গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়

Gopalganj Science and Technology University

ইললবিক্যোল অ্যোন্ড ইললিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোলদশ Gopalganj-8100, Bangladesh
Q: State two ways in which I/O is incorporated into the PLC
The two ways in which I/O (Input/Output) is incorporated into a PLC are analog and digital. The analog
inputs and outputs are used for reading analog signals. These signals are continuous and can vary smoothly
across a range. The digital inputs and outputs are used for reading discrete signals. Working with binary
numbers is essential in the context of digital data as PLCs operate on binary logic.
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All systems are continuous but they can be treated as logical for simplicity.

Q: Differences between digital and analog signals.

The signals that have only two states (ON or OFF, high or low, 1 or 0 where 24V DC represents 1 and 0V
DC represents 0) or binary states are called digital signals. Digital signals are often referred to as discrete
signals. Digital signals provide the status of any device, whether it is ON or OFF, and also information
about presence and absence. The PLC interprets the ON state as logic 1 or TRUE and the OFF state as logic
0 or FALSE.

Fig. 1(a): Digital signal.

A signal that can take any value within a specified range and vary continuously within this specified range
is called an analog signal. Analog signals have an infinite number of states. Depending on the field
conditions, the analog signal can vary between 4-20mA or 0-10Vdc. Analog signals measure and convert
physical quantities such as temperature, pressure, and flow rate into proportional voltage or current. For
Example, if you are monitoring the pressure of water flowing through a pipe using a pressure transmitter
of range 0-10 Bar, the transmitter will give a signal between 0 and 10V proportional to the pressure in the
pipe.

Dr. Md. Rabiul Islam, Associate Professor, EEE ∥ [email protected] ∥ PLC Discrete IO
 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইললবিক্যোল অ্যোন্ড ইললিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোলদশ Gopalganj-8100, Bangladesh

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Fig. 1(b): Analog signal.

Analog inputs are used when the PLC needs to monitor and respond to changes in a continuous process
variable. Analog signals are suitable for continuous monitoring or regulation. Analog signals provide more
precision and can represent a broader range of values.

Q: I/O devices
There have four types of I/O devices
• Digital input (DI) device
• Analog input (AI) device
• Digital output (DO) device
• Analog output (AO) device
Digital input device:
The field devices that have only two conditions or states, such as ‘ON’ and ‘OFF’, and are used for
collecting data are called digital input devices. For example, switches used to connect a fan to the main
power supply line have only two states either ‘ON’ or ‘OFF’. No other states in between ‘ON’ or ‘OFF’ are
possible. So these switches are digital input devices. Examples of digital input devices are,
• switches,
• push buttons,
• limit switches,
• proximity sensors, or
• Other sensors that provide a simple ON/OFF signal.
Digital input devices generate binary signals.

Analog input device:

The field devices that have any possible conditions or states within a specified range and are used for
collecting data are called analog input devices. For example, switches (regulators) connect to a fan to control
speed and may have any value within a specified range. A regulator does not have only two states such as
‘ON’ and ‘OFF’. So, the speed regulators are analog input devices. Examples of digital input devices are,
• rheostat
• temperature sensors
• thermocouple,
• microphone,
• photo sensitive resistor,
• force sensitive resistors,

Dr. Md. Rabiul Islam, Associate Professor, EEE ∥ [email protected] ∥ PLC Discrete IO
 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইললবিক্যোল অ্যোন্ড ইললিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোলদশ Gopalganj-8100, Bangladesh
• distance sensor,
• liquid level sensor,
• other sensors that provide a continuous signal.
Analog inputs devices generate analog signals.
Digital output device:
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The field devices that we want to control and have only two conditions or states ‘ON’ and ‘OFF’ are called
digital output devices. For example, an electromagnetic relay has only two states either ‘ON’ or ‘OFF’. No
other states in between ‘ON’ or ‘OFF’ is possible. When we want to control a motor (fan) is either connected
or not to the main supply then it is digital output device. Example of digital output devices are,
• Electromagnetic relays
• Solenoid valve
• Magnet contractor
• Motor starter
Digital outputs devices or actuators require digital signals.
Analog output device:
The field devices that we want to control and has many positions or state rather than only two conditions
‘ON’ or ‘OFF’ are called analog output devices. When we want to control the speed of motor (fan) then it
is an analog output device. The speed control of motor can be achieved by analog output device VFD. If
we are measuring the pressure using analog input and we would like to display it on an analog meter you
can use an analog output of PLC.
Example of digital output devices are,
• Proportional valve
• VFD
Analog outputs devices or actuators require analog control signals.

Q: What are the input and output modules?

The interface between the input field devices and the CPU of PLC is called the input module. Input modules
perform four tasks in the PLC control system,
• sense when a signal is received from a sensor on the machine
• convert the input signal to the correct voltage level for the particular PLC
• isolate the PLC from fluctuations in the input signal's voltage or current
• send a signal to the processor indicating which sensor originated the signal

The interface between the CPU of PLC and output actuator devices is called the output module. Output
modules perform four tasks in the PLC control system,
• receive a signal from the processor
• convert the received signal to the correct voltage level for the output devices
• isolate the PLC from fluctuations in the input signal's voltage or current
• activate the output devices.

Dr. Md. Rabiul Islam, Associate Professor, EEE ∥ [email protected] ∥ PLC Discrete IO
 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইললবিক্যোল অ্যোন্ড ইললিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোলদশ Gopalganj-8100, Bangladesh
Q: IO module
The input/output (I/O) section or IO module of a PLC is the section or unit to which all field devices are
connected and provides the interface between them and the CPU.

Q: What is the function of a PLC input interface module?

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Input interface modules accept signals from the machine or process devices and convert them into signals
that can be used by the controller. The input interface allows status information regarding processes to be
communicated to the CPU.

Q: What is the function of a PLC output interface module?

Output interface modules convert controller signals into external signals used to control the machine or
process. The output modules allow the CPU to communicate operating signals to the process devices under
its control.

Q: Types of signal modules.

The input module and output module are together known as the signal module.
There are four types of signal modules.
• Digital input (DI) module
• Digital output (DO) module
• Analog input (AI) module
• Analog output (AO) module
Digital input module:
The modules used to connect digital input devices are called digital input modules.
• Analog input interface modules contain the circuitry necessary to accept analog
voltage or current signals from analog field devices.
• After processing the digital signals are sent to the processor of the PLC.
The PLC can interpret and use these digital values for calculations, control algorithms, or comparison with
set points.

Analog input module:

The modules used to connect analog input devices are called analog input modules.
• Analog input interface modules contain the circuitry necessary to accept analog
voltage or current signals from analog field devices.
• The analog input is converted into a multi-bit binary word by an analog-to-digital converter (ADC)
circuit.
• The converted value is expressed as a 12-bit binary or as a 3-digit binary-coded decimal (BCD) for
use by the processor.
The PLC can interpret and use these digital values for calculations, control algorithms, or comparison with
set points.

Digital output module:

Dr. Md. Rabiul Islam, Associate Professor, EEE ∥ [email protected] ∥ PLC Discrete IO
 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইললবিক্যোল অ্যোন্ড ইললিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোলদশ Gopalganj-8100, Bangladesh
The modules used to connect digital output devices are called digital output modules.
• Digital output modules are typically used to send electrical power to loads to turn real-world output
devices either on or off.
• These modules can be used to control any two-state devices.
They are often used to energize or de-energize devices such as solenoid valves, relays, motors, indicator
Page | 5
lights, or any other devices that require discrete control. When the PLC output is ON, the digital output
delivers a voltage or current to the device, activating it. When the output is OFF, the voltage or current is
disconnected, deactivating the device.

Analog output module:

The modules used to connect analog output devices are called analog output modules.
The devices that have any positions or states within a specific range are called analog output devices. For
example:
• variable frequency drives (VFDs),
• proportional valves,
• motor speed controllers, or
• any other device that requires precise analog control.
Analog outputs receive digital values from the PLC, typically in the form of a binary number, and convert
them into analog signals, such as voltage or current using digital-to-analog converters (DACs), to generate
continuous and variable control signals that can be used to regulate or control analog devices or processes.

Q: How to choose I/O modules

When working with a PLC, the choice between digital and analog inputs/outputs depends on the specific
requirements of the control system and the type of devices being monitored or controlled. Digital signals
are suitable for discrete devices, while analog signals are necessary for systems that require continuous
control or monitoring of variables.

Q: Sourcing and sinking

When something supplies current then it is called operating in sourcing mode.
When something receives current then it is called operating in sinking mode.
The concept of sourcing and sinking is illustrated with an example in Fig. 2.

Dr. Md. Rabiul Islam, Associate Professor, EEE ∥ [email protected] ∥ PLC Discrete IO
 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইললবিক্যোল অ্যোন্ড ইললিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোলদশ Gopalganj-8100, Bangladesh

Page | 6

(a): The load is in sourcing mode and the output (a): The output module is in sourcing mode, and
module is in sinking mode the load is in sinking mode
Fig. 2: Illustration of sourcing and sinking concept.
For both of these methods, the emphasis is on current flow, not voltage.
A PNP transistor is used for the sourcing output, and an NPN transistor is used for the sinking input.

Sinking and sourcing terminology applies only to DC input and output circuits.
If a device provides current when it is ON, it is said to be sourcing current. Conversely, if a device receives
current when it is ON, it is said to be a sinking current.

Q: Explain a typical sinking sensor and sourcing input module configuration.

A sinking sensor and sourcing input module configuration is shown in Figure 4.3.
The sensor responds to a physical phenomenon. The sensor is connected to a voltage supply to operate. The
output of the sensor is directly connected to the base of the transistor.
When the sensor is inactive (nothing detected) then 0V is sent to the base of the transistor. Since the voltage
to the transistor on the active line is 0V, the transistor will not allow current to flow into the sensor. The
transistor is off. This is like an open switch. That means the NPN output will have no current in/out.
If the voltage on the active line becomes larger (say 24V) then the transistor will switch on and allow current
to flow into the sensor to the common.
When the sensor is active, it has detected some phenomenon and it will trigger the active line. So it will
make the active line high. So 24V is sent to the base of the transistor. The active line is directly connected
to an NPN transistor. This will turn on the transistor, and effectively close the switch. This will allow current
to flow in the following direction.
positive terminal of battery → pin 1 of input module → pin 2 of input module
→ Transsitor collector → transistor emitter → negative terminal of battery
So the input module is acting as the source and sensor is acting as the sink.

Dr. Md. Rabiul Islam, Associate Professor, EEE ∥ [email protected] ∥ PLC Discrete IO
 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইললবিক্যোল অ্যোন্ড ইললিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোলদশ Gopalganj-8100, Bangladesh

Page | 7

(a)

(b)
Fig. 4.3: A typical sinking sensor and sourcing input module configuration.

Q: Explain the sourcing sensor and sinking input module.

A sourcing sensor and sinking input module configuration for one input is shown in Figure 4.4.
The sensor responds to a physical phenomenon. The sensor is connected to a voltage supply to operate. The
output of the sensor is directly connected to the base of the transistor.
When the sensor is inactive (nothing detected), then 0V is sent to the base of the transistor. Since the voltage
to the transistor on the active line is 0V, the transistor will not allow current to flow into the sensor. The
transistor is off, this is like an open switch. That means the NPN output will have no current in/out.
When the sensor is active, it has detected some phenomenon and it will trigger the active line. So it will
make the active line high. So 12V is sent to the base of the transistor. The active line is directly connected

Dr. Md. Rabiul Islam, Associate Professor, EEE ∥ [email protected] ∥ PLC Discrete IO
 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইললবিক্যোল অ্যোন্ড ইললিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোলদশ Gopalganj-8100, Bangladesh
to an NPN transistor. This will turn on the transistor, and effectively close the switch. This will allow current
to flow in the following direction.
positive terminal of battery → Transsitor emitter → transistor collector → pin 1 of input module
→ pin 2 of input module → negative terminal of battery
So the transistor is acting as the source and input module is acting as the sink.
Page | 8

(a)

(b)
Fig. 4.4: Sourcing sensor and sinking input module.

Q: How basic PLC input devices are connected

Input devices are connected to the PLC via an optoisolator or optocoupler.

Q: What is an optoisolator?

Dr. Md. Rabiul Islam, Associate Professor, EEE ∥ [email protected] ∥ PLC Discrete IO
 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইললবিক্যোল অ্যোন্ড ইললিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোলদশ Gopalganj-8100, Bangladesh
Opto-isolators are devices that use a light emitter to control a photo-switch. The effect is that inputs and
outputs are electrically separate but optically connected.
Optical isolator provides electrical isolation between field wiring and the PLC internal circuit. It consists
of LED and phototransistors. The circuitry to the LHS of the isolator is powered from the field and the
circuitry to the RHS is powered from the internal PLC voltage source.
Page | 9
Q: Why are input devices not directly connected to PLC?
These PLC input devices are not just connected directly to the PLC for specific reasons.
• It is not assured that someone will always connect a properly rated device (output is 24V DC) for
the PLC input.
• A different polarity of DC input may be connected to the I/O module of the PLC.
• The optoisolation prevents the external events from interfering with the PLC and causing a
module failure.
For these specific reasons, the PLC is kept safe by a principle called optoisolation.

Q: Describe the basic principle of Opto-isolation.

Figure 1.12 shows the principle of an optoisolator.

Figure 1.12: Optoisolator [Bolton]

Optoisolation consists of an LED (emitter) and a phototransistor (detector) placed directly to each other.
When a digital pulse passes through the light-emitting diode, a pulse of infrared radiation is produced. This
pulse is detected by the phototransistor and gives rise to a voltage in that circuit. The gap between the light-
emitting diode and the phototransistor gives electrical isolation, but the arrangement still allows for a digital
pulse in one circuit to give rise to a digital pulse in another circuit.
Using Optoisolation, the PLC input side can only supply voltage to the PLC if it is in the right polarity. If
the input voltage or power is too high, only the input side of the optoisolator is damaged.
Optocoupler makes the PLC much more robust than other microcontrollers such as Arduino.

PLCs have miniature versions of photoelectric switches in order to protect the system.

Q: Draw the Optocoupler circuit for the DC input module.

Figures 4.2 show the basic input module circuits for DC inputs. Optoisolators are used to provide protection.

Dr. Md. Rabiul Islam, Associate Professor, EEE ∥ [email protected] ∥ PLC Discrete IO
 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইললবিক্যোল অ্যোন্ড ইললিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোলদশ Gopalganj-8100, Bangladesh

Page | 10

Figure 4.2: DC input module [Bolton-80]

Voltage divider: 𝑅1 and 𝑅2 form the voltage divider.
Indicator LED: This is an indication of the input signal.
Optoisolator: It provides isolation between two circuits.
Output voltage divider: It forms a voltage divider in the output section.

Q: Draw the Optocoupler circuit for the AC input module.

Figures 4.3 show the circuits for one input of a typical AC discrete input module. The input circuit is
composed of two basic sections: the power section and the logic section. An optical isolator is used to
provide electrical isolation between the field wiring and the PLC backplane internal circuitry.

Figure 4.3: Diagram of a single input of a discrete AC input module.

Dr. Md. Rabiul Islam, Associate Professor, EEE ∥ [email protected] ∥ PLC Discrete IO
 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইললবিক্যোল অ্যোন্ড ইললিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোলদশ Gopalganj-8100, Bangladesh
Signal indicator: Resistor 𝑅1 and signal indicator form a voltage divider. The signal indicator indicates
that the signal is imputing.
Bridge rectifier: Bridge rectifier converts AC voltage into DC voltage.
Resistor 𝑅2 : it is a safeguard for LED.
Optoisolator: It provides an isolation between two circuits.
Page | 11
𝑅3 and C: It forms a voltage divider in the output section.
The operation of the circuit can be summarized as follows:
• The input noise filter consisting of the capacitor and resistors R1 and R2 removes false signals
that are due to contact bounce or electrical interference.
• When the pushbutton is closed, 120 VAC is applied to the bridge rectifier input.
• This results in a low-level DC output voltage that is applied across the LED of the optical
isolator.
• The zener diode (ZD) voltage rating sets the minimum threshold level of voltage that can be
detected.
• When light from the LED strikes the phototransistor, it switches into conduction and the status of
the pushbutton is communicated in logic to the processor.
• The optical isolator not only separates the higher AC input voltage from the logic circuits but also
prevents damage to the processor due to line voltage transients. In addition, this isolation also
helps reduce the effects of electrical noise, common in the industrial environment, which can
cause erratic operation of the processor.
• For fault diagnosis, an input state LED indicator is on when the input pushbutton is closed. This
indicator may be wired on either side of the optical isolator.
• An AC/DC type of input module is used for both AC and DC inputs as the input polarity does not
matter.
• A PLC input module will have either all inputs isolated from each other with no common input
connections or groups of inputs that share a common connection.

Q: Explain the sinking sensor and sourcing input module with an optical isolator.

Dr. Md. Rabiul Islam, Associate Professor, EEE ∥ [email protected] ∥ PLC Discrete IO
 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইললবিক্যোল অ্যোন্ড ইললিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোলদশ Gopalganj-8100, Bangladesh

Page | 12

Figure 4.6 A PLC input module for sinking sensors

A sinking sensor and sourcing input module configuration is shown in Figure 4.6. This card is shown with
2 optocouplers (one for each sensor). Inside these devices there is an LED and a phototransistor, but no
electrical connection. These devices are used to isolate two different electrical systems. In this case, they
protect the 5V digital levels of the PLC computer from the various external voltages and currents.
The dashed line in the figure represents the current flow path when the sensor is active. This will allow the
current to flow in the following direction.
positive terminal of battery → pin (+V)of input module → LED of optocoupler
→ pin I0.0 of input module → Transsitorcollector → transistor emitter
→ negative terminal of battery
When the sensor is inactive the current will not flow, and the light in the optocoupler will be off. The
optocoupler is used to help protect the PLC from electrical problems outside the PLC.
So the input module is acting as the source and the sensor is acting as the sink.

Q: Explain the sourcing sensor and sinking input module with an optical isolator.

Dr. Md. Rabiul Islam, Associate Professor, EEE ∥ [email protected] ∥ PLC Discrete IO
 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইললবিক্যোল অ্যোন্ড ইললিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোলদশ Gopalganj-8100, Bangladesh

Page | 13

Figure 4.7 PLC input module for sourcing sensors

A sourcing sensor and sinking input module configuration are shown in Figure 4.7. This card is shown with
2 optocouplers (one for each sensor). Inside these devices there is an LED and a phototransistor, but no
electrical connection. These devices are used to isolate two different electrical systems. In this case they
protect the 5V digital levels of the PLC computer from the various external voltages and currents.
The dashed line in the figure represents the current flow path when the sensor is active. This will allow the
current to flow in the following direction.
positive terminal of battery → Transsitor emitter → transistor collector → pin I0.0 of input module
→ LED of optocoupler → pin com of input module → negative terminal of battery
When the sensor is inactive the current will not flow, and the light in the optocoupler will be off. The
optocoupler is used to help protect the PLC from electrical problems outside the PLC.
So the sensor is acting as the source and the input module is acting as the sink.

Q: What is the function of the optical isolator circuit used in discrete I/O module circuits?
Provide isolation between the field devices and the CPU

Q: Name the two distinct sections of an I/O module.

• Power section
• Logic section

Q: List four tasks performed by a discrete input module.

Discrete input modules perform four tasks in the PLC control system. They:
• Sense when a signal is received from a field device.
• Convert the input signal to the correct voltage level for the particular PLC.

Dr. Md. Rabiul Islam, Associate Professor, EEE ∥ [email protected] ∥ PLC Discrete IO
 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইললবিক্যোল অ্যোন্ড ইললিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোলদশ Gopalganj-8100, Bangladesh
• Isolate the PLC from fluctuations in the input signal’s voltage or current.
• Send a signal to the processor indicating which sensor originated the signal.

Q: What will happen if sinking or sourcing devices are connected in opposite direction.
Input and output points that are sinking or sourcing only can conduct current in only one direction. Page | 14
Therefore, it is possible to connect the external supply and field device to the I/O point with current trying
to flow in the wrong direction, and the circuit will not operate.

Q: With reference to sourcing and sinking I/O modules:

a. What current relationship are the terms sourcing and sinking used to describe?
b. If an I/O module is specified as a current-sinking type, then which type of field device (sinking or
sourcing) it is electrically compatible with?
a. In sinking devices, current flows into the device’s terminal from the module (the module provides,
or sources the current). In sourcing devices, current flows out of the device’s terminal into the
module (the module receives, or sinks, the current).
b. Sourcing type.

Q: PLC digital output module types

There are 2 types of PLC digital output modules:
1. Relay
2. Solid State
• BJT
• TRIAC

(a): Relay type output module (b) Solid-sate type output module
Fig. 3
• Triac outputs can be used only for control of ac devices,

Dr. Md. Rabiul Islam, Associate Professor, EEE ∥ [email protected] ∥ PLC Discrete IO
 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইললবিক্যোল অ্যোন্ড ইললিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোলদশ Gopalganj-8100, Bangladesh
• transistor outputs can be used only for control of dc devices.
• Relay outputs can be used with ac or dc devices.

Q: Relay output module

As with any typical relay, the PLC output module had physical coils and relay contacts contained inside. Page | 15
The contacts were operated by applying a voltage to the relay coil supplied by the processor module. The
contacts were connected to an external supply to turn on or off a discrete device.

(a): Motor OFF (a): Motor ON

Fig. 1: Relay output module
• Relays generally have a higher current rating than transistors, but, as with any mechanical device,
it will wear out with time.
• A relay module can operate AC or DC loads or both.
• Relays provide electrical isolation between the load and the PLC.
• Relays are slow-acting with typical response times of 10 milliseconds or greater.
• Closed relay contacts are almost zero ohms, thus ensuring no voltage loss.

Q: Solid-state output modules

Solid-state output modules are often referred to as switching modules. Output devices are turned on or off
by using solid-state devices such as a BJT or a Triac.

Q: Transistor output modules

Dr. Md. Rabiul Islam, Associate Professor, EEE ∥ [email protected] ∥ PLC Discrete IO
 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইললবিক্যোল অ্যোন্ড ইললিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোলদশ Gopalganj-8100, Bangladesh

Page | 16

• The transistor output module is voltage-dependent and can only operate DC loads.
• Transistor output modules are for DC applications only.
• Transistors typically cannot switch a large load current as can a relay.
• A transistor is fast because there are no mechanical parts. Their response time is much faster than
relays.
• Because a transistor is not a perfect switch, there is always a small voltage drop across it when
turned on.
• In some transistor modules, there is a leakage current even when turned off.

Q: Triac output module

A Triac output module is capable of controlling AC loads where transistor output modules can control DC
loads only. When the PLC signal is applied, the Triac will turn on and provide an alternating current path
for the load.

• A Triac output is used to control AC loads only.

Dr. Md. Rabiul Islam, Associate Professor, EEE ∥ [email protected] ∥ PLC Discrete IO
 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইললবিক্যোল অ্যোন্ড ইললিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোলদশ Gopalganj-8100, Bangladesh
• As with the transistor, a Triac is much faster than a relay.
• Triac outputs are suited to low-power AC loads such as lighting, motor starters, and contactors with
current ratings of around 1 amp.
• Example: The Siemens 6ES7522-5FF00-0AB0 is an 8-output Triac Output Module
Page | 17

(a) (b)
Fig. 2

Q: Discrete relay output module (Bolton 84)

Figure 2-15 shows the block diagram for one output of a typical discrete output module. It is composed of
two basic sections: the power section and the logic section, coupled by an isolation circuit. The output
interface can be thought of as an electronic switch that turns the output load device on and off. Logic circuits
determine the output status. An output LED indicates the status of the output signal.

Dr. Md. Rabiul Islam, Associate Professor, EEE ∥ [email protected] ∥ PLC Discrete IO
 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইললবিক্যোল অ্যোন্ড ইললিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোলদশ Gopalganj-8100, Bangladesh

Page | 18

The operation of the circuits can be summarized as follows:

• As part of its normal operation, the processor sets the output status according to the program.
• When the processor calls for an output load to be energized, a voltage is applied across the LED of
the opto-isolator.
• The LED then emits light, which switches the phototransistor into conduction.
• This in turn closes the contacts of the relay, allowing current to flow from the AC/DC supply to the
output load.
• Since the relay contacts carry both AC and DC currents in either direction, the output to the load
may be AC or DC.
• As with input circuits, the output interface is usually provided with LEDs that indicate the status of
each output.
• Fuses are normally required for the output module, and they are provided on a per circuit basis,
thus allowing for each circuit to be protected and operated separately. Some modules also provide
visual indicators for fuse status.
• For fault diagnosis, the LED output status indicator is on whenever the PLC is commanding that
the output load be switched on.

Q: Discrete transistor output module

Dr. Md. Rabiul Islam, Associate Professor, EEE ∥ [email protected] ∥ PLC Discrete IO
 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইললবিক্যোল অ্যোন্ড ইললিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোলদশ Gopalganj-8100, Bangladesh
Figure 2-15 shows the block diagram for one output of a typical discrete output module. It is composed of
two basic sections: the power section and the logic section, coupled by an isolation circuit. The output
interface can be thought of as an electronic switch that turns the output load device on and off. Logic circuits
determine the output status. An output LED indicates the status of the output signal.

Page | 19

The operation of the circuits can be summarized as follows:

• As part of its normal operation, the processor sets the output status according to the program.
• When the processor calls for an output load to be energized, a voltage is applied across the LED of
the opto-isolator.
• The LED then emits light, which switches the phototransistor into conduction.
• This in turn triggers the transistor switch into conduction, allowing current to flow to the output
load.
• Since the transistor conducts in one direction, the output to the load is ditect current.
• As with input circuits, the output interface is usually provided with LEDs that indicate the status of
each output.
• Fuses are normally required for the output module, and they are provided on a per circuit basis,
thus allowing for each circuit to be protected and operated separately. Some modules also provide
visual indicators for fuse status.
• The transistor cannot be used to switch a AC load.
• For fault diagnosis, the LED output status indicator is on whenever the PLC is commanding that
the output load be switched on.

Dr. Md. Rabiul Islam, Associate Professor, EEE ∥ [email protected] ∥ PLC Discrete IO
 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইললবিক্যোল অ্যোন্ড ইললিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোলদশ Gopalganj-8100, Bangladesh
Q: Discrete TRIAC output module
Figure 2-15 shows the block diagram for one output of a typical discrete output module. It is composed of
two basic sections: the power section and the logic section, coupled by an isolation circuit. The output
interface can be thought of as an electronic switch that turns the output load device on and off. Logic circuits
determine the output status. An output LED indicates the status of the output signal.
Page | 20

The operation of the circuits can be summarized as follows:

• As part of its normal operation, the processor sets the output status according to the program.
• When the processor calls for an output load to be energized, a voltage is applied across the LED of
the opto-isolator.
• The LED then emits light, which switches the phototransistor into conduction.
• This in turn triggers the triac AC semiconductor switch into conduction, allowing current to flow
to the output load.
• Since the triac conducts in either direction, the output to the load is alternating current.
• The triac, rather than having ON and OFF status, actually has LOW and HIGH resistance levels,
respectively. In its OFF state (HIGH resistance), a small leakage current of a few milliamperes still
flows through the triac.
• As with input circuits, the output interface is usually provided with LEDs that indicate the status of
each output.
• Fuses are normally required for the output module, and they are provided on a per circuit basis,
thus allowing for each circuit to be protected and operated separately. Some modules also provide
visual indicators for fuse status.

Dr. Md. Rabiul Islam, Associate Professor, EEE ∥ [email protected] ∥ PLC Discrete IO
 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইললবিক্যোল অ্যোন্ড ইললিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোলদশ Gopalganj-8100, Bangladesh
• The triac cannot be used to switch a DC load.
• For fault diagnosis, the LED output status indicator is on whenever the PLC is commanding that
the output load be switched on.

Q: Complete the PLC system

Page | 21
• The input from the field devices is received on the input module.
• The input signal could be a digital input signal (0/1) or it could be an analog input signal (4 to
20mA, 0 to 10V).
• The PLC is a digital device and the CPU of the PLC can withstand a voltage of 5V.
• The input signal received by the input module from the field devices then passes through the
optoisolation in the input module and is transferred to the opposite side of the optoisolation. The
transferred signal is then converted to the required 5V and the sent to the processor module of the
PLC system.

Fig. 8: The complete PLC system

• The signal received by the processor module is stored in the data memory as binary value 1 for 5V
and binary value 0 for 0V.
• The ladder logic program stored in the program memory of the PLC is then executed using the
binary input data stored in the data memory.
• The output status obtained from the execution of the ladder logic program is stored in the data
memory of the PLC as 0 and 1.
• The stored output value of 0 or 1 in the data memory after execution of the ladder logic program is
sent to the output module which is used to control the field devices.
• The output module also contains the optoisolation which is used to protect the PLC from external
interference.

Dr. Md. Rabiul Islam, Associate Professor, EEE ∥ [email protected] ∥ PLC Discrete IO
 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইললবিক্যোল অ্যোন্ড ইললিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোলদশ Gopalganj-8100, Bangladesh
• The signal from the PLC is converted to a corresponding analog or digital signal according to the
module to which it is connected.
This process of reading the input value, executing the program, and writing the output value is called
scanning.

Page | 22
Q: Process of turning the output devices ON or OFF
In reality, turning the output devices ON or OFF occurs in two steps. First, as the processor executes the
internal programmed logic, it will turn each of its programmed internal output coils ON or OFF. The
energizing or de-energizing of these internal outputs will not, however, turn the output devices ON or OFF.
Next, when the processor has finished evaluating all of the control logic program that turns the internal
coils ON or OFF, it will perform an update to the output interface modules, thereby turning the field devices
connected to each interface terminal ON or OFF. This process of reading the inputs, executing the program,
and updating the outputs is known as the scan.

Q: What electronic element can be used as the switching device for a 220 VAC discrete output
interface module?
TRIAC

Q: With reference to discrete output module current ratings:

a. What is the maximum current rating for a typical 220 VAC output module?
b. Explain one method of handling outputs with larger current requirements.
a. 2𝐴 × 8 = 16𝐴
b. Using relay switching

Q; What electronic element can be used as the switching device for DC discrete output modules?
Transistor

Q: A discrete relay-type output module can be used to switch either AC or DC load devices. Why?
Relay

References
1. Frank D. Petruzella. “Programmable Logic Controllers,” McGraw-Hill Education, Fifth
Edition, 2017.
2. L.A. Bryan, E.A. Bryan. “Programmable Controllers: Theory and Implementation,” An
Industrial Text Company Publication, Atlanta, Georgia, USA, Second Edition, 1997.
3. Hugh Jack. “Automating Manufacturing Systems with PLCs,” Version 5.1, March 21,
2008.
4. W. Bolton. “Programmable Logic Controllers,” Elsevier (Newnes), Sixth Edition, 2015.

Dr. Md. Rabiul Islam, Associate Professor, EEE ∥ [email protected] ∥ PLC Discrete IO