PROGRAMMABLE CONTROLLERS

Jerzy Kasprzyk

Lecture: PLC Hardware

1. Introduction
In the respect of the PLC architecture, one can distinguish:
Compact controllers,
Modular controllers.
Table 1. The most popular PLC families
Manufacturer

Intelligent
relays

Small

Medium

Large

Siemens

Logo

SIMATIC S7200

SIMATIC S7-300

SIMATIC S7-400

Schneider
Electric

Zelio

Nano,
Micro,
Twido

Premium,
Compact,
Momentum

Quantum

GE Fanuc

VersaMaxNano

VersaMaxMicro

90-30,
VersaMax,
PACSystems
RX3i

90-70,
PACSystems
RX7i

Mitsubishi
Electric

ALPHA

MELSEC FX1,
FX2

MELSEC QnAS

MELSEC QnA,
MELSEC System
Q

CPM1, CPM2,
CQM1H

C200H-alpha,
CJ1, CS1

CVM1

MicroLogix

SLC500,
FlexLogix,
ControlLogix

PLC-5

Omron

Rockwell
Automation
(Allen-Bradley)

Pico

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

Fig. 2. Omrons controller CJ1

Fig. 3. Mitsubishis family Q controller

Elements of PLC hardware:

Baseplate (rack) with slots, expansion baseplates, remote baseplates, Remote
Input/Output Station (RIOS);
Power Supply (PS), Central Processing Unit (CPU);
basic I/O modules:

Digital Input (DI), Digital Output (DO), (called also discrete),

Analog Input (AI), Analog Output (AO),

other modules (also intelligent):

High-Speed Counter (HSC),

Axis Positioning Module (APM),

Communication modules,

Input modules for temperature sensors,

PID modules or fuzzy logic controllers,

Module for code bar readers, etc.

Hardware configuration:
number and type of baseplates, types of modules,
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.

User program as well as configuration can be protected by a software or hardware key.

2. Central Processing Unit (CPU)

Basic features:
Execution Speed, e.g. duration of a typical cycle (e.g. 1K of bit instructions), processing
times for different type instructions;
Supply Voltage, Power Consumption, Wiring and Cabling;
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);
Floating Point Operations;
Forcing Capabilities;
Number of Built-in Communication Ports, Protocols;
Operating Conditions (Environment, like e.g. Temperature, Humidity, Vibration,
Schock).
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

PLC must work in Real Time.
Classical solution: Program Sweep (fraction of ms up to few dozen of ms).

INITIALIZATION
INITIALIZATION

SCAN
THE INPUTS
?

NO

YES
READING
THE INPUTS

READ THE INPUTS

MODE "RUN"
?

NO

SCAN
TIME

YES
PROCESSING OF
PROGRAM
LOGIC

EXECUTE
A PROGRAM

UPDATE
THE OUTPUTS
?
YES
WRITE
THE OUTPUTS

COMMUNICATION

DIAGNOSTICS

NO

WRITING
THE OUTPUTS

COMMUNICATION
WITH PADT
AND SYSTEM
COMMUNICATION

DIAGNOSTICS

NEW CYCLE (SCAN)

Fig. 4. Typical PLC program cycle (program sweep, scan)

Two modes of functioning:

RUN typical mode, all phases are executed including application program;

STOP application program is not executed.

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).

In modern PLCs one can define three types of tasks:

cyclic (continuous);
periodic (timer event);
event controlled.
Table 2. Times of data exchange between CPU and modules of GE Fanuc series 90-30
Time [ms]
Modules

Baseplate

Extension

Remote

16 DI

0,030

0,055

0,206

16 DO

0,030

0,053

0,197

4 AI

0,075

0,105

0,396

2 AO

0,058

0,114

0,402

16 AI

0,978

1,446

3,999

8 AO

1,274

1,988

4,472

HSC

1,381

2,106

5,221

APM (1 axis)

1,527

2,581

6,388

Ethernet

0,038

0,041

0,053

without any connections

0,567

0,866

1,830

32 nodes with 64 I/O points each

1,714

2,514

5,783

without any connections

0,798

1,202

2,540

32 nodes with 64 I/O points each

18,38

25,377

70,777

GCM

GBC

3. Digital Input Module

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)

Digital Input Module Specifications:

Rated Voltage typically 24VDC or 120/240 VAC;
Number of Inputs, optionally Number of Groups;
Isolation (e.g. RMS of breakdown voltage);
Electrical Characteristics of state levels: ON (e.g. > 15V) and OFF (e.g. < 5 V);
ON Response, OFF Response Times;
Power Consumption, Internal Power Dissipation;
Operating Conditions Temperature, Humidity, Vibration.

4. Digital Output Modules

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:

Rated Voltage typically 24VDC or 120/240 VAC;
Number of Outputs, optionally Number of Groups;
Isolation (e.g. RMS of breakdown voltage);
Electrical Characteristics of ON and OFF levels;
ON Response Time, OFF Response Time;
Load Current/Output;
Max Load Current/Module;
Inrush Current;
Power Consumption, Internal Power Dissipation;
Operating Conditions Temperature, Humidity, Vibration.

a)

b)

.022mF 100

630V

1A, 100V

DO

c)

0.5 W

DO

d)

DO

DO

Fig. 8. Protecting DO modules from Inductive Back EMF

5. Analog Input Modules

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).

Typical nominal ranges for analog signals:

10 V, +10 V;

0 V, +10 V;

+1 V, +5 V;

4 mA, 20 mA;

0 mA, 20 mA.

Analog inputs can be:

differential (A/D converts the difference voltage between the inputs IN+ and IN );

single-ended (A/D converts the difference voltage between the input and COM).

Additional element
of the curcuit

A
250

D
%IW1

A
250

GND

24V

%IW2
ANALOG
INPUT

Analog Current Input Module

Fig. 9. Wiring diagram for a single-ended AI current module and 2-wire sensors

Additional element
of the curcuit

4-wire
sensor

250

D
%IW1

4-wire
sensor

250

D
%IW2

GND
ANALOG
INPUT

24V

Analog Current Input Module

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

Analog Voltage Input Module

Fig. 11. Wiring diagram for an AI voltage module

Main (metrological) specifications for AI modules:

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 A/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;
It is defined as the difference between the measured changes corresponding exactly to 1
LSB for two neighboring channels, e.g. less than 1 LSB within the range 4 to 20 mA.

Common Mode Rejection Ratio (CMRR), e.g. 80 dB;

Cross-Channel Rejection Ratio (CCRR), e.g. 80 dB;
Update Rate, e.g. 4ms.
Other specifications:
Number Of Channels;
Input Current Ranges or Input Voltage Ranges;
User Supply Voltage;
Absolute Maximum Input Voltage;
Calibration;
Absolute Accuracy;
Update Rate;
Isolation;
Input Impedance, Inductance, Capacitance;
External Supply Voltage Range and External Supply Voltage Ripple;
Power Consumption, Internal Power Dissipation;
Operating Conditions Temperature, Humidity, Vibration, etc.

6. Analog Output Modules

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).

Typical nominal ranges for analog signals:

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

Fig. 12. Wiring diagram for an AO current module

Basic features of AO modules:

Number of Channels;
Output Current Ranges or Output Voltage Ranges;
User Supply Voltage;
Absolute Maximum Input Voltage;
Resolution;
Absolute Accuracy;
Update Rate;
Isolation;
Load Impedance, Inductance, Capacitance;
External Supply Voltage Range and External Supply Voltage Ripple;
Power Consumption, Internal Power Dissipation;
Operating Conditions Temperature, Humidity, Vibration, etc.

7. Systems with redundancy

7.1. Hot Standby

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.

Primary PLC

Secondary PLC

PS CPU RIO CHS

PS CPU RIO CHS

Fiber optic link

Connector to RIOS

Fig. 13. Hot standby solution

The following three items are important.

1.

The two systems must be identical.

2.

The order of the modules in each rack must be the same.

3.

The software revisions must be the same.

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 standalone and continues to manage the I/O networks.

Other solutions: Hot Backup, Warm Standby.

7.2. Triple Modular Redundancy (TMR)

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.

Fig. 14. GMR system (Load in H connection)