CHAPTER 2B: PLC HARDWARE COMPONENTS

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CHAPTER OBJECTIVES 1. List and describe the function of the hardware components used in PLC systems. 2. Describe the basic circuitry and applications for discrete and analog I/O modules, and interpret typical I/O and CPU specifications. 3. Explain I/O addressing. 4. Describe the general classes and types of PLC memory devices. 5. List and describe the different types of PLC peripheral support device available.

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ANALOG I/O MODULES 1.Discrete devices are inputs and outputs that have 2 static states: ON and OFF. 2.Analog devices are inputs and outputs that can have an infinite number of states. 3. Not only can these devices be ON and OFF, but they can also be barely ON, almost totally ON, not quite OFF. 4. These devices send/receive complex signals to/from a PLC.

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ANALOG I/O MODULES 1.Analog input interface modules contain the circuitry necessary to accept analog voltage or current signals from analog field devices. 2.These inputs are converted from analog to digital value by an analog-to-digital (A/D) converter circuit. 3. The conversion value which is proportional to the analog signal, is expressed as a 12bit binary or as a 3bit binary coded decimal (BCD) for use by the processor.
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ANALOG I/O MODULES 1.Analog input sensing devices include temperature, light, speed, pressure, and position transducers. See Figure 2-12 for an example. 2.A varying dc voltage in millivolt range, is proportional to the temperature being monitored is produced by the thermocouple. 3. Voltage produced by thermocouple is amplified and digitized by the analog input module and then sent to the processor on command from a program instruction.
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ANALOG I/O MODULES

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ANALOG I/O MODULES 1.There 2 basic types of analog input modules available: a) Current Sensing b) Voltage Sensing 2.Voltage input modules are available in 2 types: a) Unipolar-Can except 1 polarity input b) Bipolar- Can except split polarity input 3. The analog output interface module receives from the processor digital data. 4. The digital data is passed through a digital-to-analog (D/A) converter circuit to produce the necessary along form.
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ANALOG I/O MODULES Figure 2-13 illustrates the use of analog I/O modules in a typical PLC control system.

The value is initially open 100%

The processor modifies the output, which adjusts the valve to maintain a setp point

Fluid is placed in the holding tank As the fluid level in the tank approaches the preset point

SPECIAL I/O MODULES Special I/O modules have been developed to meet several needs. See pages 33 34 in the textbook for a complete list them. NOTE: New modules continue to be developed to meet specific application demands. At the same time, some modules, such as the PID module are no longer necessary because the newer PLC models include PID in their instruction set.

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I/O SPECIFICATIONS 1.Manufacturers specifications provide much information about how an interface is correctly and safely used. 2. The specifications place certain limitations not only on the module but on the field equipment as well. See pages 34-35 for the list of typical Manufacturers I/O specifications.

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THE CPU

1.The CPU houses the processor-memory modules, communications circuitry, and power supply. See Figure 2-14 2. CPU architectures may differ from one manufacturer to another, but generally most of the follow this same infrastructure.

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THE CPU

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THE CPU

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THE CPU Electrostatic Discharge (ESD) 1.Many electronic components found in the processors and other types of modules are sensitive to electrostatic voltages. 2. Voltages can be as low as 1mV (not able to feel ) 3. ESD can be created based on materials in the surrounding lab or manufacturing environment. 4. ESD can reach as high as 35kV. See page 38 for ESD Safety Precautions.
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THE CPU Electrostatic Discharge (ESD)

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MEMORY DESIGN

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MEMORY DESIGN 1.Memory is a physical space inside the CPU where the program files (control plan) and data files are stored and manipulated. 2.Data is typically stored in a file by address. 3.The information stored in the memory relates to the how the input and output data should be processed. 4.The memory organization of typical PLC based on I/O image tables. See Figure 2-17.

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MEMORY TYPES 1.PLCs have programmable memory that allows users to develop and modify control programs. 2.This memory is made nonvolatile so if the power is lost, the PLC holds it processor programming. See Figure 2-18. 3.Data stored in memory locations is by a process called writing. 4.Data retrieved from memory locations is by reading. See pages 40 -41 for several types of memory ICs.
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MEMORY TYPES

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PROGRAMMING DEVICES 1.Easy to use programming equipment is one of the important features of programmable controllers. 2.The programming device provides the primary means by which the user can communicate with the circuits of the controller. See Figure 2-19. 3.The programming device is used to input the desired instructions. See Figure 2-20 for an example of Programming Device. 4. Desktop PCs and notebook computers can also be used to communicate with a PLC. See Figure 2-21, page 43 in text book
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PROGRAMMING DEVICES

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PROGRAMMING DEVICES

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RECORDING AND RETRIEVING DATA

1. Printers are used to provide hard-copy printouts of the processors memory in ladder program format. 2. Hardcopy format of large programs can easily be viewed instead on a screen 3.Some older PLC systems use a magnetic cassette recorder to record and store the user program. See Figure 2-22. 4. Some PLCs use internal EEPROMs or EPROM memory modules that can store a backup to the program entered in the PLC. See Figure 2-23.
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RECORDING AND RETRIEVING DATA

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PLC WORKSTATIONS
1.A PLC workstation or operator interface can be connected to communicate with a PLC. 2. Replaces pushbuttons, pilot lights, thumbwheels , and other operator controls. 3. Luminescent touch-screen keypads provide an operator interface that operates like a traditional hard-wired control panels. 4. The PLC workstation is part of the HumanMachine-Interface (HMI) being studied at University and Manufacturing Corporations Research Labs.
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PLC WORKSTATIONS

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