LECTURE 03

PLC Hardware Components

 Learning objectives
• At the end of this lecture trainee should be
able to;
✓Define PLC Hardware
✓ Identify PLC Hardware Components
✓ Describe the PLC Hardware Components
✓ Illustrate the function of PLC Components
 Introduction to PLC Hardware
• A PLC (Programmable Logic Controller) is
made up of both hardware and software
components. The PLC hardware refers to
the physical components that make up a
PLC system.
• Whereas the PLC software refers to the
PLC’s operating system and application
program that are stored in the PLC’s
memory
 Introduction cont….
• PLC hardware is a term that describes the
physical components that make up the overall
PLC system.
• Each piece of PLC hardware is designed to
perform a specific task.
• Without all of its hardware components a PLC
system cannot operate effectively.
 Introduction cont….
• Think of the main components that make up a
car. The engine, gearbox, wheels, electrics,
steering, body etc. Without all of its
components a car cannot function properly.
And most of the components that are used,
say in a Ford, cannot be used in a Honda. In
that sense, PLC Hardware is a similar concept.
 Introduction cont….
• The majority of PLC manufacturers have
developed hardware and software
components to establish a proprietary PLC
system.
• That means PLC hardware components vary
for different manufacturers and in the
majority of cases are not interchangeable with
hardware components from other PLC brands
 Basic Hardware Components
There are 6 basic hardware components that
make up a PLC;
– Processor (CPU)
– Mounting System
– Power Supply
– Input & Output Interface
– Communication Interface
– Programming Device
Basic Hardware components cont..
• These main PLC hardware components are
found in all PLC systems regardless of
manufacturer, type and size.
• They are the essential hardware elements
that make up every PLC system.
PLC Hardware Block diagram
 Functions of PLC Block diagrams
1. PLC Processor (CPU)
At the heart of every PLC system is a processor.
It is perhaps the most crucial PLC hardware
component. Sometimes the PLC processor is
also referred as the PLC controller or PLC CPU
(Central Processing Unit).
Regardless of the name used, the PLC processor
is the workhorse of the PLC system responsible
for all the logic computation and number
operation
 Function cont…
• The PLC processor can be embedded into the
PLC unit or come as a separate PLC module.
Generally fixed PLC types have their processor
embedded in the PLC itself.
• While modular and distributed PLC types have
their PLC processors as a separate module.
 PLC samples
• Some examples of PLCs with embedded
processors are;
• Siemens Simatic S7-200 CPU 224, S7-200 CPU
226 and more recently the Siemens Simatic
S7-1200, CPU 1214C (6ES7 214).
• They are a fixed style PLC with embedded
processor, but have the ability to expand with
input and output modules. See below….
PLC samples
 PLC processor module
• Some examples of PLC processor modules are
the Allen Bradley Control Logix 5580
controller, the Mitsubishi Melsec-Q Processor
CPU (Q03UDECPU), the Delta AHCPU560-EN2
processor and the Omron CJ2M-CPU1 and
CJ2M-CPU3 controllers.
 PLC Processor
The PLC processor contains 3 fundamental
components:
• PLC CPU (Central Processing Unit)
• PLC Memory
• PLC Programming port
 1. The PLC CPU

• The PLC CPU is a microprocessor that is

similar to a computer CPU. However, the
PLC CPU is not set up to multitask like a
computer CPU, but rather to perform
dedicated tasks such as program scan and
execution.
 PLC CPU cont…
• In a PLC the CPU is responsible for control of
all PLC activity. This includes program scanning
(such as ladder logic), program executing,
handling data storage, directing data flow and
controlling communication among the various
interfaces.
 The details of PLC processor
• The most common processor used in a
PLC is a single microprocessor. However,
the higher powered PLCs have multiple
microprocessors to divide up the various
tasks in order to improve overall operating
speed.
 PLC processor detail…
• A PLC with dual microprocessors could
have a control processor to carry out data
manipulation and complex computation
as well as a second logic processor to
execute the logic, timing, counting and
other functions of the application
program
 2. The PLC Memory
• The PLC memory is made up of program
memory, data memory and firmware. The PLC
uses the memory to store the program for
processing by the CPU and to store data for
input and output processing and execution.
• The size of the PLC memory will vary
depending on the processing power of the
CPU.
• The higher powered PLC models will be
equipped with faster CPUs and will have more
onboard memory.
 PLC memory cont…
So if you have a large PLC program then
you will require a PLC controller with a
large integrated memory capacity to
accommodate.
Therefore, some PLC controllers have
expandable memory which can get you out
of trouble if you run out of memory
unexpectadly.
 2. PLC Programming Port
The programming port on the PLC processor is
used to connect to a programming device such
as a PC or laptop.
The communication protocol used for the PLC
programming port varies between PLC
manufacturers. Some examples of the
communication protocol used for the PLC
programming port includes RS232, RS485 and
Ethernet
 PLC Hardware Mounting Systems
• The hardware mounting system of a PLC
provides the means to physically connect the
various hardware components of the PLC
system. PLC hardware mounting systems can
vary from one PLC manufacturer to another
and can also vary depending on the type of
PLC used.
 PLC Hardware Mounting Systems…
The 3 main PLC mounting systems used in industrial
automation projects are:
• Rack mounted PLC
• Rail mounted PLC
• Panel mounted PLC
 PLC Mounting systems detail
• Rack Mounted PLC
A rack mounted PLC uses a mechanical
mounting system in order to physically connect
the PLC processor and other PLC hardware
components together.
The most common rack mounted PLCs use an
arrangement whereby the hardware
components are slotted into the rack.
 Mounting detail cont…
This allow the hardware components to be
secured in placed and at the same time
connected together, with plugs at the base of
the rack, via the PLC bus
• Rack Mounted PLCs are commonly used in
modular and distributed type PLC systems.
They are well suited to service higher end
and plant wide applications where multiple
PLC racks and large numbers of inputs and
outputs are required. They have a fixed
number of hardware module slots and
generally have an orderd hardware module
layout.
• Such as power supply module, PLC processor
module, communication modules then input
and output modules.
• An example of a rack mounted PLC is the
Siemens Simatic S7-400. The PLC mounting
rack, rack slots, PLC bus and PLC modules are
clearly labelled. This particular PLC mounting
rack has 9 slots, with some PLC hardware
modules taking up multiple slots. See below….
PLC Rack
• Some PLC manufacturer use different
terminology to describe their rack mounted
PLCs. Terms such
as chassis, backplane, base, base
rack and base module are all examples of
different terminology to describe rack
mounted PLCs. Siemens uses the term PLC
rack for their S7-400 PLC mounting system.
• An example of a Siemens PLC rack is shown
below…
• Allen Bradley uses the term PLC chassis for
their Control Logix PLC mounting system. An
example of an Allen Bradley Control Logix
chassis is shown below….
• The term PLC backplane is used by the the
Omron CS1, Schneider Modicon M340 and
Delta AH series PLCs to describe their PLC
mounting system.
• Examples of the Omron CS1 series PLC
backplane, Delta AH Series PLC back plane
and Modicon M340 backplane are shown
below…
PLC Backplane
 PLC base
• Koyo, Toshiba and Yokogawa use the
term PLC base to describe their PLC
mounting systems.
• Examples of the Koyo DL205 series PLC
base, Koyo DL405 series PLC base,
Yokogawa FA-M3V PLC base and the
Toshiba Type 1 Light Series PLC base.