ELE-601 Industrial Electronics

Lecture 2 – PLCs and their architecture

Dr. Arslan Dawood Butt

CLO 1 - Section 1
 Programmable Logic Controller(PLC)

PLC is a digital computer designed for multiple inputs

and output arrangements, extended temperature
ranges, immunity to electrical noise, and resistance to
vibration and impact. A PLC is an example of a real
time system.
Advantages of PLC

• Reliability.
• Flexibility in programming and reprogramming.
• Cost effective for controlling complex systems.
• Small physical size, shorter project time.
• High speed of operation.
• Ability to communicate with computer systems in
the plant.
• Ease of maintenance /troubleshooting.
• Reduced space.
• Energy saving.
 Geometric base types of PLC

❖ Rack: A rack is often large (up to 18” by 30” by 10”) and

can hold multiple cards. When necessary, multiple racks can
be connected together.

❖ Mini: these are similar in function to PLC racks, but

about half the size.

❖ Micro: these units can be as small as a deck of cards.

They tend to have fixed quantities of I/O and abilities, but
cost will be the lowest.
SIMATIC Controller (PLC)

S7-300 Rack type

S7-200

S7-1200 S7-400
Micro PLC s7-200
 Processor used in S7-200

• CPU 221
• CPU 222
• CPU 224
• CPU 224xp
• CPU 226
 Features of CPU used S7-200
Technical Data CPU 221 CPU 222 CPU 224 CPU 224xp CPU 226
Digital input 6 8 14 14 24
Digital output 4 6 10 10 16
Analog input No No No 2 No
Analog output No No No 1 No
Program Memory 4 KB 4 KB 8/12KB 12/16KB 16/24KB
Data Memory 2 KB 2 KB 8 KB 10 KB 10 KB
High speed Counter 4 4 6 6 6
Timer 256 256 256 256 256
RS-485 1 1 1 2 2
Expansion module 0 2 7 7 7
 224XP Built-in Features
Internal:
- Power Supply
I/O Point - Super Capacitor
Overview - Clock (for 224,224XP,226)
Status LEDs

CPU Status Mounting

LEDs Holes for
Panel
Installation
Removable
Analogue
Terminals
Removable
Terminal Blocks
Cartridge Slot (224,226)

Snap-On Clip
Communication 24V Sensor for DIN Rail
Ports Power Output Mounting
 Expansion I/O Modules

• Up to 2 Modules (EM) for 222 CPUs

….up to 7 EMs for 224/226 CPUs

• Removable Terminals on digital I/O Modules

• Module Connection via I/O Expansion Ribbon Cable
CPU-Basic Device + Expansion Module
S7 200 PLC Wiring Diagram
SIMATIC S7-300 within the system family
High-end range/
Medium range
S7-400

Mid- and low-end The universal PLC for

Performance range system solutions with
S7-300 production
engineering as focal
point
Micro PLCs
S7-200

+ Programming devices
+ STEP 7 software
+ Communication
+ Human Machine Interface
Integrated Automation
S7-300 – The best-selling controller from
Totally Integrated Automation
S7-300 – The automation platform for production
engineering
Modular PLC S7-300 Module
S7 – 300 CPU
Mode Selector
MRES = Memory reset function
STOP = Stop mode, program not executed
RUN = Program execution
RUNP = Program execution, read/write access
Status Indicator
SF = Group error, internal CPU or fault in module
BATF = Battery fault
DC5V = Internal 5 VDC voltage indicator
FRCE = FORCE
RUN = Flashes when the CPU is starting up,
then steady light in Run mode
STOP = Show steady light in Stop mode
SF DP = Physical bus fault
BUSF = No configuration or incorrect
configuration
 Processor used in S7-300

• CPU 312
• CPU 314
• CPU 315-2DP
• CPU 317-2DP
• CPU 318
 Features of CPU used S7-300
Technical Data CPU 312 CPU 314 CPU 315- CPU 317- CPU 318
2DP 2DP
Digital input 256 1024 1024 1024 1024
Digital output 256 1024 1024 1024 1024
Analog input 64 256 256 256 256
Analog output 64 256 256 256 256
Program Memory 16KB 48KB 128KB 512KB 512KB
Data Memory 5 KB 16 KB 42 KB 170 KB 170 KB
High speed Counter 128 256 256 512 512
Timer 128 256 256 512 512
Ethernet 1 1 1 1 1
Expansion module 6 12 16 32 32
Micro PLC s7-1200
 Processor used in S7-1200

• CPU 1211
• CPU 1212
• CPU 1214
• CPU 1215
• CPU 1217
 Features of CPU used S7-1200

Technical Data CPU 1211C CPU 1212C CPU 1214C CPU1215C CPU 1217C

Digital input 6 8 14 14 14
Digital output 4 6 10 10 10
Analog input 2 2 2 2 2
Analog output No No No 2 2
Program Memory 25 KB 25 KB 50KB 125KB 150KB
Data Memory 2 KB 2 KB 2 KB 2KB 2KB
High speed Counter 3 4 6 6 6
Timer 4 4 4 4 4
Ethernet 1 1 1 1 1
Expansion module 4 6 12 12 12
 Basic PLC Components

• CPU
• Power Supply
• Memory
• Input Blocks
• Output Blocks
• Communications
• Expansion
Connections
 Most important PLC producers

• Siemens - Germany
• AB (Allen Bradley) – US
• Schneider Electric (Modicon) – France
• Mitsubishi – Japan
• ABB - Germany
• SAIA – Switzerland
• GE Fanuc - US
• B&R (Bernecker + Reiner) – Austria
• Teco – Czech Republic
Global Players in PLC

Source: ARC Research, 2005-10

PLC Communication with PC
 General PLC architecture
RS 232 Ethernet

Real-Time RAM/flash serial port ethernet

CPU ROM
Clock EPROM controller controller
extension
bus
Parallel bus buffers

fieldbus analog- digital- external

Digital
controller digital analog Digital Output I/Os
Input
converters converters

signal power signal

relays
conditioning amplifiers conditioning

field bus direct Inputs and Outputs

General PLC Architecture
 Inputs and Outputs Devices
Inputs Outputs
• Push Buttons • Motors
• Proximity switches • Solenoids
• Photoelectric sensors • Indicator lamps
• Temperature sensors • Resistive loads
• Pressure sensors • Contactors

Push button Photo Sensor Pressure Motor

Sensor
Overview: Supporting Technologies

Sensors, Switches
PLC Software
Light Curtains / Safety Devices

Digital / Analog I-O Blocks Encoders, Actuators, Contacts

Network
PLC Hardware
 Input/output Circuits

Pilot Duty Outputs

• Outputs of this type typically are used to drive high-
current electromagnetic loads such as solenoids,
relays, valves, and motor starters.
• These loads are highly inductive and exhibit a large
inrush current.
• Pilot duty outputs should be capable of
withstanding an inrush current of 10 times the
rated load for a short period of time without
failure.
 Input/output Circuits

General - Purpose Outputs

• These are usually low- voltage and low-current and
are used to drive indicating lights and other non-
inductive loads. Noise suppression may or may not
be included on this types of modules.

Discrete Inputs
• Circuits of this type are used to sense the status of
limit switches, push buttons, and other discrete
sensors. Noise suppression is of great importance
in preventing false indication of inputs turning on
or off because of noise.
 Input/output Circuits

Analog I/O
Circuits of this type sense or drive analog signals.

• Analog inputs come from devices, such as

thermocouples, strain gauges, or pressure sensors,
that provide a signal voltage or current that is derived
from the process variable.
Standard Analog Input signals: 4-20mA; 0-10V
• Analog outputs can be used to drive devices such as
voltmeters, X-Y recorders, servomotor drives, and
valves through the use of transducers.
Standard Analog Output signals: 4-20mA; 0-5V; 0-10V
 Analogue Cards

• Typical Analogue Input • Analogue Output signals

signals are: control:
• Analogue Valves
• Flow sensors • Actuators
• Humidity sensors • Chart Recorders
• Potentiometers • Variable Speed Drives
• Analogue Meters
• Pressure sensors
• Temperature sensors
• Typical Analogue Signal
• Vibration Levels
• 4-20mA
• 1-5 Vdc
• 0-10 Vdc
• -10 – 10Vdc
 Input/output Circuits

Special - Purpose I/O

• Circuits of this type are used to interface PLCs to
very specific types of circuits such as
servomotors, stepping motors PID (proportional
plus integral plus derivative) loops, high-speed
pulse counting, resolver and decoder inputs,
multiplexed displays, and keyboards.
• This module allows for limited access to timer
and counter presets and other PLC variables
without requiring a program loader.
 OUTPUTS

INPUTS MOTOR

CONTACTOR
LAMP

PUSHBUTTONS
PLC

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Example of Output Card
PLC wiring
 PLC Wiring

• PLC I/O ports:

• Typically rated for low amperage.
• Ordinarily connected to I/O devices through American
Wire Gauge size fourteen (AWG 14).
• AWG 14 wire has more than sufficient ampere
rating for carrying current for the PLC I/O ports.
PLC Wiring

• In most applications, the output devices require

larger voltage and current ratings.
• A magnetic relay should be used to connect larger
voltage and current equipment to the output
device.
• PLC output port provides voltage and current to
the input coil of the magnetic relay.
 PLC Communications

Serial Communications

PLC communications facilities normally provides serial

transmission of information.

Common Standards
RS 232
• Used in short-distance computer communications, with
the majority of computer hardware and peripherals.
• Has a maximum effective distance of approx. 30 m at
9600 baud. The data rate of RS 232 is 20kbits/sec.

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PLC Communications

RS 422 / RS 485

• Used for longer-distance links, often between several PCs

in a distributed system. RS 485 can have a maximum
distance of about 1000 meters. The data rate of RS 485 is
10Mbits/sec.

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PLC Communications

Programmable Controllers and Networks

Dedicated Network System of Different Manufacturers

Manufacturer Network
Allen-Bradley Data Highway
Gould Modicon Modbus

General Electric GE Net Factory LAN

Mitsubishi Melsec-NET
Siemens SINEC
Texas Instruments TIWAY

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Examples of PLC Programming Software:

1. Allen-Bradley – Rockwell Software RSLogix500

2. Modicon - Modsoft
3. Omron - Syswin
4. GE-Fanuc Series 6 – LogicMaster6
5. Square D- PowerLogic
6. Siemens – Simatic
6. Telemecanique – Modicon TSX Micro
 Overview: Cost per license

Software Manufacturer Cost (Low) Cost (High)

TwinCat3 Beckhoff $0.00 $700
Rslogix 500 Allen-Bradley $500.00 $2,800.00
GX Developer Mitsubishi $600.00
Simatic Step 7 Siemens $750.00 $5,500.00
Rslogix 5000 Allen-Bradley $800.00 $7,000.00
CX-Programmer Omron $2,500.00 $4,000.00
Unity Modicon $5,000.00

*The five basic PLC programming languages outlined in Standard IEC 61131 are available
in any of the above mention software packages. Namely: IL, ST, FBD, LD, SFC.
 Q&A

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