Lecture 2’s sequence

2.1 The I/O Section

2.2 Discrete I/O Modules

2.3 Analog I/O Modules

2.4 Special I/O Modules

2.5 I/O Specifications

2.6 Central Processing Unit (CPU)

Lecture 2’s sequence
2.7 Memory Design

2.8 Memory Types

2.9 Programming Terminal Devices

2.10 Recording and Retrieving Data

2.11 Human Machine Interfaces (HMIs)

2.1. The I/O Section

▪ The input/output (I/O) section of a PLC is Inputs

the section to which all field devices are
connected and provides the interface
between them and the CPU.

Modular types use external Outputs

I/O modules that plug into
the PLC. Input/output arrangements
are built into a fixed PLC.

I/O Modules
2.1. The I/O Section

▪ Rack-based I/O section made up of

individual I/O modules
❑ Input interface modules accept
signals from the machine or
process devices and convert
them into signals that can be
used by the controller.
❑ Output interface modules convert
controller signals into external signals
used to control the machine or process.
2.1. The I/O Section

▪ The ability to locate The remote rack is linked to the

the I/O modules near local rack through a pair of
communications module.
the field devices A rack is referred to
as a remote rack
minimizes the when it is located
amount of wiring away from the
processor module.
required.
2.1. The I/O Section

▪ The PLC’s memory system stores information about the status of all the
inputs and outputs. To keep track of all this information, it uses a system
called addressing.

▪ Every input and output

device connected to a
discrete I/O module is
addressed to a specific
bit in the PLC’s memory.
2.1. The I/O Section

▪ Analog I/O modules use a word addressing format.

The bit part of the address is usually

not used but can be addressed by the
programmer if necessary.
2.1. The I/O Section

▪ An I/O module is made up of

a printed circuit board and a Status
terminal assembly. lights

The printed circuit board

contains electronic
circuitry.

The terminal assembly is

used for making field-wiring
connections.
2.1. The I/O Section

▪ Most PLC modules have plug-

in wiring terminal strips that
plug into the actual module.

If there is a problem with a

module, the entire strip is
removed, a new module is
inserted, and the terminal
block is plugged into the
new module.
2.1. The I/O Section

▪ I/O modules can be 8-,

16-, 32-, or 64-point
cards.

❑ The points refers to the

number of inputs or
outputs available.

❑ A high-density 64-point card provides a

greater space saving but with less rated
current output per output.
Lecture 2’s sequence
2.1 The I/O Section

2.2 Discrete I/O Modules

2.3 Analog I/O Modules

2.4 Special I/O Modules

2.5 I/O Specifications

2.6 Central Processing Unit (CPU)

2.2. The I/O Section

▪ The discrete or digital I/O interface

module connects field input devices
of the ON/OFF nature.

The classification of
discrete I/O covers
bit-oriented inputs
and outputs.
2.2. The I/O Section

▪ Each discrete I/O module is powered by

some field supplied voltage source.

Since these voltages can

be of different magnitude
or type, I/O modules are
available at various AC
and DC voltage ratings.
2.2. The I/O Section

▪ The modules themselves receive their voltage and current for proper operation from
the backplane of the rack enclosure into which they are inserted.

Backplane power is
provided by the PLC Currents required
module power supply by the loads are
and is used to power normally provided
the electronics that by user-supplied
reside on the I/O power.
module circuit board.
2.2. The I/O Section

▪ AC discrete input module block diagram

❑ The circuit is made up of a power section and a logic section.

❑ An optical isolator is used to provide electrical isolation between the power and
logic circuitry.
❑ The input LED turns on or off, indicating the status of the input device.
2.2. The I/O Section

▪ AC discrete input module schematic diagram

❑ When the pushbutton is closed, AC is applied to the bridge rectifier input.

❑ This results in a low-level DC output voltage that is applied across the LED of the
optical isolator.
❑ When light from
the LED strikes the
phototransistor, it
switches it into
conduction.
2.2. The I/O Section

▪ AC discrete output module block diagram

❑ The module is composed of the power section and the logic section, coupled by
an isolation circuit.
❑ The power output interface can be thought of as an electronic switch that turns
the output load device on and off.
2.2. The I/O Section

▪ AC discrete output module schematic diagram

❑ When the processor calls for the output load to be energized, a voltage is applied
across the LED of the opto-isolator.

❑ This in turn triggers the

triac AC semiconductor
switch into conduction
allowing current to flow
to the output load.
2.2. The I/O Section

▪ Individual AC outputs are usually

limited by the size of the triac to
1 A or 2 A.
❑ For controlling larger loads, an
interposing relay is connected
to the output module. The
contacts of the relay can then
be used to control a larger
load or motor starter.
2.2. The I/O Section

▪ Discrete output
modules are
used to turn
field output
devices either
on or off.

❑ Output modules can be purchased with

transistor, triac, or relay output.
2.2. The I/O Section

▪ Certain DC I/O modules

specify whether the
module is designed for
interfacing with current-
source (PNP) or current-
sink (PNP) devices.
Lecture 2’s sequence
2.1 The I/O Section

2.2 Discrete I/O Modules

2.3 Analog I/O Modules

2.4 Special I/O Modules

2.5 I/O Specifications

2.6 Central Processing Unit (CPU)

2.3. Analog I/O Modules

▪ Analog input and output devices have an infinite number of values

❑ Typical analog inputs and
outputs vary from 0 to 20
mA, 4 to 20 mA, or 0 to 10 V.
❑ The analog input interface
module accepts an analog
signal and converts it to a
digital signal.
❑ The analog output module accepts a digital signal and converts it to an analog
signal that operates the output.
2.3. Analog I/O Modules

▪ The two basic types of analog input modules are voltage sensing and
current sensing.
Cold junction
compensating (CJC)
❑ A varying DC voltage in thermistor
the low millivolt range,
proportional to the
temperatures being
monitored, is produced
by the thermocouples.
2.3. Analog I/O Modules

▪ The main element of the analog input module is an analog-to-digital

(A/D) converter
❑ Bipolar input modules can accept signals that swing between a negative and
positive value

❑ Unipolar input modules can accept

an input signal that varies in the
positive direction only

❑ Resolution refers to the smallest

change in input signal value that
can be sensed
2.3. Analog I/O Modules

▪ Unlike voltage input signals, current signals are not as sensitive to noise
and typically are not distance limited
❑ The current sensing loop power may be supplied by the sensor or the analog
output module

❑ Shielded twisted pair

cable is normally
recommended for
connecting any type
analog input signal
2.3. Analog I/O Modules

▪ Field devices that provide an analog output connected to transmitters,

which in turn send the analog signal to the module.
❑ A transducer converts a field
device’s variable (e.g., pressure,
temperature etc.) into a very
low-level electric signal
(current or voltage).

❑ A transmitter is used to amplify

the electric signal and then
send it to the analog module
2.3. Analog I/O Modules

▪ Wiring two-, three-, and four-wire sensors to an analog input module

All analog common (ANL COM)

points are electrically connected
together inside the module but
not to earth ground.
2.3. Analog I/O Modules

▪ Wiring single-ended analog input devices to the analog input card

2.3. Analog I/O Modules

▪ The main element of the analog output module is a digital-to-analog

(D/A) converter
❑ The analog output module receives from
the processor digital data, which are
converted into a proportional voltage or
current to control an analog field device

❑ The analog output signal is varied under

the control of the PLC program and can be
used for control of an analog control valve
2.3. Analog I/O Modules

▪ Analog I/O control system

The PLC controls the amount of
fluid placed in a holding tank by
adjusting the percentage of the
valve opening

❑ The valve is initially opened 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 2’s sequence
2.1 The I/O Section

2.2 Discrete I/O Modules

2.3 Analog I/O Modules

2.4 Special I/O Modules

2.5 I/O Specifications

2.6 Central Processing Unit (CPU)

2.4. Special I/O Modules

▪ High-speed counter modules are used to count pulses from sensors,

encoders, and switches that operate at very high speeds

They have the electronics needed

to count independently of the
processor

A typical count rate available is 0 to

100 kHz, which means the module
would be able to count 100,000
pulses per second
2.4. Special I/O Modules

▪ Encoder-counter module allows the user to read the signal from an

encoder on a real-time basis and stores this information so it can be read
later by the processor

An encoder is mainly used for feedback

purpose to know the position and
distance measurement

Encoders convert motion to

electrical signal pulses
2.4. Special I/O Modules

▪ Stepper-motor module provides pulse trains to a stepper-motor

translator, which enables control of a stepper motor
The commands for the module
are determined by the control
program in the PLC
2.4. Special I/O Modules

▪ Motion and position

control modules are used
in applications involving
accurate high-speed
machining and packaging
operations.

Intelligent position and motion control modules

permit PLCs to control stepper and servo motors
2.4. Special I/O Modules

▪ Serial communications modules are used

to establish point-to-point connections
with other intelligent devices for the
exchange of data

Communication modules allow to

connect the PLC to high-speed local
networks that may be different
from the network communication
provided with the PLC
Lecture 2’s sequence
2.1 The I/O Section

2.2 Discrete I/O Modules

2.3 Analog I/O Modules

2.4 Special I/O Modules

2.5 I/O Specifications

2.6 Central Processing Unit (CPU)

2.5. I/O Specifications

▪ Discrete I/O Module Specifications

❑ Nominal input voltage: specifies the magnitude and type of user-supplied
voltage that a module is designed to accept

❑ Input threshold voltages: specifies the minimum ON-state (maximum OFF-

state) voltage at which logic 1 (logic 0) is recognized

❑ Nominal current per input: specifies the minimum input current that the
discrete input devices must be capable of driving to operate the input circuit
2.5. I/O Specifications

▪ Discrete I/O Module Specifications

❑ Ambient temperature rating: specifies what the maximum temperature of
the air surrounding the I/O modules should be for best operating conditions

❑ Input ON/OFF delay (response time): 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)

❑ Output voltage: specifies the magnitude and type of user-supplied voltage

at which a discrete output module is designed to operate
2.5. I/O Specifications

▪ Discrete I/O Module Specifications

❑ Output current (maximum continuous current or maximum load current):
specifies the maximum current that a single output and the module can
safely carry under load (at rated voltage)

❑ Inrush current: specifies the maximum inrush current and duration for which
an output circuit can exceed its maximum continuous current rating

❑ Short circuit protection: specifies whether the output module’s design has
individual protection for each circuit or if fuse protection is provided for
groups of outputs
2.5. I/O Specifications

▪ Discrete I/O Module Specifications

❑ Leakage current: specifies the amount of current still conducting through
an output circuit even after the output has been turned off

❑ Electrical isolation: the specification for electrical isolation, typically 1500

or 2500 VAC, rates the module’s capacity for sustaining an excessive voltage
at its input or output terminals

❑ Points per module: this specification defines the number of field inputs or
outputs that can be connected to a single module
2.5. I/O Specifications

▪ Discrete I/O Module Specifications

❑ Backplane current draw: specifies the amount of current the module
requires from the backplane

Power
supply

Backplane
2.5. I/O Specifications

▪ Analog I/O Module Specifications

❑ Channels per module: whereas individual circuits on discrete I/O modules
are specified as points per module, circuits on analog I/O modules are
specified as channels per module

❑ Input current/voltage range(s): these are the voltage or current signal

ranges that an analog input module is designed to accept

❑ Output current/voltage range(s): defines the current or voltage signal

ranges that a particular analog output module is designed to output under
program control
2.5. I/O Specifications

▪ Analog I/O Module Specifications

❑ Input protection: analog input circuits are protected against accidentally
connecting a voltage that exceeds the specified input voltage range

❑ Resolution: specifies how accurately an analog value can be represented

digitally. This will determine the smallest measurable unit of current or
voltage change that can be detected

❑ Input impedance and capacitance: for analog I/Os, these values must be
matched to the external device connected to the module. Typical ratings
are in the Megohm (MΩ) and picofarads (pF).
2.5. I/O Specifications

▪ Analog I/O Module Specifications

❑ Common-Mode Rejection: applies only to differential inputs and refers to
an analog module’s ability to prevent noise from interfering with data
integrity on a single channel and from channel to channel on the module

Noise is generally caused by electromagnetic

interference, radio frequency interference,
and ground loops

Noise that is picked up equally in parallel wires

is rejected because the difference is zero.
Twisted pair wires are used to ensure that this
type of noise is equal on both wires
Lecture 2’s sequence
2.1 The I/O Section

2.2 Discrete I/O Modules

2.3 Analog I/O Modules

2.4 Special I/O Modules

2.5 I/O Specifications

2.6 Central Processing Unit (CPU)

2.6. The Central Processing Unit (CPU)

▪ The central processing unit (CPU) is built into

fixed PLCs while modular types typically use
a plug-in module

CPU, controller, and processor

are all terms used by different
manufacturers to denote the
same module that performs
basically the same functions
2.6. The Central Processing Unit (CPU)

▪ A processor module can be

divided into two sections:
the CPU section and the
memory section

The CPU executes the program

makes the decisions

The memory stores the program

along with other retrievable data
2.6. The Central Processing Unit (CPU)

▪ The PLC power supply provides the necessary power to the processor
and I/O modules plugged into the backplane of the rack

The power supply converts the AC

input voltage into the usable DC
voltage required by the CPU,
memory, and I/O electronic circuitry

PLC power supplies are normally

designed to withstand momentary
losses of power without affecting the
operation of the PLC (10 ms to 3 s)
2.6. The Central Processing Unit (CPU)

▪ The CPU contains the similar type of

microprocessor found in a personal
computer

A PLC microprocessor is designed to

facilitate industrial control rather than
provide general purpose computing

PLC processor handles some type of communication

include programmer, I/O modules, other PLCs and
industrial automation devices
2.6. The Central Processing Unit (CPU)

▪ The CPU of a PLC system may

contain more than one processor

Fault-tolerant PLC systems support

dual processors for critical processes.
These systems allow the user to
configure the system with redundant
(two) processors, which allows transfer
of control to the second processor in
the event of a processor fault
2.6. The Central Processing Unit (CPU)

▪ Associated with the processor unit will be

several status LED indicators to provide
system diagnostic information to the
operator.
A keyswitch may be provided that allows
you to select one of modes of operation
(RUN, PROG, REM)
Lecture 2’s sequence
2.7 Memory Design

2.8 Memory Types

2.9 Programming Terminal Devices

2.10 Recording and Retrieving Data

2.11 Human Machine Interfaces (HMIs)

2.7. Memory Design

▪ Memory is the element that stores information,

programs, and data in a PLC

The complexity of the

program determines
the amount of memory
required
2.7. Memory Design

▪ Memory location refers to an address in the CPU’s memory where a

binary word can be stored. Each binary piece of data is a bit and eight
bits make up one byte

The program is stored in the

memory as 1s and 0s, which
are typically assembled in the
form of 16-bit words
2.7. Memory Design

▪ Sections of memory used to store the status of inputs are called input
status files or tables
2.7. Memory Design

▪ Sections of memory used to store the status of outputs are called output
status files or tables
Lecture 2’s sequence
2.7 Memory Design

2.8 Memory Types

2.9 Programming Terminal Devices

2.10 Recording and Retrieving Data

2.11 Human Machine Interfaces (HMIs)

2.8. Memory Types

▪ Memory types can be placed into two general categories: volatile and
nonvolatile

❑ Nonvolatile memory can retain stored information when power is

removed accidentally or intentionally

❑ Volatile memory will lose its stored information if all operating power is
lost or removed

❑ PLCs have programmable memory that allows users to develop and modify
control programs. This memory is made nonvolatile so that if power is lost,
the PLC holds its programming.
2.8. Memory Types

▪ Nonvolatile Read Only Memory (ROM) stores programs and data that
cannot be changed after the memory chip has been manufactured

❑ ROM is used by the PLC for

the operating system and
controls the system software
that the user uses to
program the PLC
2.8. Memory Types

▪ Random Access Memory (RAM) is designed so that information can be

written into or read from the memory.
❑ PLCs use RAM as a temporary
storage area of data that may
need to be quickly changed
❑ RAM is volatile so battery backup
is required for it to avoid losing
data in the event of a power loss
2.8. Memory Types

▪ 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

UV EPROM memory can only be

erased with an ultraviolet light
2.8. Memory Types

▪ Electrically erasable programmable read-only memory (EEPROM) is a

nonvolatile memory that offers the same programming flexibility as
does RAM
❑ The EEPROM can be electrically
overwritten with new data instead
of being erased with ultraviolet light

Because the EEPROM is nonvolatile

memory, it does not require battery
backup
2.8. Memory Types

▪ Flash EEPROMs are like EEPROMs in that they can only be used for
backup storage
❑ Flash memory is extremely fast
at saving and retrieving files
❑ Flash memory is also sometimes
built into the processor module,
where it automatically backs up
parts of RAM
Lecture 2’s sequence
2.7 Memory Design

2.8 Memory Types

2.9 Programming Terminal Devices

2.10 Recording and Retrieving Data

2.11 Human Machine Interfaces (HMIs)

2.9. Programming Terminal Devices

▪ A programming terminal device is needed to enter, modify, and

troubleshoot the PLC program

❑ The hand-held proprietary

programming terminal has a
connecting cable so that it can
be plugged into a PLC’s
programming port

❑ Hand-held programmers are

compact and inexpensive but
have limited display capabilities
2.9. Programming Terminal Devices

▪ The most popular method of PLC programming is to use a personal

computer in conjunction with the manufacturer’s programming software
Lecture 2’s sequence
2.7 Memory Design

2.8 Memory Types

2.9 Programming Terminal Devices

2.10 Recording and Retrieving Data

2.11 Human Machine Interfaces (HMIs)

2.10. Recording and Retrieving Data

▪ Printers are used to provide

hard-copy printouts of the
processor’s memory in ladder
program format

A printout can show programs

of any length and analyze the
complete program
2.10. Recording and Retrieving Data

▪ The program in the PLC is

entered directly from the
keyboard or downloaded
from the computer hard drive
or thumb drive.
2.10. Recording and Retrieving Data

▪ 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.
Lecture 2’s sequence
2.7 Memory Design

2.8 Memory Types

2.9 Programming Terminal Devices

2.10 Recording and Retrieving Data

2.11 Human Machine Interfaces (HMIs)

2.11. 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 devices
2.11. Human Machine Interfaces (HMIs)

▪ Human machine interfaces allow you to view the operation in real time
▪ You can configure display screens to:
❑ Replace hardwired pushbuttons and pilot
lights with realistic-looking icons
❑ Allow the operator to change timer and
counter presets
❑ Show alarms, complete with time of
occurrence
❑ Display variables as they change over time
2.11. Human Machine Interfaces (HMIs)

▪ Human Machine Interfaces (HMIs) provide a means of controlling,

monitoring, managing, and/or visualizing device processes
❑ Set up the communication with the PLC to configure all necessary software and hardware
components
❑ Create the tag database to import tags
from the PLC programming software
❑ Insert the graphical objects on the
screen
❑ Animate the objects to allow an
operator to change tag values or
display animation