

Thanks for your topic suggestion, I will happily go ahead and pass this on to our course developers.

[@gallardezanne6164]

help how to trouble shoot cimon xpanel use at chiller ..no power .

[@sg8127]

very amazing. Thanks for this video

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[@realpars]

You're welcome! Happy learning!

[@raquelsapalaran2907]

please make video tutorial about what is the symbols , bit number and letter ABCD for???

[@realpars]

Thanks for your comment, and for sharing your topic suggestion! I will happily go ahead and pass this on to our course developers.

[@shahidaslambajwa8760]

Very useful for me. Thanks I have already subscribed this channel

[@realpars]

Great to hear that! Happy learning :)

[@almoqid]

Very helpful and easy to understand. Thank you

[@alisalem5426]

i learned how to install front connector and climp ferrule

[@adfggffffffddffd]

I don't recommend using both hands to crimp the ferrule onto the wire as the wire/ferrule might slide out of place. I recommend using two hands to partially squeeze the crimping tool down (it has a ratcheting mechanism that will hold itself in place until you've squeezed it all the way down) so you can hold and crimp the ferrule with one hand (that is if your hands aren't big enough to squeeze it with one hand when the crimping tool is wide open) and hold the wire/ferrule with the other hand. I always pre-crimp the crimping tool down enough so there there is a small hole to slide the wire/ferrule in to ensure a perfect crimp every time.

[@realpars]

Great addition, Stuart! Thank you for sharing this.

[@thedude7099]

Just make sure your card is installed first and have xtra slack on the wire in case things get moved around which they always seem to do. I always leave a loop in my wire down in the wire tray. Nothing worse than having to re-pull 800 ft of signal cable because it was cut 6 inches too short!

[@realpars]

Thanks for sharing that with us! Happy learning!

[@peterjenkins886]

Wish you would have gone into the diagram on the input card door and explained what each wire actually was not just calling them all generic control wires and finally I find crimping ferrules with a circular head doesn’t pancake your ferrules

[@realpars]

Thanks for your feedback, Peter! I will happily go ahead and pass this on to our course developers.

[@santhoshkauh3461]

Please show me the connection of field devices in PLC.

[@muhammadusama6173]

You need to attach the digital output of the sensor to the unit, right? Their Voltage and Ground are to be arranged separately. Moreover, do actuators (like motors) connect just like sensors?

[@realpars]

The signal output (4-20ma) is connected to an analog input channel of the associated analog input card of the PLC. Actuators are driven by PLC outputs. The wiring, as you indicate, is almost identical, except that the PLC sets the current level in the signal instead of the transmitter.

[@MR-bg5ls]

very nice channel video about plc thats a very very knowledge about controller so thanks RK

[@realpars]

You're very welcome!

[@engineer0646]

thanks for easy explanations. Really useful videos. there are too much to learn from you. how can i contact with you?

[@realpars]

Hi Ibrahime, Thanks for the compliment. You can contact our customer support at realpars.vhx.tv/contact/support and they can assist you with any questions that you might have.

[@jeffcrossler3186]

now i know how to install the wire ferruls correctly

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how can I get simens plc softwares

[@mktmnnvgtkisla5953]

this video is very helpful to new in plc, now i know how to remove the front connector of plc io module

[@realpars]

Glad to hear that!

[@MohamadmoeinShahbazi]

Is there any fuse between field device and modules?

[@realpars]

Thank you for your question! The answer depends on the specific project. Typically, you would use a fuse for each device, or the output card may already have a fuse built into it. The same can be true for the device itself. I hope this helps! If you have any further questions, feel free to ask. Happy learning with RealPars!

[@sharishsss]

So this Analog I/P module is all differential ended. Is single ended better or D.E.?

[@realpars]

Hi Harish, thank you for your comment. I'm not really sure if I understand your question. Can you please elaborate?

[@hossamshokry2381]

where i can find the wiring of the base units of Et200 sp module please?

[@realpars]

See chapter 6 of the ET200sp manual: cache.industry.siemens.com/dl/files/293/58649293/att_913853/v1/et200sp_system_manual_en-US_en-US.pdf

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i like your videos keep them coming

[@maki6867]

I've learned how S7-300 PLS is received , and how to connect it.

[@realpars]

Great to hear!

[@yaredmuluabay2066]

hoping to see other practical videos on PLC. thank u!

[@judetochukwuogbozor6355]

Thanks so much realpars. Please what is the criteria for choosing the colour of wire ferrules to be used.

[@realpars]

The answer is "preference". I like to use wire ferrules that are the same color as the wires if the corresponding ferrule colors are available. Wire ferrules also come in many sizes in order to accommodate wires of differing diameters. Always use the correct size for the application. So, to follow the color and size guidelines I just mentioned, you will need to keep a variety of ferrules in stock. This is why many installations opt to use a single color but stock teh various sizes needed.

[@justcoolinmike]

Great video didnt know about front connectors didnt know about wire ferrels didnt know this is how wires are connected

[@realpars]

Thanks a lot! Happy to hear that you have learned some new things today! Keep up the learning curve!

[@Kennerdoll]

excellent so helpful

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Great video. Thanks

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I learned of the names of the hardware

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Industrial what they need in plc ? For job , can you plz answer sir

[@realpars]

We need PLCs to be able to control the manufacturing processes.

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very useful thankyou.

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where is start free trial link , plz?

[@oscarmatheus1372]

What the jeck, I need to order the Front Conector that is supposed to be attached to the module... Why don't they include it in the module... This is like buying a TV but without the cable plug... Siemens...

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The best Chanel for to learning PLC and i will soon subscribe bcs I will be learning this .

[@realpars]

Awesome! Let us know if you have any questions.

[@bernielobo]

keep the info coming thanks

[@Retro_Mere]

I just learned how to equip a wire for the sensors, thanks

[@realpars]

You're very welcome!

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Nice video, it's really hard to find something like that.

[@realpars]

Happy you found the video useful!

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I teach Instrumentation and Real Pars is an excellent aid for my students!

[@realpars]

Amazing to hear, John! Thanks for your support

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Hi...thanks for the info..i have never used the siemens PLC

[@realpars]

You'll welcome! Hope you will work with Siemens PLCs soon! :)

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Nice information for fresher

[@sg8127]

I've learned that PLC have input and ouput normally isn't have front connector, so we must use front connector using wire ferrules.

[@masterchef6694]

could you do video on digital inputs.... different types of digital inputs...like from potential free contacts ..and other switches

[@mutugimaina7841]

Thanks a lot. I like your step by step explanation.

[@realpars]

Glad it was helpful!

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what courses the available to learn from you guys?

[@realpars]

Hi Tito, Thanks for your comment, and great to hear your interest! Our course library is specifically designed in a way where it provides all the tools needed for beginners to evolve into an advanced level through our hands-on courses. Feel free to browse through our course library to see all the different topics we are covering. bit.ly/30AVJaR Just to let you know, that we also have a free course on PLC Hardware bit.ly/2XnnUrF If you are interested, you will obtain full access to our complete course library (400+ video courses) by subscribing to either our monthly package for €22.12 a month or our yearly package for €159.28,-. Hope this helps! If I can be of any further assistance, please let me know - I’m more than happy to help!

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[@realpars]

Yes. You can learn the basics here.

[@brandsplanet4381]

Ok. I have subscribed. I will be watching all the videos.

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Thank you for the video

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Simply and excellent. I believe that it was harder.

[@realpars]

No it's not. Thanks for watching!

[@thechriskelly12]

This is what I have been waiting for picked up a Siemens s7-300 on ebay with a digital and analog input modules and am learning how to wire it up as I have some k type thermocouples that I would love to be able to use.

[@realpars]

Awesome! Let us know of any questions.

[@thechriskelly12]

was wondering if you have any videos regarding connecting thermo couples as I assume that the modules have an internal comp which would allow me to hook it straight up to the ai module?

[@MD-cd7em]

YOU GUYS ARE GREAT!!..GOOD VIDEO!

[@kiranchoudhari4717]

Big thank you sir, for making my profession very interesting you are such genius Man for all over world's

[@realpars]

You're more than welcome, Kiran! Happy learning!

[@kiranchoudhari4717]

@@septianti417 what you saying dear