PROGRAMMABLE: LOGIC CONTROLLERS

10 AN OVERALL LOOK AT

needed. One enample is in the use ol drum controller/scquencers. Some eauinm..

facturers still use a mechanical drun with pegs il an Overall cost advantage. Tho
hent manu
in
tional sequence is seldom or never changed, so lhe reprogramming available with th pera
would nt be necesary.
miromental C'onsiderations. Certain process cnvironments, such as high heat ans
brauom, miertcre with the electronic deVICes in PLCS, which limit their use and

Fail-Safe Operation. n relay systems. the stop button clectrically disconnects the circi
if the pwer fails, the system stops. Furthermore, the relay system docs not automaticall
restart when power is restored. This. of course, can be programmed into the PLC: howeVe
in some PLC programs. you may have to apply an inputVoltage lo cause a device to stor
These systems are not fail-safe. This disadvantage can be overcome by adding safety relav
top.
to a PLC system. as shown later in this text.

Fixed-Circuit Operation. If the circuit in operation is never altered, a fixed control

system (such as a mechanical drum) might be less costly than a PLC. The PLC is most
effective when in
periodicchanges are operation made.

1-5 OVERALL PLC SYSTEM

Figure 1-4 shows, in block form, the four major units of a PLC system and how they ar
interconnected. The four major parts, each of which is described later in detail. are
1. Central Processing Unit (CPU). The "brain" of the
system. which has three
subparts:
a.
Microprocessor. The computer center that carries out mathematic and logc
operations.
b. Memory. The area of the CPU in which data
andinformation is stored and
retrieved. Holdsthe system software and user
c. Power supply. The electrical program.
line voltage to various
supply that converts alternating current
(AC
operational DC values. In the process. the powet
supply filters and regulates the DC
operation
voltages to ensure
proper compu
2.
Progrummer/Monitor. The
programmer/monitor (PM) is a device used
communicate with the circuits of the PLC.
terminals, and the personal Hand-held terminals. industrna
computer exist as PM devices. In a
input lakes place hrough a
membrane keypad and the hand-held
display is usuauy
liquid-crystal display (1CD). With the industrial
nore
complex, typewriter-type keyboards and terminal or
personal cOmp
er

employed cathode ray tubes (CRIS are

3. 1/0 Modules. The
input module has terminals into
cal signals.
generaled by sensors or which outside process ectri
has terminals to which transducers, are entered. The output C dule
solid statle output signals are sent to
switching activate relays, various

devices, motors, and

displays.
solenoids fof
An electronic sys
OVERALL PLC SYSTEM

PM
Programmer/
Monitor

CPU

Microprocessor
Input -w-
Module Memory Output
Module

Power
Supply

Rack and Chassis

FIGURE 14
PLC System Layout and Connection

connecting 1/O modules to remote locations can be added if needed. The actual
operating process under PLC control can be thousands of feet from the CPU and
its /O modules.
4. Racks and Chassis. The racks on which the PLC
parts are mounted and the
enclosures on which the CPU, PM, and 1/O modules are mounted.

Optional units often a part of the PLC system are

DPrinter. A device on which the program in the CPU may be printed. ln addition,
operating information may be printed upon command.
11 Program Recorder/Player. Some older PLC systens use tape to provide secondary
storage for CPU programs. Today, PLCs use tloppy disks, with hard disks for sec
ondary storage. The stored programs provide backup and a way to download pro-
grams written off line from the PLC prOcess system.

For large operations, a master computer is often used to coordinate many individual,
interconnected PLCs. In such systenms, the intereonnecting elecuical buses are sometimes
referred to as data highways (nore on this topie in chapters 24 and 27).
 CONTROLLERS

P R O G R A M M A B L E
LOGIC
LOOK AT
12 ANOVERALL
CPUs AND PROGRAMMER/MONITORS

CPU iS shown
in figure |_5 TL
1-6 system. A
typical
size of the
CPU
heart ofthe depending on the
PLC
The CPU is the than the
one
shown,

be snaller o r larper
CPU according to the internal
o u u s e nmay to size he
system
controlled. n is important requires only a small
PIC unit
to ne small operation
Controlling a
would require a larger unit
with
needed o r n the process. more
controlling a larger system
with limited memory:
memory and functions. added at a later date; others cannos
annot
casily
Some CPlUs can
have additional memory m a n u t a c t u r e r is required to match
with the
Advanced planning
be added to or expanded. purchased.
needs with the size
of the system being
presen and future for connecting the cables that Do to
contains various electrical receptacles
The CPU
receptacles with the correct cables
PLC units. It is important to connect the proper
the other
manufacturer.
supplied by the process control ladder
CPUs contain backup batteries that keep the user
Many failure. Typical retentive backup time is
event of a plant power
program in storage in the
is stored permanently in the CPU. in read-
I month to I year. The basic operating system
is lost. However, the user process
only memory (ROM). and is not lost when input power
control ladder program, being in random access memory (RAM), is not stored perma-
user program in the event of
nently. Battery backuppower enables the CPU to retain the
power loss. Only the user program can be lost or erased when PLC CPU power is lost.
Secondary, permanent, storage is discussed in later chapters.)
The CPUs all have operational switches, some of which require a key to prevent
unauthorized personnel from running a turned-off process. The key-type switch also can
prevent unauthorized alterations to the operating system program. The switch positions
vary from manufacturer to manufacturer, but are similar. Typical positions are
Of System cannot be run or
progranmmed.
Run. Allows the system
to run, but no program alterations can be made.
FIGURE 1-5
A Central Processing Unit (CPU)
(Courtesy of Cutler-Hammer)
 CPUs AND PROGRAMMER/MONITORS
13

Disable. Turns all outputs off or sets them to the

Monitor.Turns on sereen that displays operating inoperable state.
information.
Run/Program. System can run, and program modifications can be
it is running. This mode must made to it while
be used with caution. In
this mode, the
not be
completely erased (for safety) but can only be modified. program can-
To delete an entire
program, the key must be in the disable position.
oOft/Program or
Program. System cannot run, but be
reprogrammed.
can
programmed or

Some manufacturers programmers may have other special key

these. positions in addition to

Figure 1-6 shows a

typical large programmer/monitor with a large
Figure 1-7 shows
screen. cathode-ray tube
windows. The difference in
a
typical, small, hand-held programmer with small display
display size is directly related to cost. The units in figure 1-6

BM
H

w.ATE
9701144A

ACHNE .

MMUYNIE

TANTEES

www.

counEMENTTAT

CAPTAGE PERSO

FIGURE 16
Large-Screen Programmer Monitor (Courtesy of Modicon/Schneider Aut nation)
 FIGURE 1-7
A Hand-Held Proprammer Monitor
Courtesy of Modicon/Schneider oioon F1x 117
Automatiom)

ADJUST

10%OD MD 5D
% Ko MENW
%TAM%KW 1%MW %SW
QWMN ERRMOD

MCNAH

cost
considerably
shows an entire mnore, but give
more
circuit at a lume. circuit. The smaller information
bee all of With the hand-held on the sereen.
just one ladder smaller unit, sereen A large monitor een
The rung. you may display
has been proganmer/nonitor have to
go
shows only one part > the
be programmed,
disconnected the PM
M is
(PM) is
connected
through two or three steps o to
operational
operational CPl and
removeded.
no
longer to the
CPU
sioP
even be used
even CPUs. The PM
may Thereiore,
Therefore, required
you
for CPU by a
cable. After uhe CPU
are
in the
offhce be
moved may and
discussed in detail in lab lo
or
about in theneed only
ly oneprocess operationa
opeperation and can
pretest
subsequent programs. PMplant as PM for aa numberr of
chapters. needed. he same PM«can nu
eyboard and The same
keyboard screen op
screen
operations
 PLC INPUT AND OUTPUT MODULES 15

PLC INPUT AND OUTPUT MODULES

1-7
We get nformatm n and out ofthe PlC through the useofinput and output modules. The
inut madule tcrminals receive signals from wires connected to input sensors and trans-
duers. 1he output module terminals provide output voltages to energize actuators and
ndcating devices
1here are typically, 4, 8, 12, or 16 terminals per module. There
may be an equal
number of input and output terminals for a PLC's I/O modules. More often, however, there
are a ditierent number of terminals for
input and output; for exarnple, a system module may
have 1 inputs and 8 outputs. A typical module is shown in figure 1-8.
In smaller systems, the input and output terminals may be included on the same
trame as the CPU. Figure 1-9 shows one such unit. In other,
larger PLC systems, the input
and output modules are separate units. In these
larger systems, modules are placed in
groups on racks, as shown in figure 1-10. The racks are connected to the CPU via
appro-
priate connector multiconductor cables.
Typically, up to 256 terminals may be controlled using only 9 to 24 interconnecting
wires. The number of wires is determined by the type of
exact
computer configuration used
for terminal-to-CPU information
interchange. The electrical controlling signals from the

FIGURE 1-s
VO Modules (Courtesy of Modico/Schneider Aulomativm)
 PROGRAMMABIELOGIC CONTROLL:RS
16 AN OVERALL LOOK AT

FIGURE 1-9
with CPU
IO Teminals Combined
(Courtesy of Menlicon/Schneiler
Automatio)

FIGURE 1-10
Larger System /O Modules
(Courtesy
of Modicon/Schneider Automation)
PLC INPUT AND OUTPUT MODULES
7
CPU to the 1/0 terminals are coded and decoded electronically,
making 256 wires for 256
terminals unnecessary.
For multiple modules in a rack, it is necessary to set module
switches for each indi-
vidual module. These settings specity each module's operational number
series. Again, for
256 inputs and 256 outputs on a rack, there are 9 to 24 wires in
CPU. Each rack group knows what numbers it should
thecable connected to the
respond to by the system of single
in-line package (SIP) switch settings.
Some PLC systems use
programming instead of switches to
settings. Some small systems require no address settings on the I/O configure
1/O module
modules. The order in
which you plug the modules in determines the address
number for these small
Other. larger systems set the address numbers systems.
by following a programming procedure on
the PM.
Various parts of a PLC system require different
operation. These rates are called baud rates. A baud is a unit ofoperational
computer rates for proper

to the number of times the state signaling speed and refers

(or condition) of a data communication line
second. At lower speeds, the baud rate and the changes per
bits-per-second rate are identical. At
speeds, the baud rate is some fraction of the bits-per-second rate. higher
baud" is being replaced by "bits Nonetheless, the term
per second"-since the latter is independent of the
method and truly represents the coding
information rate.
A PLC CPU computer
may "converse" with its keyboard at a rate of 4800 baud. For
remote operation, it might use 2400 baud. Two peripheral devices might use rates of 600 and
1200 baud. The baud rates vary for each
manufacturer and its individual PLC device. Each
device's baud rate is set
to be reset for certain
automatically when the PLC is turned on. The baud rates
may have
modes of PLC operation. If, for
example, you attempt to print a ladder
diagram and get an unreadable result, it may be that the baud rate is set
and follow the manufacturer's manual incorrectly. Refer to
program section on setting peripheral baud rates.
A most
important consideration for an 1/O module is the module's voltage and curent
rating. Both voltage and current must match the electrical requirements of the system to
which the module is connected. An
input module rated at 24 volts DC will not work on 120
volts AC and may even be
damaged if the module fuse does not act quickly. An output device
requiring 4.5 amperes cannot be turned on by a 2-ampere output module; the module fuse
WOuld blow. PLC manufacturers
have a wide variety of input and output modules available.
MOdule ratings are chosen by the manufacturers to cover the most common applications ot
neir customers. Typical ratings available from manufacturers are shown in tigure 1-11.

Sometimes the processes to be controlled by a PLC are a long distance from the CPU
Or rom each other. The normal input and output electrical signals will be reduced to a value
too low for module
recognition due to long interconnecting wires. Remote ampl
are available for cases such as these. A typical remote setup is shown in figure 1-12. i
input and output signals from the CPU are coded by an adjacent coding unit into digl
fiber optics system, to
encal pulses. The pulses are transmitted over two wires, or by a
TCmote location. At the remote location, a matching station decodes the digital signaus.
ne digital pulses are decoded back into the separate signals that feed the remotc
ne signals originally leaving the CPU are, therefore, exactly duplicated a
Other commu
module a mile away will operate as if it were 10 feet away.
a
auon systems include telemetering and radio continuous-wave communicau
 CATALOG
NUMBER CIRCUIT
IC600BF QUANTITY UNIT OF
MODULE 1O LOAD
vOLTAGE LEVEL
804 8
115 VAC DC
Input 904 8
Output
15 VAC ? amp 810
115VAC Isolated
Input 910
3amp solated
Output 4
5 VAC Output
930
E AC amp Protected 805 8
220 VA h Input
905 8
Output
220VA amp 812
220VAC Dsolatec Input
912 6
220 VAC3 amp lsolated Output
806 8
Input
Output 906 8
1VDT Sink
VOC Souroe Output 907 8
244 VAC OC Input 802 3
NVDC Sink Output 902
VDC Source Output 908
4E VDC Sink Output 903
4 VD Source Output 909
120 VDC 1 amp Output 924 8
SVTT10-50 VDC
Input 811 32
Twio ights Output 911
10-5 VDC Sinn 32
w'Oghts Output
10-50 VDC Source 913 32 3
wO4hts
A 10-60 VDC Output 919 32 3
with agh
Input 831
witghts
10-50 VDC Sn Output 921
with ignts
- b VDC. Souroe Output 923
wit AgUS 32
100VA heeas (NONC Output 929
-10 VDC Anaiog Output 914 32
-10010 VDC Anàiog input
0ma VDCAhlaiug 841
Input
- VDC Analug input 842
1 10 VDL Aliaiog 843
Output 941
faencoupie ype Output 942
he@Dupie lyjat Output 943
nput
theinaucup iypt i put 813
teVLuple ye 814
tug tjp uiti iput 815
ulput 816
1La eelve 915 8
LOca uanitilei 827 42
19
Fieaieheupive &08
800 8
90 9
801 34
GRE 1-11 901 42
1cal Avaliatie 38
18
Maauic Kaling
urtesy ot Gi
Fanuc
 MODU1LES
PLC INPUT AND OUTPUT 19

-Up to 1 Mile-
PLC VO Module PLC VO Signal
Encoder Decoder

Input Output
Terminals Terminals
Two Control
Signal Wires

One Ground
Wire

Ribbon Cable To Input To Output

from PLC Devices Devices

FIGURE 1-12
Remote PLC Operation

type of module, the discrete,

or
early chapters of this text discuss the
most common
The either
module are either on or off and the outputs
are
digital. type. Inputs in the discrete type of of a different type of mod-
covers the basic principles
energized or deenergized. Chapter 22 values.
work with variable signals with varying
ule-the analog type. These analog modules control operation.
internal computer for faster process
Many newer modules have an must be acted upon
immediately tor
have a critical input that
For example, a process might and return-
the safety of process personnel. Sending
signals to the CPU, CPU analysis. and
can do the analysis
continuously and quickly.
The module
Signal time takes too long.
can take action immediately. modules. In relay
with PLC output
precaution to be considered controled
There is one major in the associated
there is no c u r r e n t tlow
when a relay contact is open, not strictly
oft. A small
leak
operauon, when turned oft, are
exists, e v e n thougn tte
modules,
However, PLC output
Circuit. module still
to the output troni tne
terminal comes
aE Current Irom the output of each module terminal
still puts
nodule is turned off.
The output c u r r e n t turned on,
the t r i a c
is
ouput When n
neo and
semiconductor called a triuc. tew
milliannperes

output of a thyristor c u r r e n t is a
maller of a
considered
n
sOme

of current.The leakage have to be

out a small amount
may
ndeates
ent bulb that
however, the leakage a
eon

often of no conse sequence;

lerminal mighi
supply to
the ieag
ott due
PLC ouput o d u l e is out
applications. For example, a
when the
theelectrcal
will glow dimly resistors
in
is on; the n e o n
shunting
C
Oulput to add an
anmplitier or

night be necessary
t bleed off this leakage
current.
to
put system
 LOGIC CONTROLLERS
20 LOOK AT PROGRAMMABLE
AN OVERALL

PRINTING PLC INFORMATION

1-8
record information
analysis. Lenost
from the CPU tor vISual
Printers are used to
typically, a screen sho
hy adder
shown on a screen;
programs cannot be completely
A printout on a con nuous paper roll
only one to
on the type of display. cann show
she
five rungs, depending
of length. In industrial settings, the comoleto
ladder diagrams and programs any
circuit. In educational settings, printouts m
diagra
can be used to analyze
the complete used
construction.
for correct program
for written assignments to check be printed out
of PLC information that can
There are many different types
include coil/contact cross-references)
Ladder diagrams (which may
o Status of registers
Status and of forced conditions
listing
Timing diagrams of contacts
Timing diagrams of registers
information
Other special diagrams or
printer and list the possible benefits o
In chapter 26 we describe in detail how to use the
the various printouts.

EXERCISES
into the PLC.
1. Discuss the evolution of relay logic and the computer evolution
2. List a dozen advantages of using a PLC. Use items
discussed in the text plus some of your
own
idk
ideas plus your own.
3. List a few disadvantages of using a PLC. Again, use the text
and digital logic, evaluate
4. Based on your own knowledge and skill level in the areas of relay
Do the same
level of difficulty you will have in learning PLC programming and operations.
two or three typical factory workers, electricians, or technicians.
oduies
s. Obtain the manuals from one ortwo different PLC models. List the various types0
available for each model.
operae

6. From the manuals in exercise 5, determine and list the baud rates at which the mo
including the peripheral baud rates and other relevant details.