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Lecture: PLC Hardware: Programmable Controllers
Lecture: PLC Hardware: Programmable Controllers
Jerzy Kasprzyk
1. Introduction
Others: PCD family of SAIA-Burgess, Bernecker & Rainer (multitasking operating system),
Beckhoff, WAGO, Moeller, etc.
Fig. 1. Simatic families: S7-400, S7-300 and S7-200
Communication modules,
Hardware configuration:
• parameters of the modules that can be configured by the user, e.g. signal ranges, voltage
or current mode for AI or AO, code (e.g. binary, BCD), references (direct addresses).
In the older systems, some of the parameters have been set in hardware (e.g. jumpers),
nowadays it is rather done in a software way.
For communication modules, the user should declare: parameters of the communication link
(e.g. speed rate, address of the node, data protection), references for transmitted data, etc.
Basic features:
• Execution Speed, e.g. duration of a typical cycle (e.g. 1K of bit instructions), processing
times for different type instructions;
• Maximum Number of DI and DO, AI and AO, optionally the maximum number of
modules or baseplates;
• Memory size for the user program and user data and memory type (RAM, EPROM,
FLASH);
• Forcing Capabilities;
Often: Real-time clock with battery backup (can be synchronized via a network).
Usually, the CPU module is equipped with a number of LEDs to indicate the state of PLC:
POWER, READY, RUN, STOP, FAULT etc., as well as to show the states of communication
ports. Some CPUs have also switches (or keys) to change the mode of functioning
(PROGRAM, RUN)
Program sweep and CPU modes
INITIALIZATION
INITIALIZATION
SCAN NO
THE INPUTS
?
YES
NO
MODE "RUN"
?
SCAN
YES TIME
PROCESSING OF
EXECUTE
PROGRAM
A PROGRAM
LOGIC
UPDATE NO
THE OUTPUTS
?
YES WRITING
THE OUTPUTS
WRITE
THE OUTPUTS
COMMUNICATION
WITH PADT
COMMUNICATION
AND SYSTEM
COMMUNICATION
DIAGNOSTICS
DIAGNOSTICS
Other modes: Constant Sweep, test modes: Single Sweep, Step by Step, RUN without digital
output activation.
Scan Time (sweep time) can not be arbitrary long – there is a watchdog in CPU that prevents
PLC against program hang-up (typically 100 ms to 500 ms).
Table 2. Times of data exchange between CPU and modules of GE Fanuc series 90-30
Time [ms]
Modules Baseplate Extension Remote
DI module converts discrete (2-level) input signals into bits that are transferred to reference
locations defined by the prefix %I or %IX.
To other circuits
Optical
coupling
Fig. 5. Simplified schematic and field wiring diagram for MDL 646
(24Volt DC Positive/Negative Input Module)
Optical
coupling
Fig. 6. Simplified schematic and field wiring diagram for MDL 231
(240 Volt AC Isolated Input Module)
• Electrical Characteristics of state levels: ON (e.g. > 15V) and OFF (e.g. < 5 V);
DO module converts bits transferred from reference locations defined by the prefix %Q or
%QX into discrete (2-level) output signals.
To other
curcuits
Fig. 7. Simplified schematic and field wiring diagram for MDL 742
(24Volt DC Positive Output Module)
Digital Output Module Specifications:
• Load Current/Output;
• Inrush Current;
a) b)
.022mF 100 Ω
0.5 W
1A, 100V 630V
DO DO
c) d)
DO DO
In AI module analog input signals (voltage or current) are converted into digital data (usually
words) that are transferred to reference locations defined by the prefix %IW.
For some modules it is also possible to define limits (high and low) for alarms. Exceeding the
limits is indicated by setting on the associated binary references (%IX).
• –10 V, +10 V;
• 0 V, +10 V;
• +1 V, +5 V;
• 4 mA, 20 mA;
• 0 mA, 20 mA.
Additional element
of the curcuit
A
250Ω
D
%IW1
A
250Ω
D
%IW2
GND
ANALOG
24V INPUT
Fig. 9. Wiring diagram for a single-ended AI current module and 2-wire sensors
Additional element
of the curcuit
4-wire A
250Ω
sensor D
%IW1
4-wire A
250Ω
sensor D
%IW2
GND
ANALOG
INPUT
24V
Fig. 10. Wiring diagram for a differential AI current module and 4-wire sensors
Additional element
of the circuit
- +
A
D %IW1
- +
A
D %IW2
GND
ANALOG
INPUT
optional
• Resolution;
The maximum value of the quantization error is defined with reference to the LSB (Least
Significant Bit) of the register in A/D converter, e.g. 4 µA/LSB.
• Accuracy;
It is defined as the maximum difference between expected and measured values e.g.
±0.25% of the whole range at 25 °C.
• Linearity;
Other specifications:
• Number Of Channels;
• Calibration;
• Absolute Accuracy;
• Update Rate;
• Isolation;
In AO module digital data (usually words) transferred from reference locations defined by the
prefix %QW are converted into analog output signals (voltage or current).
• –10 V, +10 V;
• 0 V, +10 V;
• +1 V, +5 V;
• 4 mA, 20 mA;
• 0 mA, 20 mA.
Usually, a user can also define the signal state on the output while PLC is in the STOP mode
(Timeout State). It can be done in hardware way (using jumpers) or software way (during
configuration). Then the user can declare the state as e.g. User Defined or Last Value.
Additional element
of the circuit
%QW1 D
A
%QW2 D
A
ANALOG
OUTPUT
24V
Analog Current Output Module
• Number of Channels;
• Resolution;
• Absolute Accuracy;
• Update Rate;
• Isolation;
A hot standby system consists of two identically configured PLC units that are
communicating with each other via hot standby processors. If there is a failure of the primary
PLC, the secondary (or backup) PLC will assume the control check. Under normal
conditions, the secondary PLC assumes no control functions, it only checks status information
to detect errors.
Connector to RIOS
The Hot Standby solution provides bumpless transfer of I/O using remote I/O. In case of a
failure, the controllers switchover and the system recovers quickly.
After Hot Standby system has been started and is running normally, it will continue to
function automatically. It constantly tests itself for faults and is always ready to transfer
control from the Primary to the Standby, if it detects a fault.
While the system is running, the primary CHS module will automatically transfer a
predetermined amount of state RAM to the Standby unit each scan. This ensures that the
Standby is ready to take control if needed.
If one or both of the links between the Hot Standby modules are broken, the Primary
controller will function as though no backup is available.
If the Primary controller fails, the Standby automatically assumes control of the remote I/O
network. If the Primary controller recovers from failure, it assumes Standby responsibilities.
If it cannot recover, it remains offline.
If the Standby controller fails, it goes offline. The Primary controller functions as a stand-
alone and continues to manage the I/O networks.
TMR is a fault tolerant solution, in which three systems perform a process and that result is
processed by a voting system (two of three) to produce a single output. This means, if one of
the three systems fails, the other two systems can correct and mask the fault.
Example: the GE Fanuc Genius Modular Redundancy (GMR) system.