Programmable
Logic Controllers
Third Edition
Frank D. Petruzella
McGraw-Hill
Chapter 2
PLC Hardware
Components
I/O SECTION
Input and output (I/O) modules enable the PLC
to both sense and control a process.
The I/O section consists of an I/O rack and
individual I/O modules.
Input Interface
Input interface modules accept signals from the
machine or process devices and convert them into
signals that can be used by the controller.
Process
The input interface allows
Input Module status information
regarding processes to be
communicated to the CPU.
Sensor
Output Interface
Output interface modules convert controller signals
into external signals that can be used to control
the machine or process.
Pilot Light
External Output
From Output Module
The output interface allows
the CPU to communicate
operating signals to the
process devices under its
control.
Logical Rack
A chassis is a physical hardware assembly that houses
devices such as I/O modules, processor modules, and
power supplies.
A logical rack is an addressable unit consisting of
128 input points and 128 output points.
Logical Rack
A word in the output
image table file and its
corresponding word
in the input image
table Input and output addresses
file are called an I/O
group. Afor theuse
rack PLC-5
8 wordsfamily
in theofinput
the
controller
image table are in the
file and octal in
8 words
numbering
the system
output image table(number
file.
8 and 9 are not used).
A rack can contain a
maximum of 8 I/O
groups.
Remote I/O Rack
One benefit of a PLC system is the ability to locate the I/O modules
near the field devices to minimize the amount of wiring required.
To communicate with the processor,
the remote rack uses a special
communications network.
I/O Module Addressing
The location of a module within a rack
and the terminal number of the module
to which an input or output device
is connected will determine the device’s
address.
Each input and output device must have
a specified address.
This address is used by the processor
to identify where the device is located
in order to monitor or control it.
I/O Module Addressing
In general, the basic addressing elements include:
Type – the type determines if an input or
output is being addressed.
Slot – the slot number is the physical location
of the I/O module.
Word and Bit – the word and bit are used to
identify the actual terminal connection
in a particular I/O module.
PLC-5 Addressing
SLC 500 Addressing
Discrete I/O Module Addressing
Input module in slot 0, terminal 0 Output module in slot 0, terminal 0
Input module in slot 0, terminal 5
Output module in slot 0, terminal 6
Analog I/O Module Addressing
Symbolic Addressing
Symbolic addresses are real names or codes the
programmer can substitute for a logical address
because they relate physically to the application.
They are physical name convention for a in the
data table. In this example, the symbolic
addresses are LS_3 and pump_14, while the actual
addresses are I:3/3 and O:4/14, respectively.
Typical Combination I/O Module
Consists of a printed circuit board
and a terminal assembly. The printed
circuit board contains the electronic
circuitry used to interface the circuit
of the processor with that of the input
or output device.
It is designed to plug into a slot or connector in the
I/O rack, or directly into the processor.
The terminal assembly, which is attached to the front
edge of the printed circuit board, is used for making
field-wiring connections.
Typical Combination I/O Module
Status lights for each of the
inputs and outputs
Most modules have plug-on wiring
terminal strips. toThe
Connection theterminal
power strips
are supply
pluggedused
intotothe actual
power themodule.
If there
inputisand
a problem
output.with a module,
the entire strip is removed, a new
Terminals for input and output
module is inserted, and the terminal
connections.
strip is plugged into the new
module.
Discrete I/O Modules
Discrete type I/O interface modules connects field
devices of the ON/OFF nature.
Combination I/O Module
The arrangement of the terminals,
status
Status
indicators, and power supply
connections
Indicators may vary.
I/O modules can have both input
and output connections in the same
physical module.
Input Connections
Power Supply
A module inserted into the wrong
Connections
slot could be damaged by improper
Outputconnected
voltages Connections
through the
wiring arm.
Discrete I/O Modules
The I/O modules receive their module voltage and
current from the power supply module through the
backplane of the rack enclosure into which they are
inserted. Power from this supply is used to power the
electronics, that reside on the I/O board. The relatively
higher currents required by the loads of an output
module are supplied by user-supplied power.
AC Discrete Input Module
The input circuit is composed of two basic sections:
the power section and the logic section.
The power and logic sections are normally coupled
together with a circuit, which electrically
separates the two.
AC Discrete Input Module Operation
When the pushbutton is closed,
120 VAC is applied to the bridge
rectifier through R1 and R2.
This produces low level DC voltage across the LED.
The resulting light switches the phototransistor into conduction and
the closed status of the pushbutton is communicated to the processor.
Input Module Tasks
Sense when a signal is received
from a sensor
Convert the input signal to the
correct voltage level for the
particular PLC
Isolate the PLC from
fluctuations in the input signal’s
voltage or current
Send a signal to the processor
indicating which sensor originated
the signal
AC Discrete Output Module
The output circuit is composed of two basic sections:
the power section and the logic section, coupled by
an isolation circuit.
The output interface can be though of as a simple
electronic switch to which power is applied to
control the output device.
AC Discrete Output Module Operation
The processor sets the output status
according to the logic program.
When the processor calls for This in turn switches the
an output, a voltage is applied Triac into conduction which,
across the LED of the in turn, turns on the lamp.
isolator, which switches the
phototransistor into
AC Discrete Output Module
Provided with LEDs that indicate
the status of each output.
Fuses are generally required for
each circuit. Some modules also
provide visual indicators for
fuse status.
Individual AC outputs are
usually limited to 1 or 2 amps.
The maximum current load
for any one module is also
specified.
Interposing Relay Connection
Used for controlling larger loads such as motors.
The low current output
from the module operates
the relay coil, the
contacts of which operate
the motor starter.
Types Of Discrete Output Modules
Are used to turn two-state devices either ON or OFF
Triac outputs can only be used only for control
of AC devices.
Transistor outputs can be used only for control
of DC devices.
Relay outputs can be used with AC or DC devices.
However they have a much slower switching
time compared to solid-state outputs.
Sinking and Sourcing DC References
The design of DC field devices typically require that
they be used in a specific sinking or sourcing circuit,
depending on the internal circuitry of the device.
Sourcing device
with sinking
input module
circuit
Sinking And Sourcing References
Sinking and sourcing references are terms used to
describe a current signal flow relationship between
DC field input and output devices in a control system
and their power supply.
Sourcing device
with sinking
output module
circuit
Sinking And Sourcing References
Sinking device
with sourcing
input module
circuit
Field devices connected to the negative side (DC common)
of the field power supply are sinking field devices
Sinking device
with sourcing
output module
circuit
Discrete Versus Analog Devices
Discrete devices are inputs ON/OFF
and outputs that have toggle switch
only two states: on and
off.
Analog devices are inputs
Analog
and outputs that can have
control valve
an infinite number or states.
Analog Input Interface Module
A varying low DC
voltage proportional
to the temperature
being monitored is
produced by the
thermocouple.
This voltage is amplified and digitized
by the analog input module and then
sent to the processor on command from
a program instruction.
Analog Output Interface Module
Both analog inputs and outputs are word-oriented.
The analog output
interface module
receives from the
processor digital
data, which are
converted into a
proportional voltage
or current to control
an analog field device.
Analog I/O Control System
The valve is initially
open 100%.
As the fluid level in the tank
approaches the preset
point,
the processor modifies the output,
which adjusts the valve to maintain
Special I/O Modules
High-Speed Counter Module
Used to provide an interface for
applications requiring counter
speeds that surpass the capacity
of the PLC ladder program.
They have the electronics needed
to operate independently of the
processor.
A typical count rate is 0 to 75 kHz,
which means the module would
be able to count 75,000 pulses per
second.
Special I/O Modules
Thumb-Wheel Module
Allows the use of thumb-wheel
switches for feeding information
to the PLC to be used in the
control program.
Special I/O Modules
Encoder-Counter
Module
This module allows the user to read the signal from the
encoder on a real-time basis and stores this information
so it can be read later by the processor.
Special I/O Modules
Stepper-Motor Module
This module provides pulse trains to a stepper-motor
translator, which enables control of a stepper motor.
Special I/O Modules
BCD-Output Module
This module enables a PLC to operate devices that
require BCD-coded (binary coded decimal)
signals such as seven-segment displays.
Intelligent I/O Modules
Have their own microprocessor on board that
can function in parallel with the PLC.
PID module is used in process control applications
that incorporate PID algorithms. The PID module
allows process control to take place outside the CPU.
Intelligent I/O Modules
Communications Module
This module allows the user to connect the PLC to
high-speed local networks that may be different from
the network communications provided with the
PLC.
I/O Specifications
Nominal Input Voltage
This AC or DC value specifies
the magnitude and type of voltage
signal that will be accepted.
On State Input Voltage
Range This value specifies the
voltage at which the input
signal is
recognized as being absolutely
on.
Nominal Current Per Input
This value specifies the minimum input current that
I/O Specifications
Number of Inputs and Outputs per
Card This value indicates the number
of inputs or outputs that can be
connected to the module.
Off-State Leakage Current per Output
This value specifies the maximum value
of leakage current that flows through
the output in the OFF state.
Maximum Output Current Rating Per Output
and Module
These values specify the maximum current of a single
output and the module as a whole.
CPU - Processor
The term CPU is often used interchangeably with the
term processor. However, by strict definition, the CPU
term encompasses all the necessary elements that form
the intelligence of the system.
Processor Unit
The processor executes the operating system, manages
memory,
Status monitors
indicators inputs,system
provide evaluates the userinformation.
diagnostic logic, and
turns on the
Keyswitch appropriate
allows outputs.
you select different modes of
operation.
Typical Processor Modes Of Operation
RUN Position
Places the processor in the Run mode
Executes the ladder program and
energizes output devices
Prevents you from performing online
program editing in this position
Prevents you from using a
program/operator interface device
to change the processor mode
Typical Processor Modes Of Operation
PROG Position
Places the processor in the program
mode
Prevents the processor from scanning
or executing the ladder program,
and controller outputs are de-
energized
Allows you to perform program
entry and editing
Prevents you from using a
program/operator interface device
to change the processor mode
Typical Processor Modes Of Operation
REM Position
Places the processor in the Remote
mode: either REMote Run, REMote
Program, or REMote Test mode
Allows you to change the processor
mode from a programmer/operator
interface device
Allows you to perform program
online program editing
Electrostatic Discharge Protection
Many electronic components
found in modules are
sensitive to electrostatic
voltages.
Ground yourself before handling static-sensitive parts.
Wear a wrist strap that provides a path to bleed
off charges.
Be careful not to touch the backplane connector or
connector pins of the PLC system.
Create a static free work area by covering your
work bench and floor area with a conductive surface
that is grounded.
Memory Design
Memory is a physical space
inside the CPU where the
program files and data files
are stored and manipulated.
Program File Data File
Memory Requirements
The complexity of the program determines the amount of
memory required.
The program is stored in memory as 1’s and 0’s,
which are typically assembled in the form
of 16-bit words.
Memory Requirements
Memory sizes are commonly expressed in thousands
of words (K) that can be stored in the system.
1K
64 K 2M
MicroLogic 1000 SLC 500
Controller Controller
1 K memory ControlLogix
Up to 64 K memory Controller
Up to 20 inputs Up to 4096 Inputs
Up to 14 Up to 160 K through
and Outputs 2 M memory
outputs
Up to 128,000 Inputs
and Outputs
Memory Design
Memory location refers to an address in the CPU’s
memory where a binary word can be stored. A word
usually consists of 16 bits.
Memory utilization refers to the number of memory
locations required to store each type of instruction.
A rule of thumb for memory
location is one location per Contact
coil or contact. One K of
memory would then allow
a program containing 1,000
Coil
coils and contacts to be
stored in memory.
Input Status Table Or File
The memory of a PLC is divided into sections that have
specific functions.
If the input is closed the bit is
Each input has set to 1
one corresponding
bit in memory
If the input is
open the bit is set to 0
Output Status Table Or File
Each output has one corresponding If the bit is a 0, the output
bit in memory will be OFF
If the bit is a 1, the output will be ON
Status Table
Status Table Files: Stores information such as scan time, fault
codes, and watch dog timer; and some have
precision timing bits for use in the control
program.
Timer Table
Timer Files: Are usually three words long. One word
contains timer status information; another
contains the preset value or set-point; the last
contains the accumulated value.
Counter Table
Counter Files: Also three words long, having the same
configuration as the timer.
Volatile Memory
Volatile memory will lose its stored information if
all operating power is lost or removed.
Volatile memory is easily
altered and quite suitable
for most applications when
supported by battery
backup.
Nonvolatile Memory
Nonvolatile memory has the ability to retain stored
information when power is removed accidentally
or intentionally.
Although nonvolatile memory
generally is unalterable, there
are special types used in which
the stored information can be
changed.
Memory Types
As the name implies, programmable logic controllers
have programmable memory that allows users to develop
and modify control programs. Data are stored in memory
locations by a process called writing. Data are retrieved
from memory by what is referred to as reading.
Read-Only Memory (ROM):
Is designed so that information
stored in memory can only be
read, and under ordinary
circumstances cannot be changed. ROM memory is used
by the PLC for permanent storage of the operating system.
Memory Types
Random Access Memory (RAM):
Is designed so that information
can be written into or read from the
memory. Commonly used for the
user’s program, timer/counter values,
and input/output status.
Memory Types
Electrically Erasable Programmable Read-Only Memory
(EEPROM):
Is a nonvolatile memory
that offers the same flexibility
as does RAM. The EEPROM
can be electrically overwritten
with new data. Since it is
nonvolatile, it does not require
battery backup.
Typically, an EEPROM
memory module is
used
to store, back up, or
transfer
User Communications With PLC Circuits
Input Central Output
Module Processing
Unit Module
Programming Operator
Device
Interface
The programming device
The operator interface device
is used to input the desired
allows the process information
instructions. These
to be displayed and new control
instructions determine what
parameters to be entered.
the PLC will do for a specific
input.
Hand-Held Programming Device
Has a connecting cable so
that it can be plugged into
a PLC programming
port.
Are compact, inexpensive,
and easy to use.
Contains keys for instruction entering and editing,
and navigation keys for moving around the program.
Have limited display capabilities!
Personal Computer Programming Device
Changing Programs
The PLC can have only
one program in memory
at a time!
To change the program in the PLC, it is necessary to
enter a new program directly from the keyboard or to
download one from the computer hard drive.
PLC Workstation
Shows operation in graphic format for easier viewing
Allows operator to change settings using a touch screen
Shows alarms, complete with time of occurrence and
location
Displays variables as they change over time
