Basic Architecture Of PLC

BLOCK DIAGRAM

Programming unit

CPU M
Input Output
module Memory module S

Power supply
 What is a PLC? …. slide1

A PLC is an Industrial Computer. Just like our Personal Computer it has Inputs
and Outputs.
Some of the Inputs to the PLC are:
Limit Switches.
Float Switches.
Push Buttons. Discrete input control
field devices
Photoelectric Sensors.
Pressure Switches.

Temperature Sensors. Analog input control

Pressure Sensors. field devices

Some of the Outputs to the PLC are:

Motor Starters
Pilot Lights
Solenoids.
 Formal Definition of PLC.
The formal definition of PLC comes from the National Electric
Manufacturers Association (NEMA).

“A PLC [Programmable Logic Controller] is a digitally operated electronic

system, designed for use in an industrial environment, which uses a
programmable memory for the internal storage of user-oriented instructions
for implementing specific functions such as
Logic
Sequencing
Timing
Counting &
Arithmetic…………………

to control, through digital or analog inputs and outputs, various types of

machines or processes.
 How a Human Being is Involved with PLC?

Fig-2 shows how a human being is involved with the PC.

 PLC Hardware Configuration: 2 Types.

1] Fixed/ Composite PLC 2] Modular PLC

 Allen Bradley SLC 500 Modular PLC

Power supply Processor Input modules Output module

Slot 0 Slot 1 Slot 2 Slot 3

 Interfacing of the PLC with Programming Units.
Input modules

SLC – 500 PLC

( Modular )
Power Output module
supply Processor

Slot 0 Slot 1 Slot 2 Slot 3

1747- C10 cable

1747- PIC

RS 232

Personal Computer
 Allen Bradley MicroLogix 1200 Fixed PLC

Sensor input to PLC

PLC Input
0 8 9 10 12 13 Section
1 2 3 4 5 6 7 C 11

IN MicroLogix 1200 Power

Run
OUT Force
Communication
PLC O/P
0 1 2 3 4 5 6 7 8 9 Section
24 Volts
Power L2
Supply PLC Output to Motor Starter

Starter

Motor
Sensor
 Just take a glance at the input module wiring with limit switch!!!
Input Module

0
Input signal from limit switch to 1
input screw terminal 0 on a 24 VDC
+ input module. 2
3
24 VDC
Power 4
Supply
5
- 6
7
C
 What Do You Mean By Sinking & Sourcing?

Sinking & Sourcing are the terms used to describe current

flow through a field device in relation to the Power Supply
and the associated I/O points

Sinking Input Devices

Solid State input devices with NPN transistors.

Sourcing Input Devices

Solid State input devices with PNP transistors.
 What Do You Mean By Sinking & Sourcing?

Sourcing Module Sinking Module

Input Module Input Module

Sinking Switch Sourcing Switch

- +
24 VDC 24 VDC
Power Power
Supply Supply

+ -
Wiring Diagrams of AB SLC 500 1746-IV8 ………Sourcing I/P.

Input Module
- 24 VDC Sourcing Module
Input Module

0
Sinking Switch
1

2
-
3 24 VDC
Power
4 Supply
5
+
6
7
C
+ 24 VDC
 Wiring Diagrams of AB SLC 500 1746-IB8 ………Sinking I/ P.

Input Module
+ 24 VDC
Sinking Module
Input Module

0
1 Sourcing Switch

2
+
3
24 VDC
4 Power
Supply
5
-
6
7
C

- 24 VDC
 Input Modules: Classification…………..

Discrete Input modules Analog Input Modules

Discrete AC input modules.

Discrete DC input modules.

 Input Modules

The main Function of the Input module is…………

To take the field device Input signal.

Electrically isolate it. and

Send by the way of backplane board to the CPU.

 Discrete DC Input Modules.

The most common module types available are listed below

24 VDC
48 VDC
10 - 60 VDC
120 VDC
230 VDC
Sink/ Source 5 - 50 VDC
5 VDC TTL level
5/12 VDC TTL level
 Block Diagram of typical Discrete DC Input Circuit.

Noise &
Threshold
DC input debounce
Detector.
Filter. Module Operation
1 2 3
Optical
4 Isolation

6
5
LED Logic
8

Input
7 CPU Status
File

Simplified Circuitry of a DC Input Module

 Discrete AC Input Modules.

The most common module types available are listed below

24 VAC
48 VAC
120 VAC
240 VAC
Nonvoltage
120 Volts Isolated
240 Volts Isolated
24 VAC/DC
 Block Diagram Of Typical Discrete AC Input Circuit

To PC

1 3 5 Internal sys.

AC Pulsating DC Filtered DC

2 4 6 7 8 10 11

Bridge Noise and Threshold Logic CPU Input

Optical
rectifier detector status
isolation
debounce table
filter
LED 9

Power file Conversion Circuit

Optical Isolation Circuit
Logic Circuit
OPTICAL Isolator is used to isolate high voltage incoming signals from the CPU’s lower
voltage levels. It protects the low voltage CPU and its associated circuitry by preventing
spikes or high – voltage transients on the input circuit from transferring into the low voltage
circuitry.
Two Types of Discrete Input Device………….

Mechanical Devices Electronic Devices

Solid - State sensors like
Limit Switches.
Toggle Switches Inductive Proximity device.

Selector Switches Capacitive Proximity device.

Etc.
Push Button
Contacts from an
Electro-Mechanical relay. etc
 Binary Concept & Binary Data Representation……… slide1

Bit Position
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

0 0 l l 0 l 0 l l l l 0 0 1 0 0
Bit

4 Bits = 1 Nibble

8 Bits = 1 Byte

16 Bits = 1 Word

Information can be represented by arranging the 1s and 0s in different

combinations within a 16 bit word.
 Binary Concept & Binary Data Representation……… slide2

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

0 0 l l 0 l 0 l l l l 0 0 1 0 0

MSB LSB
= Most Significant Bit = Least Significant Bit

In the Next slide we will have a look ………. How a 16-bit word is used to
represent the ON-OFF status of each screw terminal on a 16-point I/ O module.
 Correlation of 16 bit Words to Input Signals………slide1

Input Module
One LED for each input point. LED is ON when there is an
ON signal to the corresponding input point

0
1
2
3
4
5
6 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
7
8
9
10
11
12
13
14
15
C
 Correlation of 16 bit Words to Input Signals……….slide 2
Input Module
+ 24 VDC One LED for each input point. LED is ON when there
is an ON signal to the corresponding input point

0
1

2
3
4
5
6
7
Unused bits
C
0 0 0 0 0 0 0 0 0 1 0 1 0 0 0 0
- 24 VDC 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
 Correlation of 16 bit Words to Input Signals……….slide 3
Slot 0 Slot 1 Slot 2 Slot 3 Slot 4 Slot 5 Slot 6
Power Supply CPU Input Module Output Module Input Module Input Module Output Module Input Module

00 01 00 01 00 01 00 01 00 01 00 01
02 03 02 03 02 03 02 03 02 03 02 03
04 05 04 04 05 04 05 04 04 05
05 05
06 07 06 06 07 06 07 06 06 07
VAC 07 VAC 07
08 09 08 09 08 09 08 09
08 09 08 09
10 11 10 10 11 10 11 10 10 11
12 13 11 12 13 12 13 11 12 13
12 12
14 15 13 14 15 14 15 13 14 15
14 14
com com VAC 15 com com com com VAC 15 com com

Input Status Table

Word 1
Word 3
Word 4
Word 6
 Correlation of 16 bit Words to Output Signals……….slide 4

Slot 0 Slot 1 Slot 2 Slot 3 Slot 4 Slot 5 Slot 6

Power Supply CPU Input Module Output Module Input Module Input Module Output Module Input Module

00 01 00 01 00 01 00 01 00 01 00 01
02 03 02 03 02 03 02 03 02 03 02 03
04 05 04 04 05 04 05 04 04 05
05 05
06 07 06 06 07 06 07 06 06 07
VAC 07 VAC 07
08 09 08 09 08 09 08 09
08 09 08 09
10 11 10 10 11 10 11 10 10 11
12 13 11 12 13 12 13 11 12 13
12 12
14 15 13 14 15 14 15 13 14 15
14 14
com com VAC 15 com com com com VAC 15 com com

Output Status Table

Word 2
Word 5
PLC Memory and How it is used?………………….slide 1
We are already familiar with the basic Block diagram of Architecture of PLC.

CPU M
Input Output
module Memory module S

Power supply

Personal Computer

PLC Memory.
 PLC Memory and How it is used?………………….slide 2
PLC Memory

System Memory Application Memory [ RAM ]

The Executive Volatile

“The Personality”
Data Memory
[ ROM ] Data Files

[Non- Volatile]
User Memory
User Programs
Application Memory……………………. Slide 1

1] DATA Memory

File 0 Output Status File

File 1 Input Status File
File 2 PLC Status Bits

File 3 Internal Bits

File 4 Timer
DATA Files
File 5 Counter
File 6 Control

File 7 Integers
File 8 Floating Point Data

File 9 Common Interface

File 10 - 255 User Configurable

 Application Memory……………………. Slide 2

2] User Memory

File 0 System Program File

File 1 Reserved File
File 2 Main Ladder Program File (LAD2)

File 3 User Error Fault Routine

File 4 High Speed Counter Interrupt File

File 5 Selectable Timed Interrupt

File 6 - 15 Subroutine Ladder Program

This is the File where we will do Programming in LD Language………( Ladder Diagram)

 Output Modules: Classification…………..

Discrete Output modules Analog Output Modules

Solid state Output

Relay Output
•Relay contact
•Isolated Relay contact
AC O/P Modules DC O/P Modules •Relay contact Output
•12, 24, 48 VAC •TTL Level

•120 VAC •12, 24, 48 VDC

•230 VAC •120 VDC

•230 VDC
• 24 VDC sink
• 24 VDC source
 Basic wiring for 120 VAC discrete output module

Output Module

2
LOAD
3
Signal from CPU 110 VAC
Operates switch COM
User supplied power
for field devices
S/G Flow from CPU through an output module to the field device

CPU solves Output Chassis

ladder status table backplane
program

Module Optical Module Field

logic Isolation Screw Device
circuits Terminal
 Block Diagram of a Typical Output module

FUSE
Latch Triac Controlled
Logic Optical Filter device
switching
Circuitry isolation
circuitry

LED
 Simplified Single point Relay Output

Common to other
output points
L-1 L-2

Output Module

ON or OFF signal
from output
status table

LOAD

Relay Switching Device

Sinking Output module Interface with Field Device.

Sinking Output
Module

+ DC
VDC
Out 0
Out 1
Out 2
Out 3
Out 4
Out 5
Out 6
Out 7
DC Com DC Common
Sourcing Output module Interface with Field Device.

Sourcing
Output Module

+ DC
VDC
Out 0
Out 1
Out 2
Out 3
Out 4
Out 5
Out 6
Out 7
DC Com DC Common