PLC Hardware Components

Industrial Control Systems

Fall 2006

Lecture – PLC Hardware Components MME 486 – Fall 2006 1 of 42

 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.

Lecture – PLC Hardware Components MME 486 – Fall 2006 2 of 42

 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

Lecture – PLC Hardware Components MME 486 – Fall 2006 3 of 42

 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.

Lecture – PLC Hardware Components MME 486 – Fall 2006 4 of 42

 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.
Lecture – PLC Hardware Components MME 486 – Fall 2006 5 of 42
 Logical Rack
A word in the output
image table file and its
corresponding word in
the input image table
file are called an I/O group.

A rack can contain a

maximum of 8 I/O
groups.

Lecture – PLC Hardware Components MME 486 – Fall 2006 6 of 42

 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.

Lecture – PLC Hardware Components MME 486 – Fall 2006 7 of 42

 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.

Lecture – PLC Hardware Components MME 486 – Fall 2006 8 of 42

 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.
Lecture – PLC Hardware Components MME 486 – Fall 2006 9 of 42
 PLC-5 Addressing

Lecture – PLC Hardware Components MME 486 – Fall 2006 10 of 42

 SLC 500 Addressing

Lecture – PLC Hardware Components MME 486 – Fall 2006 11 of 42

 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

Lecture – PLC Hardware Components MME 486 – Fall 2006 12 of 42

 Analog I/O Module Addressing

Lecture – PLC Hardware Components MME 486 – Fall 2006 13 of 42

 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 a physical name convention for a location 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.

Lecture – PLC Hardware Components MME 486 – Fall 2006 14 of 42

 Symbolic Addressing

Allen-Bradley ControlLogix controllers use a type of

symbolic addressing format. Each bit is referenced by a
tag name that is used to identify the memory location in
the controller.

Lecture – PLC Hardware Components MME 486 – Fall 2006 15 of 42

 Discrete I/O Modules

Discrete type I/O interface modules connects field

devices of the ON/OFF nature.
Discrete output modules
are used with field load
devices such as lights,
small motors, solenoids,
and motor starters that
require simple ON/OFF
switching.

Lecture – PLC Hardware Components MME 486 – Fall 2006 16 of 42

 Discrete I/O Modules

Discrete type I/O interface modules connects field

devices of the ON/OFF nature.

Discrete input modules

are used with field control
devices such as selector
switches, pushbuttons,
and limit switches.

Lecture – PLC Hardware Components MME 486 – Fall 2006 17 of 42

 Combination I/O Module

Status The arrangement of the terminals,

Indicators status indicators, and power supply
connections may vary.

I/O modules can have both input

and output connections in the same
physical module.

Power Supply
A module inserted into the wrong
Input Connections
slot could
Connections be damaged by improper
voltages connected through the
wiring arm.
Output Connections

Lecture – PLC Hardware Components MME 486 – Fall 2006 18 of 42

 Discrete I/O Modules
Each discrete I/O module is powered by some
field-supplied voltage source of a specified value.
Common voltage ratings are:

Input Interfaces Output Interfaces

12 V ac/dc 12-48 V ac
24 V ac/dc 120 V ac
48 V ac/dc 230 V ac
120 V ac/dc 120 V ac
230 V ac/dc 230 V dc
5 V dc (TTL level) 5 V dc (TTL level)
24 V dc

Lecture – PLC Hardware Components MME 486 – Fall 2006 19 of 42

 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.

Lecture – PLC Hardware Components MME 486 – Fall 2006 20 of 42

 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.
Lecture – PLC Hardware Components MME 486 – Fall 2006 21 of 42
 AC Discrete Input Module

Source – Rockwell International SLC500 Data CD

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 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

Lecture – PLC Hardware Components MME 486 – Fall 2006 23 of 42

 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.
Lecture – PLC Hardware Components MME 486 – Fall 2006 24 of 42
 AC Discrete Output Module

Source – Rockwell International SLC500 Data CD

Lecture – PLC Hardware Components MME 486 – Fall 2006 25 of 42

 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.

Lecture – PLC Hardware Components MME 486 – Fall 2006 26 of 42

 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.

Lecture – PLC Hardware Components MME 486 – Fall 2006 27 of 42

 Discrete Versus Analog Devices

Discrete devices are inputs ON/OFF

and outputs that have only toggle switch
two states: on and off.

Analog devices are inputs

and outputs that can have Analog
an infinite number or states. control valve

Lecture – PLC Hardware Components MME 486 – Fall 2006 28 of 42

 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.

Typical analog inputs may vary from

0 to 20 milliamperes, 4 to 20 milliamperes,
or 0 to 10 volts

Lecture – PLC Hardware Components MME 486 – Fall 2006 29 of 42

 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.

Lecture – PLC Hardware Components MME 486 – Fall 2006 30 of 42

 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
a set point.

Lecture – PLC Hardware Components MME 486 – Fall 2006 31 of 42

 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.

Lecture – PLC Hardware Components MME 486 – Fall 2006 32 of 42

 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.

Lecture – PLC Hardware Components MME 486 – Fall 2006 33 of 42

 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.
Lecture – PLC Hardware Components MME 486 – Fall 2006 34 of 42
 Special I/O Modules
Stepper-Motor Module

This module provides pulse trains to a stepper-motor

translator, which enables control of a stepper motor.

Lecture – PLC Hardware Components MME 486 – Fall 2006 35 of 42

 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.

Lecture – PLC Hardware Components MME 486 – Fall 2006 36 of 42

 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

Lecture – PLC Hardware Components MME 486 – Fall 2006 37 of 42

 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.

Lecture – PLC Hardware Components MME 486 – Fall 2006 38 of 42

 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 ControlLogix
Controller
Up to 64 K memory Controller
1 K memory
Up to 4096 Inputs Up to 160 K through
Up to 20 inputs
and Outputs 2 M memory
Up to 14 outputs
Up to 128,000 Inputs
and Outputs

Lecture – PLC Hardware Components MME 486 – Fall 2006 39 of 42

 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
coils and contacts to be Coil
stored in memory.

Lecture – PLC Hardware Components MME 486 – Fall 2006 40 of 42

 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
set to 1
Each input has
one corresponding
bit in memory

If the input is
open the bit is set to 0

Lecture – PLC Hardware Components MME 486 – Fall 2006 41 of 42

 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

Lecture – PLC Hardware Components MME 486 – Fall 2006 42 of 42