PLC components

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PLC components

The PLC mainly consists of a CPU, memory areas, and appropriate circuits to receive input and output data. We can consider the PLC to be a box full of hundreds or thousands of separate relays, counters, timers and data storage locations. These counters, timers, etc. don't "physically" exist but instead are simulated and can be considered software counters, timers, etc. These internal relays are simulated through bit locations in Registers (more on that later).

Figure 10. The Contents of the Box

What Each Part Does

The Central Processing Unit (CPU) is the most important part of the PLC. It holds the processor that defines what the PLC can and cannot do. The Processor's functions are preset so that the PLC has certain fixed limits. These limits are usually the maximum number of inputs and/or outputs (I/O) available, but they can also include the maximum number of timers, counters, and registers, as well as type of functions the PLC can perform.

INPUT RELAYS are connected to the outside world. They physically exist and receive signals from switches, sensors, etc. Typically they are not relays, but are transistors.

INTERNAL UTILITY RELAYS do not receive signals from the outside world, nor do they physically exist. They are simulated relays and are what enables a PLC to eliminate external relays.

COUNTERS do not physically exist. They are simulated counters and they can be programmed to count pulses. What does the term "pulse" mean in this context? Well, one example of a pulse would be a bottle passing by a sensor. Typically these counters can count up, down, or both up and down. Because they are simulated they are limited in their counting speed. Some manufacturers also include high-speed hardware based counters.

TIMERS do not physically exist. They come in many varieties and increments. The most common type is an On-Delay Timer. Others include Off-Delay Timers, Retentive and Non-retentive. Increments vary from 1ms (millisecond) through 1s (second).

OUTPUT RELAYS are connected to the outside world. They physically exist and send on/off signals to Solenoids, lights, etc. They can be Transistors, relays, or Triacs, depending upon the model chosen.

DATA STORAGE. They are typically registers assigned simply store to data. They are usually used as temporary storage for math or data manipulation. They are also often used for retentive data storage.

An Outside View

Now that we have discussed the inner workings of the PLC, let's take a look at the outward appearance of the device. There are two basic forms that a PLC comes in: "block" and "rack mounted" I/O.

Block and Block I/O with Expanders

The block I/O is a design more common to PLCs that communicate with small amounts I/O. ("Small amount" refers to a quantity less than 60 I/O.) The input and output terminals are where the user would hard wire the devices to be controlled by the PLC. Each terminal has a unique "address." (We will discuss addressing in greater detail in the next section.)

The CPU is located inside of the block. The communication ports allow the PLC to be connected to a computer or hand held programmer. They may also be used to connect special modules or Expanders. Expander blocks do not contain a CPU. They merely "expand" the number of I/O controlled by the CPU. Based on the manufacturer, each expander could allow a different type of input or output to be used. For example, the base unit could control Digital I/O and the first expander may control analog outputs only.

Figure 11. Block I/O

Figure 12. Block I/O with Expanders

Rack Mounted I/O

Rack mounted I/O is composed of several printed circuit board I/O cards that are mounted on a "rack" or metal back plate. Generally, the "rack" is designed to hold 4, 6, 8, or more cards. Hundreds of inputs and output devices can be controlled with rack I/O. Like the block I/O, each terminal on each card has a specific PLC address. Unlike the block I/O, based on the end user's needs, each card can control different types of I/O. For example, a digital, an analog input, and a triac output can all be mounted on the same rack. It is also possible for many rack mounted PLC products to support additional racks of I/O modules located as much as hundreds or thousands of feet from the CPU. In this configuration, there is a "master" CPU attached to "remote" I/O. (A brief discussion of this set-up is covered in the last section of the module.)

 

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