Short Circuit Article, Volume 7 Number 5

MORE PLC APPLICATIONS in TRAFFIC SIGNAL

OPERATIONS

Written by Tony Rucker, City of Campbell, CA.

What's a PLC?

Generally speaking, a Programmable Logic Controller, or PLC, is a solid

state control system which has a user-programmable memory for storage
of instructions to implement specific tasks, such as: I/O control logic,
timing, counting, arithmetic, and data manipulation. PLC's are generally
programmed in what is known as Ladder Logic. This method of
programming was established because it could be closely related to
hardwired relay logic that PLC's were developed to replace. PLC's are
used in many industries for process control such as parts manufacturing,
lumber mills, food processing and auto manufacturing.

The City of Campbell uses PLC's to supplement the operational needs of

several signalized intersections and were chosen because of their high
performance-to-cost ratio over relays and 24 volt external logic cards. The
PLC receives inputs from the signal controller's NEMA outputs, makes
logic decisions based on its operator-written stored program, and then
outputs commands to the signal controller's NEMA inputs. The PLC used
in Campbell for traffic signal operation, the "IDEC Micro-1® ", is a fixed,
8 input/6 output, "brick type" PLC that can be expanded to a total of 16
inputs and 12 outputs. Although several I/O types are available, the model
used in Campbell has "source" inputs and "sink" outputs, so that like a
NEMA signal controller, it recognizes a ground as a "true" input and
outputs a ground as a "true" output, in reference to the cabinet's +24 volt
dc power supply. It has EEPROM memory capable of storing 600 steps of
user program and numerous internal logic components such as "AND"
gates, "OR" gates, latches, 80 timers, and 48 counters. It can be
programmed with either a hand-held "Boolean type" loader with LCD
display or ladder logic software that runs on an IBM, or equivalent
computer. Other PLC models and brands are available that can be
modularly expanded as needed to provide up to 512 I/O points, floating
point math, high speed counting, line voltage I/O and analog I/O. These
more costly, higher-end units can be configured with RS-232/422/485
serial interfaces for peer-to-peer networking and telephone modem
interfacing, providing remote control and monitoring. Of course, the
concept of using external logic cards has been available for some time
from controller manufacturers, e.g. "Econologic", "MultiLogic", etc..
However, this PLC only occupies 1/4 cubic foot of space and for only
$300 it can replace relays and timers costing 10 times as much and taking
up 50 times more space.

A Sample PLC Application in Campbell

Refer to Figure 1 below. The intersection of Hamilton Avenue and Eden

Avenue utilizes 6 phases. Hamilton, the arterial, utilizes phases 2 for EB
Thru, 1 for WB LT, 5 for EB LT, 6 for WB. Eden, the SB side street, is
phase 3 and a commercial driveway is phase 4 for NB. Pedestrian
movements are with phases 2 for EB, 6 for WB and 3 for SB. Figure 1
shows the signal phase sequence and intersection configuration. The goal
was to provide alternate pedestrian timing for the SB movement phase 3
which could be enabled by a crossing guard. The guard would flip a
toggle switch inside the locked police door to enable or disable the
alternate ped timing. The alternate ped timing was necessary for the guard
to be able to accompany a large group of students across the wide arterial
and still be able to return to the appointed post before the arrival of the
next large group. The operation was designed with the following logic:
Utilize phase 3 ped timing during "normal" ped timing operation, allowing
the 3 ped to operate concurrently as it normally does with phase 3 vehicle.
However, when "alternate" ped timing is selected by the crossing guard,
phase 8 ped timing will be selected to time AND display the "WALK" and
"DON'T WALK" display for the SB ped movement, concurrently with
phase 3 for the vehicles. The logic will also insure that this "alternate"
phase 8 ped will only serve with phase 3 SB and NOT with phase 4 NB,
as that combination (8 ped with 4 vehicle) would be allowed in normal
NEMA controller operation and configuration. At this intersection,
however, NB and SB are each protected movements with left turn green
arrows, hence, the SB ped can operate concurrently ONLY with the SB
vehicle, phase 3.

Figure 1.

The following is a description of the ladder logic program in the PLC

(refer to figure 2):

Line 0 allows that the enabling of the alternate ped occurs only when the
toggle switch (Input #1) is closed AND phase 3 is NOT in green (Input
#7). Thus, the alternate ped is enabled when internal relay #401 is SET.

Line 3 allows that the disabling of the alternate ped occurs only when the
toggle switch (Input #1) is NOT closed and phase 3 is NOT green (Input
#7). Thus, the alternate ped is disabled when internal relay #401 is
RESET.

Line 6 allows that the walk output (Output #200) to the loadswitch will be
driven by phase 3 walk (Input #2) when the alternate ped is disabled (relay
#401 has NOT been SET) OR by phase 8 walk (Input #4) when the
alternate ped is enabled (relay #401 has been SET).

Similarly, line 12 allows that the don't walk output (Output #201) to the
loadswitch will be driven by phase 3 don't walk (Input #3) when the
alternate ped is disabled (relay #401 has NOT been SET) OR by phase 8
don't walk (Input #5) when the alternate ped is enabled (relay #401 has
been SET).

Line 18 allows that phase 8 will be omitted (Output #202) when NOT in
phase 3 green (Input #7) OR when the alternate ped is disabled (relay
#401 has NOT been SET).

Line 21 allows that a hold will be placed on phase 3 (Output #203) when
phase 8 is displaying walk (Input #4) OR ped clearance (Input #6). To
clarify, ped clearance is TRUE whenever a NEMA controller is timing the
flashing don't walk interval.

Figure 2.
The cabinet wiring was modified and the Conflict Monitor was
programmed to additionally protect the SB "WALK" from NB phase 4.
Also, a jumper plug that mates with the PLC's connector was added so
that if the PLC must be removed, the technician connects the cabinet
harness to the jumper plug instead of to the PLC. This passes the NEMA
controller's phase 3 "WALK" and "DON'T WALK" outputs directly to the
loadswitch so that the phase 3 ped operates "normally" (concurrently)
with phase 3 vehicle until the PLC is returned to service.

Another Distinct Advantage

Another distinct advantage of PLC's is that they can be easily modified or

reprogrammed to meet changing intersection operational needs without
having to purchase and install more connectors, sockets, cards, or relays.
Usually the required modifications are limited to running a couple of
wires between I/O points of the NEMA controller and the PLC. After the
new logic operation has been checked thoroughly in the shop for the
correct operation, the technician can download the revised program in the
field with a loader or a laptop PC and then field check the operation to
insure its conformance. However, if the PLC-to-Cabinet wiring is installed
as described below, in a matter of seconds you can replace the existing
PLC with a spare PLC already pre-programmed with the revision.

PLC Wiring in Controller Cabinet

PLC's are usually hardwired in their more familiar process control

environment such as plants and factories. This is generally not acceptable
in the realm of traffic signals, as technicians prefer the modular,
connectorized concept of the controller, conflict monitor and other cabinet
equipment applied to all active components. This facilitates maintenance
and decreases down time. To achieve this, the City of Campbell selected a
24 pin "AMP" brand circular plastic connector (CPC) cable system. The
chassis-mounted plug with male contacts is mounted on a small piece of
sheet aluminum that is mounted with stand-offs to the PLC's mounting
holes. Standard nylon-jacketed, 19 strand #22 AWG wire is used to
connect the pins from the rear of the CPC to the terminal points on the
PLC. Only the AC power, neutral and ground should be carried on
shielded #18 AWG cable. A mating CPC receptacle with female contacts
is wired with conductors of sufficient length to be connected to the
appropriate controller I/O terminals in the cabinet. A 35 mm DIN rail is
secured to the cabinet's inside wall where appropriate and then the PLC is
snapped in place. Terminal blocks, fuse holders and relay bases are also
available that are specifically designed to snap onto the DIN rail, further
facilitating the process. Installation is completed by screwing on the
female harness to the PLC. A standard wire list of PLC I/O function
assignments was adopted early and adhered to, so that PLC's are
interchangeable throughout the City. A PLC can be removed and replaced
with another unit in less than 30 seconds. The only unique feature of the
PLC installation at a site is the PLC's internal logic program.

Conclusion

This article describes the use of reasonably priced, readily available

alternative control tools to enhance the signal operation beyond what a
typical NEMA signal controller offers. A PLC application has been
successful in Campbell but it should be noted that, to successfully
program and install a PLC requires above-average knowledge of NEMA
controller operational specifications in addition to PLC programming. An
experienced signal technician can obtain the knowledge required to
implement PLC operation by taking courses in PLC operation and Ladder
Logic Programming, beginning with basics and fundamentals and then
graduating to the more advanced classes. Most major manufacturers offer
factory courses and many are free. Contact the manufacturer's
representative for the PLC of your choice for details.

It would be ideal if a signal controller had a user programmable area for a

traffic engineer or signal technician to program the desired logical
operation without having to rely on external devices. But until that time
arrives, you might consider using a PLC to enhance or optimize your
signal operation. There are four PLC's currently in use in Campbell. They
have provided continuous, trouble-free operation since installation in
1994. And although there have been numerous power outages in that time
frame, not once has any of the PLC's caused a problem.
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