Chapter 2 PLC Hardware Components

Department Of Mechatronics Engineering
Faculty Of Engineering And Information Technology
An-Najah National University
Programmable
Logic Controllers
(10651572)
Dr. Mohammad Abuabiah

m.abuabiah@najah.edu
Office: 11-4-130 1
Chapter 2
PLC Hardware
Components
2
Chapter Objectives 3
• List and describe the function of the hardware components used in PLC
systems
• Describe the basic circuitry and applications for discrete and analog
I/O modules, and interpret typical I/O and CPU specifications
• Explain I/O addressing
• Describe the general classes and types of PLC memory devices
• List and describe the different types of PLC peripheral support devices
available
4
PLC Panel
Dr. Mohammad Abuabiah An-Najah National University
Siemens PLC (Modular I/O) 5
Power CPU DI AI DO AO Function Communication

Supply Module Processor
2.1 Power Supply (PS) 6

2.1 Power Supply (PS) 7
• The PLC power supply provides the necessary power (typically 5 VDC)
to the processor and I/O modules plugged into the backplane of the
rack.
• PLC power supplies are normally designed to withstand momentary
losses of power without affecting the operation of the PLC. Hold-up
time, which is the length of time a PLC can tolerate a power loss,
typically ranges from 10 ms to 3 s.
8
24 VDC
2.1 Power Supply (PS)
110-220 VAC
9
2.1 Power Supply (PS)
2.2 The Central Processing Unit (CPU) 10

• The Central Processing Unit (CPU) is built into single-unit fixed PLCs while
modular rack types typically use a plugin module.

• A processor module can be divided into two sections: the CPU section
and the memory section.
• Associated with the processor unit will be a number of status

LED indicators to provide system diagnostic information to the

operator:
• SF - System Fault: Red light indicate Software or Hardware error.
• BF – Buss Fault: Red light indicate Network error.
• DC5V: Green light indicate the power supply is connected and

the CPU is on.
• FRCE: Green light indicated that one of the I/O is in the force
mode.
• RUN: Green light indicated that the CPU is running.
• STOP: Orange light indicated that the CPU is stop.

• A key switch may be provided that allows you to

select one of the following three modes of

operation:
• RUN Mode:
– Places the processor in the Run mode.
– Executes the ladder program and energizes output
devices.
– Prevents you from performing online program editing in this

position.
• STOP Mode:
– Places the processor in the stop mode.

– Prevents the processor from scanning or executing the
ladder program, and the controller outputs are de-
energized
– Allows you to perform program entry and editing.
• MRES Mode:
– Reset the CPU memory.

– Memory reset per mode selector switch requires a specific
sequence of operation.
2.2.1 Memory Design 15
• Memory is the element that stores information, programs, and data in a

PLC.
• The user memory of a PLC includes space for the user program as well
as addressable memory locations for storage of data.
• Data are stored in memory locations by a process called writing. Data
are retrieved from memory by what is referred to as reading.
• Memory location refers to an address in the CPU’s memory where a
binary word can be stored. A word usually consists of 16 bits. Each
binary piece of data is a bit and eight bits make up one byte.
• Load memory in the S7-300/400 series PLC, which is the externally

inserted MMC card. This card is a Flash Memory, and the information in
the card will not be lost after a power failure. For the load memory of
the S7-1500 CPU, it can only be expanded by an external memory
card, and the maximum capacity is supported to 32G.
• The load memory mainly stores the PLC Program: program blocks, data
blocks, technological objects, and hardware configuration in the
project.
• The load memory is similar to the hard disk of a computer.

17
2.2.1 Memory Design
• Load memory
• The work memory is a RAM memory integrated

in the CPU. The capacity is determined by the

model and cannot be expanded.
• It can be divided into code working memory
and data work memory, which are
respectively used to save codes (OB/FC/FB)
and data blocks (DB) related to program
operation.
• The work memory is similar to the memory card
in a personal computer. The data will be lost

when the power is cut off.
• When the power supply is restored, the CPU will
copy the data from the load memory to the
working memory.
• The system memory, like the work memory, is the RAM memory integrated in
the CPU, and the data is lost when power is off, and the capacity cannot be
expanded.
• The system memory mainly includes:
– Input process image area (I area)
– Output process image area (Q area)
– Bit storage area (M area)
– Timer area (T area)
– Counter area (C area)
– Local data area (L area)

– I/O peripheral memory
• The system memory is used by the CPU system to process data. It is rarely
possible to operate the memory when programming, so it is enough to know
that there is such a memory.
• Retentive Memory is a non-volatile

memory integrated in the CPU.

Through parameter settings, part of
the data can not be lost after
power failure.
• The data in M, T, C and data
blocks will be reset by default
when power is off, and can be set
to be retained through
parameters. Then the data will be
saved in the retentive memory
when power is off.
2.2.2 CPU Ports 21
1) MPI (Multi-Point Interface ) is a proprietary interface of the

programmable logic controller SIMATIC S7.

HMI
2.2.2 CPU Ports 22
2) DP (Decentralized Peripheral) port provides an even higher

data transfer rate than an MPI port. You can connect

another automation facility like VFD, Interface module, etc.
Using the DP network one can transmit data remotely.
2.2.2 CPU Ports 23
3) PTP (Precision Time Protocol) If this port is available on CPU of PLC then
we can connect it with printer and barcode reader.

2.2.2 CPU Ports 24
4) PN (ProfiNet/EtherNet) It uses RJ45 (Register Jack) network interface to

communicate with other facilities. You can connect it with an HMI or

Laptop to transfer the data.
2.3 The I/O Section 25

• The input/output (I/O) section of a PLC is the section to which all field
devices are connected and provides the interface between them and
the CPU.
• Input/output arrangements are built into a fixed PLC while modular
types use external I/O modules that plug into the PLC.
• The I/O system provides an interface between the hardwired

components in the field and the CPU. The input interface allows status
information regarding processes to be communicated to the CPU, and
thus allows the CPU to communicate operating signals through the
output interface to the process devices under its control.
• Most PLC modules have plug-in wiring terminal strips. The terminal
block is plugged into the actual module as illustrated in Figure

2.3.1 Discrete I/O Modules 29
• The most common type of I/O interface module is the discrete type.
The PLC’s memory system stores information about the status of all the
inputs and outputs.
DI16 X DC24V DO16 X DC24V / 0.5A
Digital Input Requires a 24 Digital Output Maximum output

with 16 inputs Volt DC in order with 16 inputs current
to turn on
The output voltage
of this module is a
24 Volt DC
• 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.
• The modules themselves receive their voltage and current for proper
operation from the backplane of the rack enclosure into which they
are inserted.
• To keep track of all this information, it uses a system

called addressing.
• An address is a label or number that indicates where a
certain piece of information is located in a PLC’s memory.
I = input Bit number

Q = output
XX.X
Byte number
Siemens SIMATIC S7 addressing

• For Example:
I1.0 Q3.0
I1.0
I1.1
Q3.0
I1.1 I1.0 I1.1 Q3.0

• This type of interface connects

field input devices of the

ON/OFF nature such as selector
switches, pushbuttons, and limit
switches.
• Likewise, output control is limited
to devices such as lights, relays,
solenoids, and motor starters
that require simple ON/OFF

switching.
36
2.3.1 Discrete I/O Modules
2.3.2 Analog I/O Modules 38
• Discrete devices are inputs and outputs that have only two states: on
and off. In comparison, analog devices (AI/AO) represent physical

quantities that can 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.
• Analog input modules normally have multiple input channels that allow
4, 8, or 16 devices to be interface to the PLC. The two basic types of
analog input modules are voltage sensing and current sensing.
• Analog sensors measure a varying physical quantity over a specific
range and generate a corresponding voltage or current signal.
• Common physical quantities measured by a PLC analog module
include temperature, speed, level, flow, weight, pressure, and position.
• For example, a sensor may measure temperature over a range of 0 to

500°C, and output a corresponding voltage signal that varies between
0 and 50 mV.
• Analog voltage input modules are available in two types: unipolar and
bipolar.
• Unipolar modules can accept an input signal that varies in the positive
direction only. For example, if the field device outputs 0 to +10 V, then
the unipolar modules would be used.
• Bipolar signals swing between a maximum negative value and a
maximum positive value. For example, if the field device outputs −10 to
+10 V a bipolar module would be used.
• The resolution of an analog input channel refers to the smallest change

in input signal value that can be sensed and is based on the number of
bits used in the digital representation.
• Typical specifications are as follows:

• Field devices that provide an analog output as their signal are usually
connected to a transducer that converts a field device’s variable (e.g.,

pressure, temperature etc.) into a very low-level electric signal (current
or voltage) that can be amplified by a transmitter and then input into
the analog module.
• The method user to wire two-, three-, and four-wire sensors to an

analog input module is illustrated in Figure below

• When wiring single-ended analog input devices to the analog input

card, the number of total wires necessary can be limited by using the
ANALOG COMMON terminal
• Figure below 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 adjusting the percentage of the valve opening.
2.3.3 Special I/O Modules 46
• Many different types of I/O modules have been developed by Siemens

to meet special needs. For example:
– F-digital/analog modules
– Standard and fail-safe digital input modules
– Standard and fail-safe digital output modules

– Other special modules
– Connections
2.4 Function Module (FM) 47

• Function modules (FM) are

intelligent modules that perform
technological tasks such as position
determination, counting and
positioning, and other complex
functions in the automation
independently.
• They are used when there are high

demands on accuracy and
dynamic in the starting of
automation tasks.
• FM do the following three things:

– Convert the signal to processable data,

– Process the data,
– Convert the procced results back to
electrical signals
High Accuracy
Measurements
2.5 Interface Module (IM) 50
Power CPU IM
DI AI DO AO FM CP
Supply
Power CPU IM DI AI DO AO FM CP
Supply
• The data transfer between higher levels of PLCs takes place via an
interface module.
53
2.5 Interface Module (IM)
2.6 Communication Processor (CM) 54

2.6 Communication Processor (CM) 55
• The CP (Communication processor) module is used to transfer the data

in a case of not having the required port on your CPU.

56
2.6 Communication Processor (CM)
2.7 Human Machine Interface (HMI) 57
• In the past, the typical user interface to a control system consisted of a

panel with switches, pushbuttons, pilot lights, gauges, analog meters,

and the like.
• With the advent of digital control systems, larger hard-wired panels
have been replaced by a Human Machine Interface (HMI).
2.7 Human Machine Interface (HMI) 58
• Through personal computer–based

setup software, you can configure

display screens to:
– Replace hardwired pushbuttons and pilot
lights with realistic-looking icons.
– Show operations in graphic format for
easier viewing.
– Allow the operator to change timer and
counter presets by touching the numeric
keypad graphic on the touch screen.

– Show alarms, complete with time of
occurrence and location.
– Display variables as they change over
time.
59
2.7 Human Machine Interface (HMI)
60
2.7 Human Machine Interface (HMI)
2.8 SCADA System 61
• SCADA (Supervisory Control And Data Acquisition) is a category of

software applications for controlling industrial processes, which is the

gathering of data in real time from remote locations in order to control
equipment and conditions.
2.8 SCADA System 62
• SCADA VS HMI: The main difference is that SCADA is a remote

monitoring system, where as HMI is local to machine. An HMI for

example, would be placed on the control panel near a part of a
machine, where as SCADA would be set up in a control room, far away
from the machine itself.
2.8 SCADA System 63
• SCADA System example: Biogas Power Plant


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Department Of Mechatronics Engineering

Faculty Of Engineering And Information Technology

An-Najah National University

Dr. Mohammad Abuabiah

Power CPU DI AI DO AO Function Communication

Power CPU DI AI DO AO Function Communication

Power CPU DI AI DO AO Function Communication

modular rack types typically use a plugin module.

• Associated with the processor unit will be a number of status

LED indicators to provide system diagnostic information to the

• SF - System Fault: Red light indicate Software or Hardware error.

• BF – Buss Fault: Red light indicate Network error.

• DC5V: Green light indicate the power supply is connected and

• RUN: Green light indicated that the CPU is running.

• STOP: Orange light indicated that the CPU is stop.

• A key switch may be provided that allows you to

select one of the following three modes of

– Prevents you from performing online program editing in this

– Places the processor in the stop mode.

– Reset the CPU memory.

• Memory is the element that stores information, programs, and data in a

• Load memory in the S7-300/400 series PLC, which is the externally

• The load memory is similar to the hard disk of a computer.

• The work memory is a RAM memory integrated

in the CPU. The capacity is determined by the

in a personal computer. The data will be lost

– Local data area (L area)

• Retentive Memory is a non-volatile

memory integrated in the CPU.

1) MPI (Multi-Point Interface ) is a proprietary interface of the

programmable logic controller SIMATIC S7.

2) DP (Decentralized Peripheral) port provides an even higher

data transfer rate than an MPI port. You can connect

we can connect it with printer and barcode reader.

4) PN (ProfiNet/EtherNet) It uses RJ45 (Register Jack) network interface to

communicate with other facilities. You can connect it with an HMI or

Power CPU DI AI DO AO Function Communication

• The I/O system provides an interface between the hardwired

block is plugged into the actual module as illustrated in Figure

DI16 X DC24V DO16 X DC24V / 0.5A

Digital Input Requires a 24 Digital Output Maximum output

• 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

• To keep track of all this information, it uses a system

I = input Bit number

Siemens SIMATIC S7 addressing

I1.1 I1.0 I1.1 Q3.0

• This type of interface connects

field input devices of the

that require simple ON/OFF

and off. In comparison, analog devices (AI/AO) represent physical

• For example, a sensor may measure temperature over a range of 0 to

• The resolution of an analog input channel refers to the smallest change

• Typical specifications are as follows:

connected to a transducer that converts a field device’s variable (e.g.,

• The method user to wire two-, three-, and four-wire sensors to an

analog input module is illustrated in Figure below

• When wiring single-ended analog input devices to the analog input

• Many different types of I/O modules have been developed by Siemens

– Standard and fail-safe digital input modules

– Standard and fail-safe digital output modules

– Other special modules

Power CPU DI AI DO AO Function Communication

• Function modules (FM) are