PLC Hardware Components

I/O Section
Remote I/O Rack
I/O Module Addressing
Discrete I/O module addressing
Analog I/O Module Addressing Symbolic Addressing
(e) Symbolic addresses are real
names or codes that the
programmer can substitute for a
logical address because they relate
physically to the application.

In this example . the symbolic

addresses are lS_3 and pump_14,
while the actual addresses are I:3/3
and 0:4/14., respectively.

AIIen·Bradley Conlrollogix
controllers use a type 01 symbolic
addressillg format. Each bit is
relerenced by a tag name that is
used to identify the melT'lOfY
location in the controller
Typical combination I/O module
 An A/C discrete input module

The input circuit responds to an input signal in the following manner:

• An input litter removes false signals that are due to contact bounce or electrical
interference.
• Opto-ellectrical isolation protects the input circuit and backplane circuits by isolating logic
circuits from input signals.
• Logic circuits process the signal.
• An input LEO turns ON Of OFF, indicating the status of the corresponding input device
Simplified schematic for an ac input module
 An ac discrete output module

The output circuit controls the output signal in the following manner:
• Logic circuits determine the output status.
• An output LED indicates the status of the output Signal.
• Opto-electrical isolation separates output circuit logic and backplane circuits from
the field signals.
• The output driver turns the corresponding output ON or OFF.
Simplified schematic for an ac output
module
Interposing relay connection
Typical thermocouple connection to
an analog input module
Relay, transistor, and triac switching
elements.

•Triac outputs can 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, but they
have a much slower switching time compared to solid state
outputs.
Sinking and sourcing inputs.

Sinking and sourcing outputs.

Special I/O Modules
Intelligent I/O Modules
Language Module
The language module enables the user to
write programs in a high-level language via a
high-level-language interpreter. It converts
the high-level commands into machine
language understandable to a PLC 's
processor. BASIC, C etc

Speech Module
Speech modules typically are used to
digitize a human voice pronouncing the
desired word phrase, or sentence. The
digitized sound is stored in the module's
memory. Each word, phrase or sentence
is given a number. Ladder logic is used to
output the appropriate message at the
appropriate time.
 CPU

Sections of a PLC processor module.

 Typical processor unit

Three modes of operation: RUN, PROG, and REM

 Mode Switch and Analog Adjustment
• Each S7-200 CPU has a mode switch with three
positions, RUN, STOP, and TERM. When the mode
switch is in the RUN position, the CPU is in the
RUN mode and executing the program, unless a
fault has occurred. When the mode switch is in the
STOP position, the CPU is in the STOP mode and
not executing the user program. When the mode
switch is in the TERM position, the programming
device can select the operating mode.

• An analog adjustment is available to increase or

decrease values stored in special memory. This can
allow a variable in the user program to change as
the analog adjustment is changed. CPU 221 and
CPU 222 models have one analog adjustment. CPU
224, CPU 224XP, CPU 224 XPsi, and CPU 226 have
two analog adjustments .
 Memory Design

Input and output status tables or files

 Types of Memory
•Read-Only Memory (ROM)
•Random Access Memory (RAM or R/W)
•Programmable Read-Only Memory (PROM)
•Erasable Programmable Read-Only Memory (EPROM)
•Electrically Erasable Programmable Read-Only Memory (EEPROM)
 Memory Types and Size
• Random Access Memory (RAM) is memory from which data can be
directly accessed at any address. Data can be written to and read from
RAM. RAM is used as a temporary storage area for data that may need to
be quickly changed. RAM is volatile, meaning that the data stored in RAM
will be lost if power is lost. A battery backup is required to avoid losing
data in the event of a power loss.

• Read Only Memory (ROM) stores programs and data that cannot be
changed after the memory chip has been manufactured. ROM is normally
used to store the programs and data that define the capabilities of the
PLC. ROM memory is non-volatile, meaning that its contents will not be
lost if power is lost.

• Erasable Programmable Read Only Memory (EPROM) provides some level

of security against unauthorized or unwanted changes in a program.
EPROMs are designed so that data stored in them can be read, but not
easily altered without special equipment. For example, UV EPROMs
(ultraviolet erasable programmable read only memory) can only be
erased with an ultraviolet light. EEPROM (electrically erasable
programmable read only memory), can only be erased electrically.
Memory Types and Size
 PROGRAMMING DEVICES

User communications
with PLC circuits

Handheld programming device Personal computer used as the

programming device.
 PLC Scan
• The PLC program is executed as part of
a repetitive process referred to as a
scan.

• A typical PLC scan starts with the CPU

reading the status of inputs. Then, the
application program is executed.

• Once the program execution is

completed, the CPU performs internal
diagnostic and communication tasks.
Next, the status of all outputs is
updated. This process is repeated
continuously as long as the PLC is in the
run mode.

• The time required for a scan depends

on the capabilities of the CPU, size of
the program, the number of I/Os, and
the amount of communication
required.
Software, Hardware, and Firmware
• Software is the name given to
computer instructions regardless of
the programming language.
Essentially, software includes the
instructions or programs that
direct hardware.

• Hardware is the name given to all

the physical components of a
system. The PLC, the programming
device, and the connecting cable
are examples of hardware.

• Firmware is user or application

specific software burned into
EPROM and delivered as part of
the hardware. Firmware gives the
PLC its basic functionality.
 Recording and Retrieving Data
Printers are used to provide hard-copy printouts of the processor’s
memory in ladder program format. Lengthy ladder programs cannot be
shown completely on a screen. Typically, a screen shows a maximum of
five rungs at a time. A printout can show programs of any length and
analyze the complete program.
The PLC can have only one program in memory at a time. To
change the program in the PLC, it is necessary either to enter a
new program directly from the keyboard or to download one from
the computer hard drive. Some CPUs support the use of a
memory cartridge that provides portable EEPROM storage for the
user program. The cartridge can be used to copy a program from
one PLC to another similar type PLC.
 Human Machine Interfaces (HMIs)
A human machine interface (HMI)
can be connected to communicate
with a PLC and to replace
pushbuttons, selector switches,
pilot lights, thumbwheels, and
other operator control panel
devises.

Luminescent touch-screen keypads

provide an operator interface that
operates like traditional hardwired
control panels.
Human machine interfaces give the ability to the operator and to
management to view the operation in real time. Through personal
computer–based setup software, you can configure display screens to:
• Replace hardwired pushbuttons and pilot lights with realistic-looking
icons. The machine operator need only touch the display panel to
activate the pushbuttons.
• Show operations in graphic format for easier viewing.
• Allow the operator to change timer and counter presets by touching
the numeric keypad graphic on the touch screen.
• Show alarms, complete with time of occurrence and location.
• Display variables as they change over time.
 Typical Discrete I/O Module Specifications
• NOMINAL INPUT VOLTAGE - This discrete input module voltage value
specifies the magnitude (e.g., 5 V, 24 V, 230 V) and type (AC or DC) , +/-
10% input voltage.
• INPUT THRESHOLD VOLTAGES-a minimum ON-state voltage that is the
minimum voltage at which logic 1 is recognized as absolutely ON; and a
maximum OFF-state voltage which is the voltage at which logic 0 is
recognized as absolutely OFF.
• NOMINAL CURRENT PER INPUT - This value specifies the minimum
input current that the discrete input devices must be capable of driving
to operate the input circuit.
• AMBIENT TEMPERATURE RATING - This value specifies what the
maximum temperature of the air surrounding the I/O modules should
be for best operating conditions.
• INPUT ON/OFF DELAY - Also known as response time , this value
specifies the maximum time duration required by an input module’s
circuitry to recognize that a field device has switched ON (input ON-
delay) or switched OFF (input OFF- delay). Typically in the 9 to 25 mS
• OUTPUT VOLTAGE - This AC or DC value specifies the magnitude
(e.g., 5 V, 115 V, 230 V) and type (AC or DC) of user-supplied
voltage. +/- 10%
• OUTPUT CURRENT - These values specify the maximum current
that a single output and the module as a whole can safely carry
under load (at rated voltage). Other names for the output current
rating are maximum continuous current and maximum load current.
• INRUSH CURRENT - An inrush current is a momentary surge of
current that an AC or DC output circuit encounters when energizing
inductive, capacitive, or filament loads. This value specifies the
maximum inrush current and duration (e.g., 20 A for 0.1 s)
• LEAKAGE CURRENT - This value specifies the amount of current still
conducting through an output circuit even after the output has
been turned off. Solid-state switching devices such as transistors
and triacs and is normally less than 5 milliamperes.
• POINTS PER MODULE - This specifi cation defi nes the number of fi
eld inputs or outputs that can be connected to a single module.
Most commonly, a discrete module will have 8, 16, or 32 circuits;
• however, low-end controllers may have only 2 or 4 circuits. Modules
with 32 or 64 input or output bits are referred to as high-density
modules.
 PLC vs PC PLC Size
• Operating Environment • Nano – Less than 15 I/O
• Method of Programming • Micro – 15 to 128 I/O
• Execution of program 90% Instruction
• Maintenance • Medium - 128 to 512I/O
• Large – over 512 I/O
Application
•Single Ended PLC – Single
Memory
Process
In common memory capacity
•Multi Task PLC (Medium) –
of PLC in “Words”
Several Process, Subsystem
•Control Management PLC – One
256 words to 2 Mega words
PLC controlling several
1K means 1024 words
others
 Size of PLC
The size of the PLC depends on
• No. of I/O
• Size of the control program
• Data collecting requirement
• Supervisory function
• Future Expansion