PLC Hardware Components
The input/output (I/O) section of a PLC is the section to which all field devices are
connected and provides the interface between them and the CPU. Input/output
arrangements are built into a fixed PLC while modular types use external I/O modules
that plug into the PLC.
Figure 2-1 illustrates a rack-based I/O section made up of individual I/O modules. Input
interface modules accept signals from the machine or process devices and convert
them into signals that can be used by the controller. Output interface modules convert
controller signals into external signals used to control the machine or process. A typical
PLC has room for several I/O modules, allowing it to be customized for a particular
application by selecting the appropriate modules. Each slot in the rack is capable of
accommodating any type of I/O module.
Discrete I/O Modules
The most common type of I/O interface module
is the discrete type (Figure 2-11). This type of
interface connects field input devices of the
ON/OFF nature such as selector switches,
pushbuttons, and limit switches. Likewise,
output control is limited to devices such as
lights, relays, solenoids, and motor starters that
require simple ON/OFF switching. The
classification of discrete I/O covers bit- oriented
inputs and outputs. In this type of input or
output, each bit represents a complete
information element in itself and provides the
status of some external contact or advises of
the presence or absence of power in a process
circuit.
Basics of PLC Programming
Program Scan
When a PLC executes a
program, it must know—in
real time—when external
devices controlling a
process are changing.
During each operating
cycle, the processor reads
all the inputs, takes these
values, and energizes or
de- energizes the outputs
according to the user
program. This process is
known as a program scan
cycle.
Figure 5-11 illustrates the scan process applied to a simple single rung program. The
operation of the scan process can be summarized as follows:
• If the input device connected to address I:3/6 is closed, the input module circuitry
senses voltage at the input terminal and a 1 (ON) condition is entered into the input
image table bit I:3/6.
• During the program scan, the processor examines bit I:3/6 for a 1 (ON) condition.
• In this case, because input I:3/6 is 1, the rung is said to be TRUE or have logic
continuity.
• The processor then sets the output image table bit O:4/7 to 1.
• The processor turns on output O:4/7 during the next I/O scan, and the output
device (light) wired to this terminal becomes energized.
• This process is repeated as long as the processor is in the RUN mode.
• If the input device opens, electrical continuity is lost, and a 0 would be placed in the
input image table. As a result, the rung is said to be FALSE due to loss of logic
continuity.
• The processor would then set the output image table bit O:4/7 to 0, causing the
output device to turn off.
There are two basic scan patterns that different PLC manufacturers use to accomplish
the scan function(Figure 5-13). Allen-Bradley PLCs use the horizontal scan by rung
method. In this system, the processor examines input and output instructions from the
first command, top left in the program, horizontally, rung by rung. Modicon PLCs use
the vertical scan by column method. In this system, the processor examines input and
output instructions from the top left command entered in the ladder diagram, vertically,
column by column and page by page. Pages are executed in sequence. Both methods
are appropriate; however, misunderstanding the way the PLC scans a program can
cause programming bugs.
PLC Programming Languages
Ladder diagram language is the most commonly used PLC
language and is designed to mimic relay logic. The ladder
diagram is popular for those who prefer to define control
actions in terms of relay contacts and coils, and other
functions as block instructions.
Bit-Level Logic Instructions
The ladder diagram language is basically a symbolic set of instructions used to create
the controller program. Bit- level symbolic instructions fall into two separate categories:
instructions that examine data and instructions that control data. Each symbolic
instruction is a command to perform a specific operation. These ladder instruction
symbols are arranged to obtain the desired control logic that is to be entered into the
memory of the PLC.
Representations of contacts and coils are the basic symbols of the logic ladder diagram
instruction set. The three fundamental symbols that are used to translate relay control
logic to contact symbolic logic are Examine If Closed (XIC), Examine If Open (XIO), and
Output Energize (OTE). Each of these instructions relates to a single bit of PLC memory
that is specified by the instruction’s address. While the XIO and XIC are represented by
symbols that resemble a normally-open and normally-closed relay contact, they do not
operate like relay contacts. Instead, they operate as commands that examine the value
(0 or 1) of a bit of data to determine its true or false logical condition.
Feature Normally Open (Relay Logic) Examine If Closed (PLC Ladder Logic)
Nature Physical relay contact in a Instruction in PLC programming
circuit
Behavior Allows current flow when coil is Passes logic flow if the
energized condition/tag is TRUE
Implementati Requires physical wiring Implemented as software logic in
on
the PLC
Practical Takeaway:
● Relay (NO): A physical contact that works with mechanical
switches and electromechanical relays.
● PLC (XIC): A software representation of a NO contact, checking
if the condition is true (logic ON).
