Pico Controllers
Pico Controllers by Allen-Bradley are a family of small-footprint, cost-effective controllers for simple machine control. The family consists of two controller series: Pico and Pico GFX-70. The Pico controllers work like an intelligent relay and feature basic PLC operations. In contrast, Pico GFX-70 controllers offer a graphic display and advanced programming operations like high-speed counters, Boolean sequences, and PID control. The Pico controller’s installation, mounting method, and programming techniques are kept simple and effective to minimize cost and commissioning time. The program and data manipulation can be performed through an onboard keypad and specialized software. The Pico controllers also support DeviceNet configuration.
The typical applications of these controllers include commercial lighting, machine control, HVAC systems, material handling, pumps, fans, and vessel control. The Pico GFX-70 controllers can be utilized in more complex scenarios like speed and valve control, analog inputs and outputs, and advanced math instructions. This guide further explores the hardware capabilities of Pico and Pico GFX-70, which can assist in decision-making for a primary control solution.
1) Overview of Pico Controllers
Pico
Pico is an electronic control relay with built-in functions like logic, timer, counter, and real-time clock (RTC). Pico is a control device with inputs and outputs suitable for machine control and building applications. It can be programmed using a ladder diagram. The complete code can be entered directly through the available onboard buttons and display. Most Pico controllers also offer RTC, which allows up to 32 different ON and OFF times. Two analog inputs can be received and compared using eight comparators.
Pico GFX-70
Pico GFX-70 is an HMI unit with a control relay. The modular controller offers flexible options and an IP65-protected keypad and display. Compared to the Pico, many advanced functions can be performed using Pico GFX-70, such as logic, timing relay, counter, arithmetic, and PID. It can be used to design domestic solutions and tasks in machine control. The Pico-Link is available in this controller, which allows connection of up to 8 stations with a separate program, thus making a single extensive control system with decentralized intelligence. The terminal mode of Pico GFX-70 provides control of devices in the network. The two Pico GFX-70 controllers can be connected through a simple serial interface. These controllers can be programmed using the keypad and display options, which makes it beneficial for creating and modifying the program in a short time and without the use of a personal computer (PC).
2) Processor and I/O Modules
I/O Module
The Pico controllers are available in various models based on hardware features. Most of the models have twelve or eighteen I/O combinations. The controllers are available with and without the display, keypad, and real-time clock. There are 8-channel or 12-channel digital inputs that accept different input voltages, including DC (12V, 24V) or AC (24V, 100-240V). Most models offer 4-channel or 6-channel digital outputs, which are relay-type, and some models have 8-channel MOSFET-type digital outputs. Pico controllers are available without, with two, or with four voltage-type analog inputs. The input channels can take an input voltage of 0 to 10V DC.
The Pico GFX-70 offers five I/O modules with 16 embedded I/O. The 12 inputs are either 120/240V AC inputs or 24V DC inputs. In contrast, the other four channels are a combination of relay output, transistor output, analog input, and analog output. The analog input and analog output work on a voltage signal of 0 to 10V DC.
Expansion I/O Module
Pico expansion modules are available for increasing the I/O capacity. The expansion module also features terminals for incoming power, inputs, and outputs, along with a status LED. A write-on surface is available in Pico controllers only.
With the Pico controller, modules with 12 inputs and up to 8 outputs can be chosen. The input channels support an input voltage of 100-240V AC or 24V DC, and the output channels support relay or transistor-type output. With the help of the expansion module, the I/O count can be increased to 40.
There are four Pico GFX-70 compatible I/O modules available. One is a simple two-channel relay-type output module, and the other three modules have either 12-channel AC (120/240V) inputs or DC inputs (24V) with a combination of 6-channel relay or 8-channel transistor-type outputs. With the help of the expansion module, the I/O count can be increased to 36. By adding Pico-Link to the system, the I/O count can reach up to 272.
Remote Processor
A remote processor compatible with all controllers is used to operate Pico Controller’s terminal mode. It features a power supply of 24V DC and an interface terminal for cable connection.
Other than the remote processor unit, multiple processor types are available for the Pico GFX-70, including the DC and AC processors with and without the Pico-Link terminal.
3) HMI
The Pico controllers offer an LCD. The Pico controllers can display 16 screens of text with a maximum of four lines of text on each screen. The length of the text is limited to 12 characters. The controller supports 12 languages. There is one integrated status LED present in the HMI.
The Pico GFX-70 controllers offer an LCD with enhanced and advanced features. The controllers can display 255 screens of a four lines text. The length of the text is limited to 16 characters. Instead of simple characters, eight double-type or four seven-segment characters can be displayed. The controller supports ten languages. There are two integrated status LEDs in the HMI. Five onboard keys can also be re-defined. The Pico GFX-70 offers a graphics display feature, on which 24 KB graphics can be displayed with 255 elements per screen, up to 255 screens.
4) Physical Appearance and Operation
Generally, Pico controllers have terminals for incoming power, inputs, and output. There is a liquid crystal display (LCD), status LED(s), buttons for screen control, and sockets for the PC interface cable or memory module.
Buttons
In Pico, there is a large four-directional cursor button surrounded by four small function buttons, including Del, Alt, Ok, and Esc. These buttons are used to create a circuit diagram, choose special functions, assign values, and move across the menu. A combination of keys also triggers different functions.
Pico GFX-70 has four cursor buttons with an OK button in the center. Surrounding the cursor button are four function buttons, including Del, Alt, Esc, and Mode. These buttons perform functions like the buttons in Pico controllers but can be programmed for different functions using visualization applications. The standard functions can still work outside the application.
Display
In Pico, the status display provides the status of the inputs and outputs of the system. The ON and OFF status of each I/O is differentiated by showing a filled or an empty shape, respectively. Besides the I/O status, the display screen also shows the weekday, time, and RUN or STOP status of the controller.
The Pico GFX-70 status display shows inputs, outputs, weekday or time, operating or terminal mode, RUN, STOP, or BUSY mode. For local expansion and advanced operation, the display also shows expansion status and Pico-Link Station information.
LED Indicators
The Pico controller models with LED indicators feature a single LED, which indicates three states of the controller. The LED is either turned OFF, continuously lit, or flashing, representing no power, power with stop mode, and power with run mode, respectively.
In Pico GFX-70, there are two LED indicators available. One functions the same as in the Pico, and the other is dedicated to the Pico-Link status. The Pico-Link LED can be off, continuously lit, or flashing, indicating no operational or configuration fault, initialized with no station detected, and operating fault-free.
5) Memory Module
The program can be saved to a memory module using the Pico interface, or an interface cable can be used to transfer the program to a PC. The memory module is available in both Pico and Pico GFX-70 controllers. Circuit diagrams with relevant data can be transferred from the memory module to the controller. Each module can contain one program. The memory is non-volatile, which means you can archive, transfer and copy the circuit diagram, and the data inside the module is not lost upon removing the power source. Many settings, configurations, and parameters can be saved on the module along the circuit diagram.
6) Security Feature
The controllers with keypads and LCDs can be password protected to restrict unauthorized access. For Pico controllers, a password may contain a value between 0001 and 9999. In contrast, the Pico GFX-70 controller can have a value between 000000 to 999999. The password can be applied to various settings to limit access to sensitive data such as modification in the circuit diagram, modifications in relay parameters, transfer of circuit diagram, changing the operation mode (RUN/STOP), communication with other devices, modification of system parameters, and password delete function.
7) Retention Feature
Some applications require the retention of function values and states of the machine when the power is lost. It is desired that when the power is back, the machine must resume from where it stopped so that it knows where it left the operation to avoid any safety hazards. There are integrated functions in Pico controllers that should be used instead of simple functions such as retention marker relay, timing relays, and up/down counter so that they can retain their values in case of short power disconnection or failure. In Pico GFX-70, a user-defined function block range can be used in addition to the marker, counter functions, and timing relays.
8) DC Simulator
The DC simulator board is (1760-SIM) a useful piece of equipment for testing and troubleshooting programs. It consists of push buttons that simulate digital input devices such as limit switches, proximity switches, and potentiometers that can simulate analog inputs like pressure and temperature transducers, and LEDs, which simulate digital output devices like relays, solenoids, and motor starters. In Pico GFX-70 DC simulator board is not available separately.
9) Function Blocks
The Pico controllers are built for basic PLC operations, and yet they support many useful function blocks, which can help design a simple control solution.
The Pico controller supports function blocks which include a timer, counter, comparator, text display, analog comparator, set cycle time, frequency counter, high-speed counter operating hours counter, 7-day time switch, and a year time switch.
The Pico GFX-70 controller supports all the function blocks available for Pico. Many advanced function blocks related to Math and other control operations are available in this controller. The list includes arithmetic function, PID controller, block functions, high-speed incremental encoder, signal smoothing filter, value scaling, value limitation, Boolean operation, numerical converters, Pulse Width Modulation (PWM), Pico-Link value, and clock synchronization via Pico-Link.
10) Operating Power
The Pico controllers offer flexible power requirements for the operation. The Pico and Pico GFX-70 possess an AC operating power of 120/240V and a DC operating power of 12V and 24V. The Pico GFX-70 can also operate on a 24V AC power supply.
11) Pico-Link Terminal
The Pico-Link terminals are available in the Pico GFX-70 units. Up to 8 Pico-Link stations are supported. The Pico-Link feature enhances the controller’s functionality by enabling additional I/O processing, improved and fast control using distributed control, reading & writing I/O, sending & receiving values among stations, and loading programs to and from other stations. The baud rate for the link is between 10 Kbits/s to 1000 Kbits/s, and the recommended length for the link is 1000 m. The Pico-Link can transfer data up to 32 double words.
The Pico-Link is based on Controller Area Network (CAN) as specified by ISO 11898 standard. There are two methods of line topology for addressing the stations. One is to loop through the unit, which assigns addresses to stations relative to station 1. In case the line is interrupted, the network stops working. The other line topology is T-connector and Spur Line, where all devices are addressed individually. If the spur line is removed on one station, other devices in the network remain in working order.
The Pico GFX-70 controller also offers point-to-point communication through a serial interface. Data such as I/O status can be read or written using this interface. The active station has complete control of the interface, whereas the remote station can only respond to the requests made by active stations or from software on a PC.
12) Operating Temperature Range
The operating temperature range for Pico and Pico GFX-70 controllers is from -25°C to 55°C, whereas the storage or transportation temperature range is -40°C to 70°C. The display temperature range for the Pico GFX-70 controller is -5°C to 55°C.