2

PLC Hardware Components

Image Used with Permission of Rockwell Automation, Inc.

Chapter Objectives
After completing this chapter, you will be able to: This chapter exposes you to the details of PLC
2.1 List and describe the function of the hardware hardware and modules that make up a PLC con-
components used in PLC systems trol system. The chapters illustrations show the
2.2 Describe the basic circuitry and applications for various subparts of a PLC as well as general
discrete and analog I/O modules, and interpret typical connection paths. In this chapter we discuss
I/O and CPU specifications the CPU and memory hardware components,
2.3 Explain I/O addressing including the various types of memory that are
2.4 Describe the general classes and types of PLC available, and we describe the hardware of the
memory devices input/output section, including the difference be-
2.5 List and describe the different types of PLC tween the discrete and analog types of modules.
peripheral support devices available

17

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 2.1 The I/O Section Processor
128 I/O rack
The input/output (I/O) section of a PLC is the section to 0 1 2 3 4 5 6 7
which all field devices are connected and provides the in-
terface between them and the CPU. Input/output arrange-
ments are built into a fixed PLC while modular types use 8-slot
external I/O modules that plug into the PLC. chassis
Figure2-1 illustrates a rack-based I/O section made
up of individual I/O modules. Input interface modules
accept signals from the machine or process devices and Figure 2-2 Allen-Bradley PLC chassis and rack.
convert them into signals that can be used by the con-
troller. Output interface modules convert controller sig-
nals into external signals used to control the machine
or process. A typical PLC has room for several I/O communicate operating signals through the output inter-
modules, allowing it to be customized for a particular face to the process devices under its control.
application by selecting the appropriate modules. Each Allen-Bradley controllers make a distinction between
slot in the rack is capable of accommodating any type a PLC chassis and rack as illustrated in Figure2-2. The
of I/O module. hardware assembly that houses I/O modules, processor
The I/O system provides an interface between the hard- modules, and power supplies is referred to as the chassis.
wired components in the field and the CPU. The input Chassis come in different sizes according to the number
interface allows status information regarding processes to of slots they contain. In general, they can have 4, 8, 12,
be communicated to the CPU, and thus allows the CPU to or 16 slots.
A logical rack is an addressable unit consisting of 128
input points and 128 output points. A rack uses 8 words in
the input image table file and 8 words in the output image
table file. A word in the output image table file and its cor-
responding word in the input image table file are called an
Power I/O group. A rack can contain a maximum of 8 I/O groups
supply
(numbered from 0 through 7) for up to 128 discrete I/O.
There can be more than one rack in a chassis and more
0 1 2 3 4 5 6 Slot than one chassis in a rack.
Processor One benefit of a PLC system is the ability to locate
I/O modules
module
the I/O modules near the field devices, as illustrated in
Figure 2-1 Rack-based I/O section. Figure 2-3, in order to minimize the amount of wiring

Local I/O Remote I/O

Processor

Output

Output
Power

Power
Input

Input

Hopper
Communication

Stop/Start On/Off
control

Motor

Sensor

Figure 2-3 Remote I/O rack.

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 required. The processor receives signals from the remote SlotThe slot number is the physical location of the
input modules and sends signals back to their output mod- I/O module. This may be a combination of the rack
ules via the communication module. number and the slot number when using expansion
A rack is referred to as a remote rack when it is lo- racks.
cated away from the processor module. To communi- Word and BitThe word and bit are used to identify
cate with the processor, the remote rack uses a special the actual terminal connection in a particular I/O mod-
communications network. Each remote rack requires a ule. A discrete module usually uses only one word,
unique station number to distinguish one from another. and each connection corresponds to a different bit that
The remote racks are linked to the local rack through a makes up the word.
communications module. Cables connect the modules
with each other. If fiber optic cable is used between the With a rack/slot address system the location of a mod-
CPU and I/O rack, it is possible to operate I/O points ule within a rack and the terminal number of a module
from distances greater than 20 miles with no voltage to which an input or output device is connected will
drop. Coaxial cable will allow remote I/O to be in- determine the devices address. Figure 2-4 illustrates
stalled at distances greater than two miles. Fiber optic the Allen-Bradley PLC-5 controller addressing format.
cable will not pick up noise caused by adjacent high The following are typical examples of input and output
power lines or equipment normally found in an indus- addresses:
trial environment. Coaxial cable is more susceptible to
this type of noise.
The PLCs memory system stores information about
the status of all the inputs and outputs. To keep track of I1:27/17 Input, le 1, rack 2, group 7, bit 17
all this information, it uses a system called addressing. An O0:34/07 Output, le 0, rack 3, group 4, bit 7
address is a label or number that indicates where a certain I1:0/0 Input, le 1, rack 0, group 0, bit 0 (Short
piece of information is located in a PLCs memory. Just form blank 5 0)
as your home address tells where you live in your city, a O0:1/1 Output, le 0, rack 0, group 1, bit 1 (Short
form blank 5 0)
devices or a piece of datas address tells where informa-
tion about it resides in the PLCs memory. That way, if a
PLC wants to find out information about a field device, it
Figure2-5 illustrates the Allen-Bradley SLC 500 con-
knows to look in its corresponding address location. Ex-
troller addressing format. The address is used by the pro-
amples of addressing schemes include rack/slot-based,
cessor to identify where the device is located to monitor or
versions of which are used in Allen-Bradley PLC-5 and
control it. In addition, there is some means of connecting
SLC 500 controllers, tag-based used in Allen-Bradley
field wiring on the I/O module housing. Connecting the
ControlLogix controllers, and PC-based control used in
field wiring to the I/O housing allows easier disconnec-
soft PLCs.
tion and reconnection of the wiring to change modules.
In general, rack/slot-based addressing elements include:
Lights are also added to each module to indicate the ON
TypeThe type determines if an input or output is or OFF status of each I/O circuit. Most output modules
being addressed. also have blown fuse indicators. The following are typical

O 0 : 0 1 / 00

Terminal number (bit address)

Bit delimiter
Group (07); 8 groups in a rack
Rack no.
File delimiter
File no.
File type (Ooutput; input)

Figure 2-4 Allen-Bradley PLC-5 rack/slot-based addressing format.

Source: Image Used with Permission of Rockwell Automation, Inc.

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 File type
File number
Element number
Subelement number
Memory Bit number
address
I 1 : 3 . 0 / 01
Real-world
address Terminal number
For terminals above #15
Slot number
Module type

Figure 2-5 Allen-Bradley SLC 500 rack/slot-based addressing format.

Source: Image Used with Permission of Rockwell Automation, Inc.

examples of SLC 500 real-world general input and output in Figure2-9. A module is made up of a printed circuit
addresses: board and a terminal assembly. The printed circuit board
contains the electronic circuitry used to interface the
circuit of the processor with that of the input or output
device. Modules are designed to plug into a slot or con-
nector in the I/O rack or directly into the processor. The
O:4/15 Output module in slot 4, terminal 15
terminal assembly, which is attached to the front edge of
I:3/8 Input module in slot 3, terminal 8 the printed circuit board, is used for making field-wiring
O:6.0 Output module, slot 6 connections. Modules contain terminals for each input
I:5.0 Input module, slot 5 and output connection, status lights for each of the inputs
and outputs, and connections to the power supply used to
power the inputs and outputs. Terminal and status light
Every input and output device connected to a discrete arrangements vary with different manufacturers.
I/O module is addressed to a specific bit in the PLCs Most PLC modules have plug-in wiring terminal strips.
memory. A bit is a binary digit that can be either 1 or 0. The terminal block is plugged into the actual module as il-
Analog I/O modules use a word addressing format, which lustrated in Figure2-10. If there is a problem with a mod-
allows the entire words to be addressed. The bit part of ule, the entire strip is removed, a new module is inserted,
the address is usually not used; however, bits of the digital and the terminal strip is plugged into the new module.
representation of the analog value can be addressed by the Unless otherwise specified, never install or remove I/O
programmer if necessary. Figure 2-6 illustrates bit level modules or terminal blocks while the PLC is powered.
and word level addressing as it applies to an SLC 500 A module inserted into the wrong slot could be dam-
controller. aged by improper voltages connected through the wiring
Figure2-7 illustrates the Allen-Bradley ControlLogix arm. Most faceplates and I/O modules are keyed to pre-
tag-based addressing format. With Logix5000 controllers, vent putting the wrong faceplate on the wrong module.
you use a tag (alphanumeric name) to address data (vari- In other words, an output module cannot be placed in the
ables). Instead of a fixed numeric format the tag name slot where an input module was originally located.
itself identifies the data. The field devices are assigned Input and output modules can be placed anywhere in a
tag names that are referenced when the PLC ladder logic rack, but they are normally grouped together for ease of
program is developed. wiring. I/O modules can be 8, 16, 32, or 64 point cards
PC-based control runs on personal or industrial hard- (Figure2-11). The number refers to the number of inputs
ened computers. Also known as soft PLCs, they simulate or outputs available. The standard I/O module has eight
the functions of a PLC on a PC, allowing open architecture inputs or outputs. A high-density module may have up to
systems to replace proprietary PLCs. This implementa- 64 inputs or outputs. The advantage with the high-density
tion uses an input/output card (Figure2-8) in conjunction module is that it is possible to install up to 64 inputs or
with the PC as an interface for the field devices. outputs in one slot for greater space savings. The only dis-
Combination I/O modules can have both input and out- advantage is that the high-density output modules cannot
put connections in the same physical module as illustrated handle as much current per output.

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 Processor memory
Input Output
Data files addressing
addressing
Inputs Output
I:1/0 1 0:3/0 0
I:1/0
I:1/1 0
O:3/0
I:1/1
I:1/0 I:1/1 O:3/0

Program files

(a)

Output Input
Power

Analog

Thermocouple IN 0
analog input IN 0
I0:2.0
(address)

Meter
OUT 0
analog
2: 20 OUT 0
output
O0:2.0
(address)

0 1 2
module
Analog

Processor

Address Address
Type Slot Word Bit Inputs Outputs Type Slot Word Bit
1 0 0
Not used

Not used
2 0 O 2 0
1 1

(b)

Figure 2-6 SLC 500 bit level and word level addressing. (a) Bit level
addressing. (b) Word level addressing.

Description assigned
Start to alias tag
I_PBO
Alias tag pointing
<Local:6:1.Data.0> to base address

Base address

Input instruction

Figure 2-7 Allen-Bradley ControlLogix tag-based addressing format.

Source: Image Used with Permission of Rockwell Automation, Inc.

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 Module

Terminal
block

Figure 2-8 Typical PC interface card.

Source: Photo Beckhoff Automation GmbH.
Figure 2-10 Plug-in terminal block.

switching. The classification of discrete I/O covers bit-

oriented inputs and outputs. In this type of input or output,
2.2 Discrete I/O Modules each bit represents a complete information element in itself
The most common type of I/O interface module is the dis- and provides the status of some external contact or advises
crete type (Figure 2-12). This type of interface connects of the presence or absence of power in a process circuit.
field input devices of the ON/OFF nature such as selec- Each discrete I/O module is powered by some field-
tor switches, pushbuttons, and limit switches. Likewise, supplied voltage source. Since these voltages can be of
output control is limited to devices such as lights, relays, different magnitude or type, I/O modules are available at
solenoids, and motor starters that require simple ON/OFF various AC and DC voltage ratings, as listed in Table 2-1.

Status

Status
indicators Input Output

Inputs Outputs
Power supply
connections
0 0
1 1
2 2
Input 3 3 Output
connections 4 4 connections
5 5
6 6
7 7
Power supply
connections

Figure 2-9 Typical combination I/O module.

Source: Image Used with Permission of Rockwell Automation, Inc.

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 Figure 2-11 16, 32, and 64 point I/O modules.
Source: (all ) Photos courtesy Omron Industrial Automation, www.ia.omron.com.

The modules themselves receive their voltage and cur- Table 2-1 Common Ratings for Discrete
rent for proper operation from the backplane of the rack I/O Interface Modules
enclosure into which they are inserted, as illustrated in Fig-
ure2-13. Backplane power is provided by the PLC module Input Interfaces Output Interfaces
power supply and is used to power the electronics that re- 12 V AC/DC /24 V AC/DC 1248 V AC
side on the I/O module circuit board. The relatively higher 48 V AC/DC 120 V AC
120 V AC/DC 230 V AC
230 V AC/DC 120 V DC
5 V DC (TTL level) 230 V DC
5 V DC (TTL level)
24 V DC

Indicator Signaling Relays Motor

lights column starter Backplane power

Discrete outputs

Power
supply

Discrete inputs

Pushbuttons Selector Limit Proximity

switch switch switches
Figure 2-13 Modules receive their voltage and current
Figure 2-12 Discrete input and output devices. from the backplane.

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 Logic

Power Input status

indicator

L1 Zener
Input Bridge diode Opto-electrical Logic To processor
(120 VAC) signal rectifier level isolation circuits (low VDC)
L2 detection

Figure 2-14 Discrete AC input module block diagram.

currents required by the loads of an output module are The zener diode (ZD) voltage rating sets the mini-
normally provided by user-supplied power. Module power mum threshold level of voltage that can be detected.
supplies typically may be rated for 3 A, 4 A, 12 A, or 16 A When light from the LED strikes the phototransis-
depending on the type and number of modules used. tor, it switches into conduction and the status of
Figure2-14 shows the block diagrams for one input of the pushbutton is communicated in logic to the
a typical alternating current (AC) discrete input module. processor.
The input circuit is composed of two basic sections: the The optical isolator not only separates the higher
power section and the logic section. An optical isolator is AC input voltage from the logic circuits but also
used to provide electrical isolation between the field wir- prevents damage to the processor due to line volt-
ing and the PLC backplane internal circuitry. The input age transients. In addition, this isolation also helps
LED turns on or off, indicating the status of the input de- reduce the effects of electrical noise, common in the
vice. Logic circuits process the digital signal to the pro- industrial environment, which can cause erratic op-
cessor. Internal PLC control circuitry typically operates at eration of the processor.
5 VDC or less volts.
For fault diagnosis, an input state LED indicator
A simplified diagram for a single input of a discrete AC
is on when the input pushbutton is closed. This in-
input module is shown in Figure2-15. The operation of
dicator may be wired on either side of the optical
the circuit can be summarized as follows:
isolator.
The input noise filter consisting of the capacitor and An AC/DC type of input module is used for both
resistors R1 and R2 removes false signals that are AC and DC inputs as the input polarity does not
due to contact bounce or electrical interference. matter.
When the pushbutton is closed, 120 VAC is applied A PLC input module will have either all inputs iso-
to the bridge rectifier input. lated from each other with no common input con-
This results in a low-level DC output voltage that is nections or groups of inputs that share a common
applied across the LED of the optical isolator. connection.

Input module
terminal strip

PB Bridge LED input

Fuse R1 status indicator
Filter R2 rectifier
L1
Threshold Optical
detector isolator

ZD Digital
Field wiring R3 logic
C circuit

Common
L2
Internal module circuit

Figure 2-15 Simplied diagram for a single input of a discrete AC input module.

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 Logic

Output status Power

indicator
Load
L1
Digital signal Logic Opto-electrical Electronic
from processor 120 VAC
circuits isolation switch
L2

Figure 2-16 Discrete AC output module block diagram.

Discrete input modules perform four tasks in the PLC When the processor calls for an output load to be
control system. They: energized, a voltage is applied across the LED of
the opto-isolator.
Sense when a signal is received from a field device.
The LED then emits light, which switches the pho-
Convert the input signal to the correct voltage level
totransistor into conduction.
for the particular PLC.
This in turn triggers the triac AC semiconductor
Isolate the PLC from fluctuations in the input
switch into conduction allowing current to flow to
signals voltage or current.
the output load.
Send a signal to the processor indicating which sen-
Since the triac conducts in either direction, the out-
sor originated the signal.
put to the load is alternating current.
Figure2-16 shows the block diagram for one output of The triac, rather than having ON and OFF status,
a typical discrete output module. Like the input module, actually has LOW and HIGH resistance levels,
it is composed of two basic sections: the power section respectively. In its OFF state (HIGH resistance),
and the logic section, coupled by an isolation circuit. The a small leakage current of a few milliamperes still
output interface can be thought of as an electronic switch flows through the triac.
that turns the output load device on and off. Logic circuits As with input circuits, the output interface is usually
determine the output status. An output LED indicates the provided with LEDs that indicate the status of each
status of the output signal. output.
A simplified diagram for a single output of a discrete Fuses are normally required for the output module,
AC output module is shown in Figure2-17. The operation and they are provided on a per circuit basis, thus al-
of the circuit can be summarized as follows: lowing for each circuit to be protected and operated
As part of its normal operation, the digital logic cir- separately. Some modules also provide visual indi-
cuits of the processor sets the output status accord- cators for fuse status.
ing to the program. The triac cannot be used to switch a DC load.

Output module
Triac
terminal strip
LED output switch
L1
status indicator
Fuse
Optical
isolator

Field wiring
Digital
logic
circuit

Load L2
Internal module circuit

Figure 2-17 Simplied diagram for a single output of a discrete AC

output module.

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 L1 L2 L3 whereas transistor outputs can be used only for control
of DC devices. The discrete relay contact output module
M M M uses electromechanical as the switching element. These
relay outputs can be used with AC or DC devices, but they
have a much slower switching time compared to solid-
CR OL state outputs. Allen-Bradley modules are color-coded for
M identification as follows:
Motor T1 T2 T3
starter coil

L1 Motor
Color Type of I/O
Red AC inputs/outputs
Interposing Blue DC inputs/outputs
CR relay coil
Orange Relay outputs
Green Specialty modules
L2 Black I/O wiring; terminal blocks
are not removable

Figure 2-18 Interposing relay connection.

Source: Photo courtesy Tyco Electronics, www.tycoelectronics.com. Certain DC I/O modules specify whether the module
is designed for interfacing with current-source or current-
sink devices. If the module is a current-sourcing module,
For fault diagnosis, the LED output status indica-
then the input or output device must be a current-sinking
tor is on whenever the PLC is commanding that the
device. Conversely, if the module is specified as current-
output load be switched on.
sinking, then the connected device must be current-
Individual AC outputs are usually limited by the size of sourcing. Some modules allow the user to select whether
the triac to 1 A or 2 A. The maximum current load for any the module will act as current sinking or current sourcing,
one module is also specified. To protect the output module thereby allowing it to be set to whatever the field devices
circuits, specified current ratings should not be exceeded. require.
For controlling larger loads, such as large motors, a standard The internal circuitry of some field devices requires
control relay is connected to the output module. The con- that they be used in sinking or sourcing circuits. In gen-
tacts of the relay can then be used to control a larger load or eral, sinking (NPN) and sourcing (PNP) are terms used to
motor starter, as shown in Figure2-18. When a control relay describe a current signal flow relationship between field
is used in this manner, it is called an interposing relay. input and output devices in a control system and their
Discrete output modules are used to turn field output power supply. Figure2-20 illustrates the current flow re-
devices either on or off. These modules can be used to lationship between sinking and sourcing inputs to a DC
control any two-state device, and they are available in AC input module.
and DC versions and in various voltage ranges and cur- Figure 2-21 illustrates the current flow relationship
rent ratings. Output modules can be purchased with tran- between sinking and sourcing outputs to a DC output
sistor, triac, or relay output as illustrated in Figure2-19. module. DC input and output circuits are commonly con-
Triac outputs can be used only for control of AC devices, nected with field devices that have some form of internal

Coil Contact AC/DC AC DC

Load Load Load

Relay output Triac output Transistor output

Figure 2-19 Relay, transistor, and triac switching elements.

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 Sinking input Sourcing input
module module
0 0
1 1
2 2
Sourcing 3 Sinking 3
sensor sensor
4 4
5 5
Power 6 Power 6
supply 7 supply 7

Common Common
Current Current

Figure 2-20 Sinking and sourcing inputs.

Sourcing output Sinking output

module module
0 0
Sinking Sourcing
1 1
field device field device
2 2
3 3
4 4
5 5
6 Power 6 Power
7 supply 7 supply

Common Current Common Current

Figure 2-21 Sinking and sourcing outputs.

solid-state circuitry that needs a DC signal voltage to current signal from the level transmitter field device. This
function. Field devices connected to the positive (1) side input is converted from an analog to a digital value for
of the field power supply are classified as sourcing field use by the processor. The circuitry of the analog output
devices. Conversely, field devices connected to the nega- module accepts the digital value from the processor and
tive (2) side or DC common of the field power supply are converts it back to an analog signal that drives the field
sinking field devices. tank level meter.
Analog input modules normally have multiple input
2.3 Analog I/O Modules channels that allow 4, 8, or 16 devices to be interface to
the PLC. The two basic types of analog input modules
Earlier PLCs were limited to discrete or digital I/O in-
are voltage sensing and current sensing. Analog sen-
terfaces, which allowed only on/off-type devices to be
sors measure a varying physical quantity over a specific
connected. This limitation meant that the PLC could have
range and generate a corresponding voltage or current
only partial control of many process applications. Today,
signal. Common physical quantities measured by a PLC
however, a complete range of both discrete and analog
analog module include temperature, speed, level, flow,
interfaces are available that will allow controllers to be
weight, pressure, and position. For example, a sensor may
applied to practically any type of control process.
Discrete devices are inputs and outputs that have only
PLC Level
two states: on and off. In comparison, analog devices rep- Level indicator
resent physical quantities that can have an infinite number transmitter Analog Analog
input Processor output
of values. Typical analog inputs and outputs vary from module module
0 to 20 milliamps, 4 to 20 milliamps, or 0 to 10 volts.
Figure2-22 illustrates how PLC analog input and output
modules are used in measuring and displaying the level
of fluid in a tank. The analog input interface module con-
tains the circuitry necessary to accept an analog voltage or Figure 2-22 Analog input and output to a PLC.

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 Grounded
CJC IN 0 thermocouple

Ungrounded IN 0
thermocouple
CJC
IN 1
IN 2
IN 1
IN 2
IN 3

IN 3

Figure 2-23 MicroLogix 4-channel analog thermocouple input module.

Source: Image Used with Permission of Rockwell Automation, Inc.

measure temperature over a range of 0 to 500C, and out- modules must produce a range of digital values between
put a corresponding voltage signal that varies between 0 a maximum and minimum value to represent the analog
and 50 mV. signal over its entire span. Typical specifications are as
Figure2-23 illustrates an example of a voltage sensing follows:
input analog module used to measure temperature. The
connection diagram applies to an Allen-Bradley Micro-
Logic 4-channel analog thermocouple input module. A
varying DC voltage in the low millivolt range, propor-
10 V 210 to 110 V
tional to the temperature being monitored, is produced by Bipolar
the thermocouple. This voltage is amplified and digitized Span
5V 25 to 15 V
of
by the analog input module and then sent to the processor analog
on command from a program instruction. Because of the 10 V 0 to 110 V
input
Unipolar
low voltage level of the input signal, a twisted shielded 5V 0 to 15 V
pair cable is used in wiring the circuit to reduce unwanted
electrical noise signals that can be induced in the conduc- Resolution 0.3 mV
tors from other wiring. When using an ungrounded ther-
mocouple, the shield must be connected to ground at the
module end. To obtain accurate readings from each of the When connecting voltage sensing inputs, close adher-
channels, the temperature between the thermocouple wire ence to specified requirements regarding wire length is
and the input channel must be compensated for. A cold important to minimize signal degrading and the effects
junction compensating (CJC) thermistor is integrated in of electromagnetic noise interference induced along the
the terminal block for this purpose. connecting conductors. Current input signals, which
The transition of an analog signal to digital values is are not as sensitive to noise as voltage signals, are typi-
accomplished by an analog-to-digital (A/D) converter, the cally not distance limited. Current sensing input modules
main element of the analog input module. Analog volt- typically accept analog data over the range of 4 mA to
age input modules are available in two types: unipolar 20mA, but can accommodate signal ranges of 20 mA
and bipolar. Unipolar modules can accept an input signal to 120 mA. The loop power may be supplied by the sen-
that varies in the positive direction only. For example, if sor or may be provided by the analog output module as
the field device outputs 0 V to 110V, then the unipolar illustrated in Figure2-24. Shielded twisted pair cable is
modules would be used. Bipolar signals swing between a normally recommended for connecting any type analog
maximum negative value and a maximum positive value. input signal.
For example, if the field device outputs 210 V to 110V The analog output interface module receives from the
a bipolar module would be used. The resolution of an ana- processor digital data, which are converted into a propor-
log input channel refers to the smallest change in input tional voltage or current to control an analog field device.
signal value that can be sensed and is based on the num- The transition of a digital signal to analog values is accom-
ber of bits used in the digital representation. Analog input plished by a digital-to-analog (D/A) converter, the main

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 Sensor supplied power Module supplied power

420 mA loop 420 mA loop

Power

supply
Sensor Sensor


Power
supply

Figure 2-24 Sensor and analog module supplied power.

element of the analog output module. An analog output

signal is a continuous and changing signal that is varied
under the control of the PLC program. Common devices
controlled by a PLC analog output module include instru-
ments, control valves, chart recorder, electronic drives,
and other types of control devices that respond to analog
signals.
Figure2-25 illustrates the use of analog I/O modules in
a typical PLC control system. In this application the PLC
controls the amount of fluid placed in a holding tank by High-speed pulses
adjusting the percentage of the valve opening. The ana-
log output from the PLC is used to control the flow by Figure 2-26 High-speed counter module.
Source: Courtesy Control Technology Corporation.
controlling the amount of the valve opening. The valve
is initially open 100 percent. As the fluid level in the tank
approaches the preset point, the processor modifies the
available is 0 to 100 kHz, which means the module would
output, which adjusts the valve to maintain a set point.
be able to count 100,000 pulses per second.

2.4 Special I/O Modules THUMBWHEEL MODULE

The thumbwheel module allows the use of thumbwheel
Many different types of I/O modules have been developed switches (Figure2-27) for feeding information to the PLC
to meet special needs. These include: to be used in the control program.
HIGH-SPEED COUNTER MODULE
TTL MODULE
The high-speed counter module is used to provide an in- The TTL module (Figure 2-28) allows the transmitting
terface for applications requiring counter speeds that sur- and receiving of TTL (Transistor-Transistor-Logic) sig-
pass the capability of the PLC ladder program. High-speed nals. This module allows devices that produce TTL-level
counter modules are used to count pulses (Figure 2-26) signals to communicate with the PLCs processor.
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

Analog output

Valve

PLC
Level
sensor

Analog input
Figure 2-27 Thumbwheel switch.
Figure 2-25 Typical analog I/O control system. Source: Photo courtesy Omron Industrial Automation, www.ia.omron.com.

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 Figure 2-28 TTL module. Figure 2-30 BASIC module.
Source: Courtesy Control Technology, Inc. Source: Image Used with Permission of Rockwell Automation, Inc.

ENCODER-COUNTER MODULE processor. Typical applications include interfaces to bar

code readers, robots, printers, and displays.
An encoder-counter module allows the user to read the
signal from an encoder (Figure2-29) on a real-time basis STEPPER-MOTOR MODULE
and stores this information so it can be read later by the The stepper-motor module provides pulse trains to a
processor. stepper-motor translator, which enables control of a step-
per motor (Figure2-31). The commands for the module
BASIC OR ASCII MODULE are determined by the control program in the PLC.
The BASIC or ASCII module (Figure 2-30) runs user-
written BASIC and C programs. These programs are in- BCD-OUTPUT MODULE
dependent of the PLC processor and provide an easy, fast The BCD-output module enables a PLC to operate devices
interface between remote foreign devices and the PLC that require BCD-coded signals such as seven-segment
displays (Figure2-32).

Figure 2-29 Encoder. Figure 2-31 Stepper-motor.

Source: Photo courtesy of Allied Motion Technologies, Inc. Source: Courtesy Sherline Products.

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 Outputs
Servo
Servo
motor
drive
Inputs Encoder

Figure 2-32 Seven-segment display.

Source: Courtesy Red Lion Controls. PLC servo module

Figure 2-34 PLC servo module.

Some special modules are referred to as intelligent I/O

because they have their own microprocessors on board These systems require a drive, which contains the power
that can function in parallel with the PLC. These include: electronics that translate the signals from the PLC module
into signals required by the motor (Figure2-34).
PID MODULE
The proportional-integral-derivative (PID) module (Fig- COMMUNICATION MODULES
ure 2-33) is used in process control applications that Serial communications modules (Figure2-35) are used to
incorporate PID algorithms. An algorithm is a complex establish point-to-point connections with other intelligent
program based on mathematical calculations. A PID mod- devices for the exchange of data. Such connections are
ule allows process control to take place outside the CPU. normally established with computers, operator stations,
This arrangement prevents the CPU from being burdened process control systems, and other PLCs. Communication
with complex calculations. The basic function of this modules allow the user to connect the PLC to high-speed
module is to provide the control action required to main- local networks that may be different from the network
tain a process variable such as temperature, flow, level, or communication provided with the PLC.
speed within set limits of a specified set point.

MOTION AND POSITION CONTROL

MODULE
Motion and position control modules are used in applica-
tions involving accurate high-speed machining and pack-
aging operations. Intelligent position and motion control
modules permit PLCs to control stepper and servo motors.

Figure 2-33 PID module. Figure 2-35 Serial communications module.

Source: Courtesy Red Lion Controls. Source: Photo courtesy Automation Direct, www.automationdirect.com.

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 2.5 I/O Specications This input delay is typically in the 9 to 25millisecond
range.
Manufacturers specifications provide information about
how an interface device is correctly and safely used. OUTPUT VOLTAGE
These specifications place certain limitations not only on This AC or DC value specifies the magnitude (e.g., 5 V,
the I/O module but also on the field equipment that it can 115V, 230V) and type (AC or DC) of user-supplied voltage
operate. Some PLC systems support hot swappable I/O at which a discrete output module is designed to operate.
modules designed to be changed with the power on and The output field device that the module interfaces to the
the PLC operating. The following is a list of some typi- PLC must be matched to this specification. Output modules
cal manufacturers I/O specifications, along with a short are typically designed to operate within a range of plus or
description of what is specified. minus 10 percent of the nominal output voltage rating.
Typical Discrete I/O Module
OUTPUT CURRENT
Specications
These values specify the maximum current that a single
NOMINAL INPUT VOLTAGE output and the module as a whole can safely carry under
This discrete input module voltage value specifies the load (at rated voltage). This rating is a function of the
magnitude (e.g., 5V, 24V, 230V) and type (AC or DC) of modules components and heat dissipation characteris-
user-supplied voltage that a module is designed to accept. tics. A device drawing more than the rated output current
Input modules are typically designed to operate correctly results in overloading, causing the output fuse to blow. As
without damage within a range of plus or minus 10 per- an example, the specification may give each output a cur-
cent of the input voltage rating. With DC input modules, rent limit of 1 A. The overall rating of the module current
the input voltage may also be expressed as an operating will normally be less than the total of the individuals. The
range (e.g., 2460 volts DC) over which the module will overall rating might be 6 A because each of the eight de-
operate. vices would not normally draw their 1 A at the same time.
Other names for the output current rating are maximum
INPUT THRESHOLD VOLTAGES continuous current and maximum load current.
This discrete input module specification specifies two val-
INRUSH CURRENT
ues: a minimum ON-state voltage that is the minimum
voltage at which logic 1 is recognized as absolutely ON; An inrush current is a momentary surge of current that an
and a maximum OFF-state voltage which is the voltage at AC or DC output circuit encounters when energizing in-
which logic 0 is recognized as absolutely OFF. ductive, capacitive, or filament loads. This value specifies
the maximum inrush current and duration (e.g., 20 A for
NOMINAL CURRENT PER INPUT 0.1 s) for which an output circuit can exceed its maximum
This value specifies the minimum input current that the continuous current rating.
discrete input devices must be capable of driving to op-
erate the input circuit. This input current value, in con- SHORT CIRCUIT PROTECTION
junction with the input voltage, functions as a threshold Short circuit protection is provided for AC and DC output
to protect against detecting noise or leakage currents as modules by either fuses or some other current-limiting
valid signals. circuitry. This specification will designate whether the
particular modules design has individual protection for
AMBIENT TEMPERATURE RATING each circuit or if fuse protection is provided for groups
This value specifies what the maximum temperature of (e.g., 4 or 8) of outputs.
the air surrounding the I/O modules should be for best
operating conditions. LEAKAGE CURRENT
This value specifies the amount of current still conducting
INPUT ON/OFF DELAY through an output circuit even after the output has been
Also known as response time, this value specifies the turned off. Leakage current is a characteristic exhibited
maximum time duration required by an input modules by solid-state switching devices such as transistors and
circuitry to recognize that a field device has switched ON triacs and is normally less than 5 milliamperes. Leakage
(input ON-delay) or switched OFF (input OFF-delay). current is normally not large enough to falsely trigger an
This delay is a result of filtering circuitry provided to output device but must be taken into consideration when
protect against contact bounce and voltage transients. switching very low current sensitive devices.

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 ELECTRICAL ISOLATION OUTPUT CURRENT/VOLTAGE RANGE(S)
Recall that I/O module circuitry is electrically isolated to This specification defines the current or voltage signal
protect the low-level internal circuitry of the PLC from ranges that a particular analog output module is designed
high voltages that can be encountered from field device to output under program control. The output ranges must
connections. The specification for electrical isolation, be matched according to the varying voltage or current
typically 1500 or 2500 volts AC, rates the modules ca- signals that will be required to drive the analog output
pacity for sustaining an excessive voltage at its input or devices.
output terminals. Although this isolation protects the
INPUT PROTECTION
logic side of the module from excessive input or output
voltages or current, the power circuitry of the module may Analog input circuits are usually protected against acci-
be damaged. dentally connecting a voltage that exceeds the specified
input voltage range.
POINTS PER MODULE
RESOLUTION
This specification defines the number of field inputs or
The resolution of an analog I/O module specifies how ac-
outputs that can be connected to a single module. Most
curately an analog value can be represented digitally. This
commonly, a discrete module will have 8, 16, or 32 cir-
specification determines the smallest measurable unit of
cuits; however, low-end controllers may have only 2 or
current or voltage. The higher the resolution (typically
4circuits. Modules with 32 or 64 input or output bits are
specified in bits), the more accurately an analog value can
referred to as high-density modules. Some modules pro-
be represented.
vide more than one common terminal, which allows the
user to use different voltage ranges on the same card as INPUT IMPEDANCE AND CAPACITANCE
well as to distribute the current more effectively. For analog I/Os, these values must be matched to the ex-
ternal device connected to the module. Typical ratings are
BACKPLANE CURRENT DRAW in Megohm (MV) and picofarads (pF).
This value indicates the amount of current the module
COMMON-MODE REJECTION
requires from the backplane. The sum of the backplane
current drawn for all modules in a chassis is used to select Noise is generally caused by electromagnetic interfer-
the appropriate chassis power supply rating. ence, radio frequency interference, and ground loops.
Common-mode noise rejection applies only to differ-
Typical Analog I/O Module ential inputs and refers to an analog modules ability to
Specications prevent noise from interfering with data integrity on a
single channel and from channel to channel on the mod-
CHANNELS PER MODULE ule. Noise that is picked up equally in parallel wires is
Whereas individual circuits on discrete I/O modules are rejected because the difference is zero. Twisted pair wires
referred to as points, circuits on analog I/O modules are are used to ensure that this type of noise is equal on both
often referred to as channels. These modules normally have wires. Common-mode rejection is normally expressed in
4, 8, or 16 channels. Analog modules may allow for either decibels or as a ratio.
single-ended or differential connections. Single-ended
connections use a single ground terminal for all channels
or for groups of channels. Differential connections use a 2.6 The Central Processing
separate positive and negative terminal for each channel. Unit (CPU)
If the module normally allows 16 single-ended connec- The central processing unit (CPU) is built into single-
tions, it will generally allow only 8 differential connec- unit fixed PLCs while modular rack types typically use
tions. Single-ended connections are more susceptible to a plug-in module. CPU, controller, and processor are all
electrical noise. terms used by different manufacturers to denote the same
module that performs basically the same functions. Pro-
INPUT CURRENT/VOLTAGE RANGE(S) cessors vary in processing speed and memory options. A
These are the voltage or current signal ranges that an ana- processor module can be divided into two sections: the
log input module is designed to accept. The input ranges CPU section and the memory section (Figure2-36). The
must be matched accordingly to the varying current or CPU section executes the program and makes the deci-
voltage signals generated by the analog sensors. sions needed by the PLC to operate and communicate

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 Processor module user logic (ladder program), and turns on the appropriate
outputs.
Power
supply
CPU Memory The CPU of a PLC system may contain more than one
processor. One advantage of using multiprocessing is that
the overall operating speed is improved. Each processor
Communication has its own memory and programs, which operate simul-
interface
taneously and independently. In such configurations the
I/O modules scan of each processor is parallel and independent thus
reducing the total response time. Fault-tolerant PLC sys-
Discrete Analog
I/O I/O tems support dual processors for critical processes. These
devices devices systems allow the user to configure the system with redun-
dant (two) processors, which allows transfer of control to
the second processor in the event of a processor fault.
Associated with the processor unit will be a number of
status LED indicators to provide system diagnostic infor-
Figure 2-36 Sections of a PLC processor module. mation to the operator (Figure 2-38). Also, a keyswitch
Source: Courtesy Mitsubishi Automation. may be provided that allows you to select one of the fol-
lowing three modes of operation: RUN, PROG, and REM.
with other modules. The memory section electronically RUN Position
stores the PLC program along with other retrievable digi-
Places the processor in the Run mode
tal information.
The PLC power supply provides the necessary power Executes the ladder program and energizes output
(typically 5 VDC) to the processor and I/O modules devices
plugged into the backplane of the rack (Figure 2-37). Prevents you from performing online program edit-
Power supplies are available for most voltage sources ing in this position
encountered. The power supply converts 115 VAC or Prevents you from using a programmer/operator in-
230VAC into the usable DC voltage required by the CPU, terface device to change the processor mode
memory, and I/O electronic circuitry. PLC power supplies
are normally designed to withstand momentary losses of PROG Position
power without affecting the operation of the PLC. Hold- Places the processor in the Program mode
up time, which is the length of time a PLC can tolerate Prevents the processor from scanning or executing
a power loss, typically ranges from 10 milliseconds to the ladder program, and the controller outputs are
3seconds. de-energized
The CPU contains the similar type of microproces-
Allows you to perform program entry and editing
sor found in a personal computer. The difference is that
the program used with the microprocessor is designed to Prevents you from using a programmer/operator in-
facilitate industrial control rather than provide general- terface device to change the processor mode
purpose computing. The CPU executes the operating
system, manages memory, monitors inputs, evaluates the REM Position
Places the processor in the Remote mode: either the
REMote Run, REMote Program, or REMote Test
Power Backplane
mode
Allows you to change the processor mode from a
programmer/operator interface device
Power
supply Allows you to perform online program editing
The processor module also contains circuitry to com-
municate with the programming device. Somewhere on
the module you will find a connector that allows the PLC
to be connected to an external programming device. The
decision-making capabilities of PLC processors go far
Figure 2-37 PLC power supply. beyond simple logic processing. The processor performs

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 Battery (battery provides
backup power for the
CMOS RAM)

SLC 5/05 CPU

RUN FORCE
FLT ENET
BATT RS232

RUN REM PROG

Memory
module

Keyswitch Channel 1
ethernet
(10Base-T)
Hardware
address
Channel 0
RS232
(DH485, DF1,
or ASCII)

Side view Front view

Figure 2-38 Typical processor module.

other functions such as timing, counting, latching, com- 2.7 Memory Design
paring, motion control and complex math functions.
PLC processors have changed constantly due to ad- Memory is the element that stores information, programs,
vancements in computer technology and greater demand and data in a PLC. The user memory of a PLC includes
from applications. Today, processors are faster and have space for the user program as well as addressable memory
additional instructions added as new models are intro- locations for storage of data. Data are stored in memory
duced. Because PLCs are microprocessor based, they can locations by a process called writing. Data are retrieved
be made to perform tasks that a computer can do. In ad- from memory by what is referred to as reading.
dition to their control functions, PLCs can be networked The complexity of the program determines the amount
to do supervisory control and data acquisition (SCADA). of memory required. Memory elements store individual
Many electronic components found in processors and pieces of information called bits (for binary digits). The
other types of PLC modules are sensitive to electrostatic amount of memory capacity is specified in increments of
voltages that can degrade their performance or damage 1000 or in K increments, where 1 K is 1024 bytes of
them. The following static control procedures should be memory storage (a byte is 8 bits).
followed when handling and working with static-sensitive The program is stored in the memory as 1s and 0s,
devices and modules: which are typically assembled in the form of 16-bit
words. Memory sizes are commonly expressed in thou-
Ground yourself by touching a conductive surface sands of words that can be stored in the system; thus 2K
before handling static-sensitive components. is a memory of 2000 words, and 64 K is a memory of
Wear a wrist strap that provides a path to bleed off 64,000 words. The memory size varies from as small as
any charge that may build up during work. 1K for small systems to 32 MB for very large systems
(Figure2-39). Memory capacity is an important prereq-
Be careful not to touch the backplane connector or
uisite for determining whether a particular processor will
connector pins of the PLC system (always handle
handle the requirements of the specific application.
the circuit cards by the edge if possible).
Memory location refers to an address in the CPUs
Be careful not to touch other circuit components in memory where a binary word can be stored. A word usu-
a module when you configure or replace its internal ally consists of 16 bits. Each binary piece of data is a bit
components. and eight bits make up one byte (Figure2-40). Memory
When not in use, store modules in its static-shield bag. utilization refers to the number of memory locations re-
If available, use a static-safe work station. quired to store each type of instruction. A rule of thumb

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 PLCs execute memory-checking routines to be sure
that the PLC memory has not been corrupted. This mem-
32 M ory checking is undertaken for safety reasons. It helps en-
64 K sure that the PLC will not execute if memory is corrupted.
1K

2.8 Memory Types

MicroLogic 1000 SLC 500 ControlLogix
Controller Controller Controller Memory can be placed into two general categories: vola-
1 K memory Up to 64 K memory 2 to 32 M memory
Up to 20 inputs Up to 4096 inputs Up to 128,000 inputs
tile and nonvolatile. Volatile memory will lose its stored
Up to 14 outputs and outputs and outputs information if all operating power is lost or removed.
Volatile memory is easily altered and is quite suitable for
Figure 2-39 Typical PLC memory sizes. most applications when supported by battery backup.
Nonvolatile memory has the ability to retain stored
information when power is removed accidentally or in-
Bit tentionally. As the name implies, programmable logic
0 0 0 1 1 0 0 0 0 0 0 1 1 0 0 0 controllers have programmable memory that allows users
Byte to develop and modify control programs. This memory is
Word made nonvolatile so that if power is lost, the PLC holds
Figure 2-40 Memory bit, byte, and word. its programming.
Read Only Memory (ROM) stores programs, and data
cannot be changed after the memory chip has been manu-
for memory locations is one location per coil or contact. factured. ROM is normally used to store the programs and
One K of memory would then allow a program containing data that define the capabilities of the PLC. ROM memory
1000 coils and contacts to be stored in memory. is nonvolatile, meaning that its contents will not be lost if
The memory of a PLC may be broken into sections that power is lost. ROM is used by the PLC for the operating
have specific functions. Sections of memory used to store system. The operating system is burned into ROM by the
the status of inputs and outputs are called input status files PLC manufacturer and controls the system software that
or tables and output status files or tables (Figure 2-41). the user uses to program the PLC.
These terms simply refer to a location where the status of Random Access Memory (RAM), sometimes re-
an input or output device is stored. Each bit is either a 1or ferred to as read-write (R/W) memory, is designed so that
0, depending on whether the input is open or closed. A information can be written into or read from the memory.
closed contact would have a binary 1 stored in its respec- RAM is used as a temporary storage area of data that may
tive location in the input table, whereas an open contact need to be quickly changed. RAM is volatile, meaning
would have a 0 stored. A lamp that is ON would have that the data stored in RAM will be lost if power is lost. A
a 1 stored in its respective location in the output table, battery backup is required to avoid losing data in the event
whereas a lamp that is OFF would have a 0 stored. Input of a power loss (Figure 2-42). Most PLCs use CMOS-
and output image tables are constantly being revised by RAM technology for user memory. CMOS-RAM chips
the CPU. Each time a memory location is examined, the have very low current draw and can maintain memory
table changes if the contact or coil has changed state. with a lithium battery for an extended time, two to five

Input
module
Output
Processor memory Processor memory module
Input image table Output image table
Closed Output OFF
0000000000000000
Open 0000000000000010 0000000000000000
0000000000000000 0000000000000000
Input devices 0000000000000000 0000000000000000
0000000000000000 0000000010000000 Output ON
0000000000000000

Figure 2-41 Input and output tables.

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 RAM EEPROM
(volatile) (nonvolatile)

Executed Program
program backup

Current
data
Parameters
Memory
bits,
timers,
counters

Figure 2-43 EEPROM memory module is used to store,

back up, or transfer PLC programs.

d ule
sor Mo
Figure 2-42 Battery used to back up processor RAM. Proces

h
Flasard
C
years in many cases. Some processors have a capacitor
that provides at least 30 minutes of battery backup when
Figure 2-44 Flash memory card installed in a socket on
the battery is disconnected and power is OFF.
the processor.
Erasable Programmable Read-Only Memory
(EPROM) provides some level of security against unau-
will resume running without having lost any working data
thorized or unwanted changes in a program. EPROMs are
after power is restored.
designed so that data stored in them can be read, but not
easily altered without special equipment. For example,
UV EPROMs (ultraviolet erasable programmable read- 2.9 Programming Terminal Devices
only memory) can only be erased with an ultraviolet light. A programming terminal device is needed to enter, mod-
EPROM memory is used to back up, store, or transfer ify, and troubleshoot the PLC program. PLC manufac-
PLC programs. turers use various types of programming devices. The
Electrically erasable programmable read-only mem- simplest type is the hand-held type programmer shown
ory (EEPROM) is a nonvolatile memory that offers the in Figure2-45. This proprietary programming device has
same programming flexibility as does RAM. The EEPROM a connecting cable so that it can be plugged into a PLCs
can be electrically overwritten with new data instead of programming port. Certain controllers use a plug-in panel
being erased with ultraviolet light. Because the EEPROM rather than a hand-held device.
is nonvolatile memory, it does not require battery backup.
It provides permanent storage of the program and can be
changed easily using standard programming devices. Typi-
cally, an EEPROM memory module is used to store, back
up, or transfer PLC programs (Figure2-43).
Flash EEPROMs are similar to EEPROMs in that they
can only be used for backup storage. The main difference
comes in the flash memory: they are extremely fast at sav-
ing and retrieving files. In addition, they do not need to
be physically removed from the processor for reprogram-
ming; this can be done using the circuitry within the pro-
cessor module in which they reside. Flash memory is also
sometimes built into the processor module (Figure2-44),
where it automatically backs up parts of RAM. If power
fails while a PLC with flash memory is running, the PLC Figure 2-45 Hand-held programming terminal.

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 Processor

Laptop computer

A (Disk drive)
C (Internal hard drive)
Software
A
Copy
C
Serial port

Figure 2-46 Personal computer used as the programming

device.
Figure 2-47 Copying programs to a computer hard drive.

Hand-held programmers are compact, inexpensive,

and easy to use. These units contain multifunction keys
and a liquid-crystal display (LCD) or light-emitting keyboard or to download one from the computer hard
diode (LED) window. There are usually keys for instruc- drive (Figure 2-47). Some CPUs support the use of a
tion entering and editing, and navigation keys for mov- memory cartridge that provides portable EEPROM stor-
ing around the program. Hand-held programmers have age for the user program (Figure 2-48). The cartridge
limited display capabilities. Some units will display only can be used to copy a program from one PLC to another
the last instruction that has been programmed, whereas similar type PLC.
other units will display from two to four rungs of ladder
logic. So-called intelligent hand-held programmers are 2.11 Human Machine Interfaces
designed to support a certain family of PLCs from a spe- (HMIs)
cific manufacturer. A human machine interface (HMI) can be connected to
The most popular method of PLC programming is to communicate with a PLC and to replace pushbuttons, se-
use a personal computer (PC) in conjunction with the lector switches, pilot lights, thumbwheels, and other op-
manufacturers programming software (Figure 2-46). erator control panel devices (Figure2-49). Luminescent
Typical capabilities of the programming software include touch-screen keypads provide an operator interface that
online and offline program editing, online program moni- operates like traditional hardwired control panels.
toring, program documentation, diagnosing malfunctions Human machine interfaces give the ability to the op-
in the PLC, and troubleshooting the controlled system. erator and to management to view the operation in real
Hard-copy reports generated in the software can be
printed on the computers printer. Most software pack-
ages will not allow you to develop programs on another
manufacturers PLC. In some cases, a single manufac-
turer will have multiple PLC families, each requiring its
own software to program.

2.10 Recording and Retrieving Data

Printers are used to provide hard-copy printouts of the
processors memory in ladder program format. Lengthy
ladder programs cannot be shown completely on a screen.
Typically, a screen shows a maximum of five rungs at a Memory cartridge
time. A printout can show programs of any length and
analyze the complete program.
The PLC can have only one program in memory at
a time. To change the program in the PLC, it is neces- Figure 2-48 Memory cartridge provides portable storage
sary either to enter a new program directly from the for user program.

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 Figure 2-49 Human Machine Interfaces (HMIs).
Source: Photo courtesy Omron Industrial Automation, www.ia.omron.com.

time. Through personal computerbased setup software,

you can configure display screens to:
Replace hardwired pushbuttons and pilot lights Figure 2-50 Allen-Bradley Pico GFX-70 controller.
with realistic-looking icons. The machine operator Source: Image Used with Permission of Rockwell Automation, Inc.
need only touch the display panel to activate the
pushbuttons. This device consists of three modular parts: an HMI,
Show operations in graphic format for easier viewing. processor/power supply, and I/O modules.
Allow the operator to change timer and counter pre- The display/keypad can be used as an operator inter-
sets by touching the numeric keypad graphic on the face or can be linked to control operations to provide real-
touch screen. time feedback. It has the ability to show text, date and
Show alarms, complete with time of occurrence and time, as well as custom messages and bitmap graphics,
location. allowing operators to acknowledge fault messages, enter
values, and initiate actions. Users can create both the
Display variables as they change over time.
control program and HMI functionality using a personal
The Allen-Bradley Pico GFX-70 controller, shown in computer with PicoSoft Pro software installed or the con-
Figure2-50, serves as a controller with HMI capabilities. trollers on-board display buttons.

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 CHAPTER 2 REVIEW QUESTIONS

1. What is the function of a PLC input interface 21. With reference to discrete output module current
module? ratings:
2. What is the function of a PLC output interface a. What is the maximum current rating for a typical
module? 120 VAC output module?
b. Explain one method of handling outputs with
3. Define the term logical rack.
larger current requirements.
4. With reference to a PLC rack:
22. What electronic element can be used as the switch-
a. What is a remote rack?
ing device for DC discrete output modules?
b. Why are remote racks used?
23. A discrete relay type output module can be used to
5. How does the processor identify the location of a
switch either AC or DC load devices. Why?
specific input or output device?
24. With reference to sourcing and sinking I/O
6. List the three basic elements of rack/slot-based
modules:
addressing.
a. What current relationship are the terms sourcing
7. Compare bit level and word level addressing. and sinking used to describe?
8. In what way does tag-based addressing differ from b. If an I/O module is specified as a current-sinking
rack/slot-based addressing? type, then which type of field device (sinking or
9. What do PC-based control systems use to interface sourcing) it is electrically compatible with?
with field devices? 25. Compare discrete and analog I/O modules with
10. What type of I/O modules have both inputs and respect to the type of input or output devices with
outputs connected to them? which they can be used.
11. In addition to field devices what other connections 26. Explain the function of the analog-to-digital (A/D)
are made to a PLC module? converter circuit used in analog input modules.
12. Most PLC modules use plug-in wiring terminal 27. Explain the function of the digital-to-analog (D/A)
strips. Why? converter circuit used in analog output modules.
13. What are the advantage and the disadvantage of 28. Name the two general sensing classifications for
using high-density modules? analog input modules.
14. With reference to PLC discrete input modules: 29. List five common physical quantities measured by
a. What types of field input devices are suitable for a PLC analog input module.
use with them? 30. What type of cable is used when connecting a ther-
b. List three examples of discrete input devices. mocouple to a voltage sensing analog input mod-
15. With reference to PLC discrete output modules: ule? Why?
a. What types of field output devices are suitable 31. Explain the difference between a unipolar and bi-
for use with them? polar analog input module.
b. List three examples of discrete output devices. 32. The resolution of an analog input channel is speci-
16. Explain the function of the backplane of a PLC fied as 0.3 mV. What does this tell you?
rack. 33. In what two ways can the loop power for current
17. What is the function of the optical isolator circuit sensing input modules be supplied?
used in discrete I/O module circuits? 34. List three field devices that are commonly controlled
18. Name the two distinct sections of an I/O module. by a PLC analog output module.
19. List four tasks performed by a discrete input 35. State one application for each of the following spe-
module. cial I/O modules:
20. What electronic element can be used as the switch- a. High-speed counter module
ing device for a 120 VAC discrete output interface b. Thumbwheel module
module? c. TTL module

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 d. Encoder-counter module 44. List five important procedures to follow when han-
e. BASIC or ASCII module dling static-sensitive PLC components.
f. Stepper-motor module 45. Define each of the following terms as they apply to
g. BCD-output module the memory element of a PLC:
36. List one application for each of the following intel- a. writing
ligent I/O modules: b. reading
a. PID module c. bits
b. Motion and position control module d. location
c. Communication module e. utilization
37. Write a short explanation for each of the following 46. With reference to the I/O image tables:
discrete I/O module specifications: a. What information is stored in PLC input and
a. Nominal input voltage output tables?
b. Input threshold voltages b. What is the input status of a closed switch
c. Nominal current per input stored as?
d. Ambient temperature rating c. What is the input status of an open switch
e. Input ON/OFF delay stored as?
f. Output voltage d. What is the status of an output that is ON
g. Output current stored as?
h. Inrush current e. What is the status of an output that is OFF
i. Short circuit protection stored as?
j. Leakage current 47. Why do PLCs execute memory-checking
k. Electrical isolation routines?
l. Points per module
48. Compare the memory storage characteristics of
m. Backplane current draw
volatile and nonvolatile memory elements.
38. Write a short explanation for each of the following
49. What information is normally stored in the ROM
analog I/O module specifications:
memory of a PLC?
a. Channels per module
b. Input current/voltage range(s) 50. What information is normally stored in the RAM
c. Output current/voltage range(s) memory of a PLC?
d. Input protection 51. What information is normally stored in an
e. Resolution EEPROM memory module?
f. Input impedance and capacitance 52. What are the advantages of a processor that utilizes
g. Common-mode rejection a flash memory card?
39. Compare the function of the CPU and memory sec- 53. List three functions of a PLC programming termi-
tions of a PLC processor. nal device.
40. With reference to the PLC chassis power supply: 54. Give one advantage and one limitation to the use of
a. What conversion of power takes place within the hand-held programming devices.
power supply circuit? 55. What is required for a personal computer to be used
b. Explain the term hold-up time as it applies to the as a PLC programming terminal?
power supply.
56. List four important capabilities of PLC program-
41. Explain the purpose of a redundant PLC processor. ming software.
42. Describe three typical modes of operation that can 57. How many programs can a PLC have stored in
be selected by the keyswitch of a processor. memory at any one time?
43. State five other functions, in addition to simple 58. Outline four functions that an HMI interface screen
logic processing, that PLC processors are capable can be configured to perform.
of performing.

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 CHAPTER 2 PROBLEMS

1. A discrete 120 VAC output module is to be used to c. If the ambient temperature rating for an I/O
control a 230 VDC solenoid valve. Draw a diagram module is specified as 60C, how much is this
showing how this could be accomplished using an expressed in degrees Fahrenheit?
interposing relay. 4. Create a five-digit code using the SLC 500 rack/
2. Assume a thermocouple, which supplies the input slot-based addressing format for each of the
to an analog input module, generates a linear volt- following:
age of from 20 mV to 50 mV when the temperature a. A pushbutton connected to terminal 5 of module
changes from 750F to 1250F. How much voltage group 2 located on rack 1.
will be generated when the temperature of the b. A lamp connected to terminal 3 of module
thermocouple is at 1000F? group0 located on rack 2.
3. With reference to I/O module specifications: 5. Assume the triac of an AC discrete output module
a. If the ON-delay time of a given discrete input fails in the shorted state. How would this affect the
module is specified as 12 milliseconds, how much device connected to this output?
is this expressed in seconds? 6. A personal computer is to be used to program sev-
b. If the output leakage current of a discrete output eral different PLCs from different manufacturers.
module is specified as 950 A, how much is this What would be required?
expressed in amperes?

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