27/04/2023

PLC
PLC Components
Lecture 2

PLC main Parts

• A PLC (Programmable Logic Controller) is made up of both hardware and
software components.
• The PLC hardware refers to the physical components that make up a PLC
system.
• The PLC software refers to the PLC’s operating system and application
program that are stored in the PLC’s memory.

• PLC hardware -> physical components

•

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Six basic hardware components

1.Processor (CPU)
2.Mounting System
3.Power Supply
4.Input & Output Interface
5.Communication Interface
6.Programming Device

1. PLC Processor (CPU)

• At the heart of every PLC system is a processor
• PLC processor is also referred as the PLC controller or PLC CPU
• processor is the workhorse of the PLC system responsible for:
• all the logic computation and number crunching.
• PLC processor have two types as A PLC UNIT:
• Processor embedded : fixed style PLC with embedded processor,
- they have ability to expand
• Processor separated :
• PLC processor modules
• Ddistributed PLC types
have their PLC processors as a separate module

• The PLC processor contains 3 fundamental components:

1. PLC CPU (Central Processing Unit)
2. PLC Memory
3. PLC Programming port

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1.1 PLC CPU (Central Process Unit)

• The PLC CPU is a microprocessor that is similar to a computer CPU.
• But PLC CPU is not set up to multitask like a computer CPU,
• rather to perform dedicated tasks such as program scan and execution.

• In a PLC the CPU is responsible for control of all PLC activity:

• scanning (such as ladder logic),
• program executing,
• handling data storage,
• directing data flow
• and controlling communication among the various interfaces.

• The most common processor used in a PLC is a single microprocesso

• higher powered PLCs have multiple microprocessors
•

1.2 PLC Memory

• The PLC memory is made up of
• program memory: store the program for processing by the CPU
• data memory : to store data for input and output processing and execution
• and firmware : PLC operating system code that is burned into a ROM sort
• The size vary depending on the processing power of the CPU.
•
•
• some PLC controllers have expandable memory
• Memory Types:
• Load Memory
• Use for user program, data, and configuration
• Work Memory – RAM
• Work memory is volatile storage for some elements of the user program while executing
the program
• Retentive Memory
• PLC system provides some part of the memory to store data permanently

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1.3 PLC Programming Port

• The programming port used for :
• communicate with external devices (sensors, actuators)
• communicate with systems (programming software, SCADA).
• User interface ( HMI , SCADA )

• The built-in ports varies for PLC manufacturers:

• RS-232,
• RS-485
•
• Communication is carried over various industrial network protocols:
1. EtherNet/IP
2. Profibus
3. Modbus

2. PLC Hardware Mounting Systems

• provides the means to physically connect the various hardware components of the PLC system.
• Rack mounted PLC : chassis, backplane, base, base rack and base module
• Rail mounted PLC : DIN rail
• 35mm DIN rail
• Siemens Simatic DIN rail
• Panel mounted PLC

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3. PLC Power Supply

• The main purpose :convert the available power supply voltage into a voltage that is
• usable by the PLC processor (CPU) and other PLC modules.

• 3 main types of PLC power supplies:

• Integrated PLC power supply
• PLC power supply module
• Remote PLC power supply

• PLC Power Supply Size

• The PLC power supply size will depend upon the overall size of the PLC system.
• power (W) or apparent power (VA)
• PLC Power Supply Rating
• specified in Voltage (V) and Current (A).
• Calculate the total current load of the combined modules on the PLC rack must not be greater
than the PLC power supply rated output current.

4. PLC Input and Output Hardware Interface

• PLC input and output modules are a common interface between the field devices and the PLC
processor (CPU)
• Connection between I/O module and field devices
• terminal strip.

• Some field devices can use Ethernet, RS-485,.. For connection

• PLC input devices like pushbuttons, limit switches,
proximity sensors, temperature transmitters,
pressure transmitters, level transmitters, encoders
• PLC outputs are connected to PLC output devices such as
relays, motor contactors, VFDs (Variable Frequency Drives)
, solenoid valves, proportional vales, indication lights,
sire

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5. PLC Communication Hardware Interface

• PLCs can communicate to multiple devices by using a communication interface.
• allows cable connection to devices such as other PLCs, remote I/O drops, fieldbus devices, touch
screens, programming PCs and servers
•
• Available in two form :
• embedded communication ports
• extra communication modules s

• Ethernet based protocols used for PLC communication

• Ethernet IP, Profinet, Ethercat,

• Serial communication ports, some of the common

DeviceNet, Profibus DP, Modbus RTU,

6. PLC Programming Device

• Programmable Logic Controllers need to be programmed somehow.
There are 2 devices that can do it:
• handheld programming devices
• They are generally limited to programming small applications
with low numbers of I/O.
• and personal computers (PC).
• enables use of large amounts of programming memory
• easy programming of complex applications with large amounts of I/O.

•
• The PLC programming devices connect to the PLC using
• a cable via
• Ethernet or
• Serial based communication protocol.