Dr.

Manjula Sutagundar
Dept of E&IE, BEC, Bagalkot

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 Syllabus
• Unit -1
Introduction to Industrial Automation: Utility of automation, General
structure of automated process, Examples of some simple automated
systems. Introduction to Programmable Logic Controllers(PLC): Introduction
to PLC operation-The digital concept, Analog signals, The input status file,
The output status file, Input and output status files, Sixteen point I/O
modules, PLC memory. Introduction to Logic: The logic, Conventional ladder
v/s LPLC ladder, Series and parallel function of OR, AND, NOT, XOR logic,
Analysis of rung. Input modules - Discrete type, Discrete AC and DC type.
Output Modules - Discrete type, Solid-state type, Switching relay type.
• Text book
Garry Dunning, “Introduction to Programmable Logic Controllers”, 2nd
Edition. Thomson Publishing, ISBN: 981-240-625-5.

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 Introduction
• What is automation?
 Technology by which a process or procedure is
performed with minimal human assistance.
 Use of control system for operating equipments
such as machinery, process in factories, switching
on telephone networks, steering and stabilization
of ships, aircrafts, vehicles etc with minimal
human intervention

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 Introduction
• Mechanization
 Introduction and use of machines into a process,
activity or place

Whether automation and mechanization are

same? ………………

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 Introduction
• Automation Vs Mechanization
Automation Mechanization
Replaces human thinking Replaces human muscle
with processors/computers power with some
mechanical power
Displaces mental labor Displaces physical labor
More focused on computer Use of machines for
technology and electronic replacing heavy and
data processing monotonous physical work

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 Introduction
• Process Control

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 Introduction
• Automation is achieved by various means
 Mechanical
 Hydraulic
 Pneumatic
 Electrical devices
 Electronic devices
 Computers
 Usually in combination

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 Introduction
• Advantages of Automation
 Increased productivity
 Improved quality
 Improved robustness (consistency/repetability)
 Reduced human labor cost
 Reduced cycle time
 High accuracy
 Reduced human operators in hard physical or monotonous work
 Reduced occupational injuries
 Replaces humans in hazardous environment
 Performs task that are beyond human capabilities
 Reduces operation time and work handling time significantly
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 Introduction
• Disadvantages of Automation
 Possible security threats
 Unpredictable or excessive development cost
 High initial cost
 Displaces workers

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 Programmable Logic Controller
(PLC)
• The brain of automation
• To understand PLC:
 What is PLC?
 Where did the PLC come from?
 Where is a PLC used?
 What makes a PLC work?
 How do PLCs know what they are supposed to do?
How do instructions get into PLC memory?

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 Programmable Logic Controller
(PLC)

What is PLC?

• PLC is an industrial computer.

• Electronic device: (Hardware + Software)
used to perform control functions

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 Programmable Logic Controller (PLC)
PLC & PC In Comparison
Computer PLC

CPU/Memory CPU/ RAM/ Hard disk CPU/ RAM/ Flash Card

Power Supply 220V AC, 1 Ph. 220V AC / 24V DC

Key board, Mouse, Push Button, Selector, Limit

Inputs
Remote station (LAN) Switch, Bus Interface

Outputs Monitor, Printer, Solenoids, Relays,

Projector Etc., Lamps, Motors, HMI

OS: Windows XP / OS: Firmware / SW:

Software SW: MS Office Machine Logic

Internal Calculator etc., Markers, Timers,

Counters, FBs

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 Programmable Logic Controller (PLC)
Machine Automation Over View
Command Signals Status Signals
Push Buttons, Limit Switch, Proximity, Machine
Controller Selector Switches Reed Switch etc.,

Inputs

Basics Concepts of PLC

Outputs

Relays, Solenoids, Power contactors

Actuators: Motors, Cylinders, Heaters, Lamps etc.,

HMI

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 Programmable Logic Controller
(PLC)
Where did the PLC come from?
(History)
• Before the PLC, control, sequencing, and
safety interlock logic for manufacturing was
accomplished using hundreds or thousands of
relays, timers, and sequencers and dedicated
closed-loop controllers.

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 Programmable Logic Controller
(PLC)
• The Hydramatic Division of the General Motors
Corporation specified the design criteria for the first
programmable controller in 1968 with the primary goals
of:
 Elimination of high costs associated with inflexible,
relay-controlled systems.
 Modular control system
 Capability to pass data collection to a central system.
 Reusable.
 Easily Programmable

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 Programmable Logic Controller
(PLC)

1968  Programmable concept developed

1969  Hardware CPU controller, with logic instructions, 1K
memory and 128 I/O points
1974  Use of several (multi) processors within a PLC - timers
and counters; arithmetic operations; 12 K of memory
and 1024 I/O points
1976  Remote input/output systems introduced
1977  Microprocessors - based PLC introduced
1980  Intelligent I/O modules developed Enhanced
communications facilities Enhanced software features
(e.g. documentation) Use of personal microcomputers as
programming aids
1983  Low - cost small PLC’s introduced
1985 on  Networking of all levels of PLC, computer and machine
using SCADA software.

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 Programmable Logic Controller
(PLC)
• Definition according to NEMA(National Electrical
Manufacturer’s Association) standard ICS3-1978
A digitally operated electronic device which
uses a programmable memory for the
internal storage of user oriented instructions
for implementing specific functions such as :
Logic, Sequencing, Timing, Counting
Arithmetic to control through digital or analog
modules, various types of machines or
process
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 Programmable Logic Controller
(PLC)
Where is a PLC used?
 PLC’s are used with all kinds of production plants which are
process oriented .
 Process which involve repeated operations with each operation
to be carefully monitored.
 Operations where human fatigue is a major concern due to close
supervision.
 It is difficult to think of a plant which does not make use of PLC’s
 Typically found in Packaging, Automobile, heavy engineering,
constructions, Pharmaceutical, tool making, assembly line plants.

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 Programmable Logic Controller
(PLC)
• What makes a PLC work
• How do PLCs know what they are
supposed to do?
 In the past the movements of industrial machines were controlled
by relay circuits. These relay-controlled systems were replaced by
PLC
 The primary function of the PLC was to perform the sequential
operations that were previously implemented with relays
 Before we can talk about the working method of an PLC, we must
understand the function of relay circuits.

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 Programmable Logic Controller
(PLC)
What is a Relay ?
A relay is an electrical switch.
It contains:

a coil a switch
and a iron bar
a iron core connected to
the switch

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 Programmable Logic Controller
(PLC)
How does a Relay work ?
When a current goes through the coil...

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 Programmable Logic Controller
(PLC)
How does a Relay work ?
… a magnetic field is produced in the coil and the iron core in
the coil becomes magnetic.
I

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 Programmable Logic Controller
(PLC)
How does a Relay work ?
The electromagnetic force pulls in the switch and...

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 Programmable Logic Controller
(PLC)
How does a Relay work ?
…a current can go through the switch.

I I

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 Programmable Logic Controller
(PLC)
How does the PLC replace Relay in an electric circuit ?

The answer to this question shall be shown with the following

example circuits, A, B, C, and D.
A).
24V technical symbol
of a relay
internal
switch

S1
electro magn.
connection

coil

K1 L1

0V

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 Programmable Logic Controller
(PLC)
How does the PLC replace Relay in an electric circuit ?
The answer of this question shall be shown with a little
example circuit.
B).
24V Function of the electrical circuit:

S1
When the user presses button S1, the relay
K1 pulls in its internal switch and the lamp
L1 turns on.

K1 L1

0V

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 Programmable Logic Controller
(PLC)
How does the PLC replace Relay in an electric circuit ?
The answer of this question shall be shown with a little
example circuit.
C).
24V 24V

S1
S1
Input Power

PLC
Power Output

K1 L1 L1
0V 0V

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 Programmable Logic Controller
(PLC)
How does the PLC replace Relay in an electric circuit ?
The answer of this question shall be shown with a little
D). example circuit.

24V 24V

S1 PLC logic
S1

K1 L1 L1
0V 0V

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 Programmable Logic Controller
What is PLC logic ?
(PLC)
The PLC logic is not a mechanical part of the controller.
The PLC logic is a software program, which runs on the
processor in the PLC. This program has to be created with a
special programming tool on a PC. After downloading the
24V the program into the PLC, the control
automatically starts the program.
S1 SPS logic

L1
0V

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 Programmable Logic Controller
(PLC)
How do instructions get into PLC memory?

 Instructionsare transferred to the memory of the controller

from either handheld programmer or a personal computer

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 Programmable Logic Controller
(PLC)

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 Programmable Logic Controller
(PLC)
 Download – After the program is developed,
entered and verified for correctness
 Transfers the program into processors memory
 Program mode
 Run mode

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 Programmable Logic Controller
(PLC)
Block diagram

POWER
SUPPLY

I M O M
N O
P D U O
U U PROCESSOR T D
T L P U
From E U L
T E To
SENSORS
OUTPUT
Pushbuttons, Solenoids,
contacts, contactors,
limit switches, alarms
etc. etc.
PROGRAMMING
DEVICE

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 Programmable Logic Controller
(PLC)
Architecture of PLC

PROCESSOR
 Provides intelligence to command and govern the
activities of the entire PLC systems.
 The processor (called as CPU), as in the self contained
units, is generally specified according to memory required
for the program to be implemented.
 The processor consists of the microprocessor, system
memory, serial communication ports for printer, PLC LAN
link and external programming device.

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 Programmable Logic Controller
(PLC)
I/O MODULES
 Provides signal conversion and isolation between the internal logic level
signals inside the PLC and the field’s high level signal.
 Input and output (I/O) modules are specified according to the input and
output signals associated with the particular application
 Modules fall into the categories of discrete or analog
 Discrete I/O modules are generally capable of handling 8 or 16, 32, on-
off type inputs or outputs per module.
The module can be specified as AC only, DC only or AC/DC along with the
voltage values for which it is designed
 Analog input and output modules are available and are specified
according to the desired resolution and voltage or current range
 Analog modules are also available which can directly accept
thermocouple inputs for temperature measurement and monitoring by the
PLC

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 Programmable Logic Controller
(PLC)
POWER SUPPLY
Provides the voltage needed to run the primary PLC
components
 The power supply specified depends upon the
manufacturer's PLC being utilized in the application
 In some cases a power supply capable of delivering all
required power for the system is furnished as part of the
processor module
 If the power supply is a separate module, it must be
capable of delivering a current greater than the sum of all the
currents needed by the other modules

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 Programmable Logic Controller
(PLC)
PROGRAMMING DEVICE
 Used to enter the desired program
 The programming unit allows the engineer or technician
to enter and edit the program to be executed.
 It can be a hand held device with a keypad for program
entry and a display device (LED or LCD) for viewing program
steps
 More advanced systems employ a separate personal
computer which allows the programmer to write, view, edit
and download the program to the PLC
 Accomplished with proprietary software available from
the PLC manufacturer
 Communication with the programmable controller with
this system is via a cable connected to a special
programming port on the controller
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 Programmable Logic Controller
(PLC)
•Innovations Incorporated in PLC
 PLC is hardened industrial computer
designed to withstand harsh factory
environment
 PLCs are reusable
 PLCs offer easy troubleshooting
 PLCs feature easy installation and
trouble shooting

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 How a PLC works: internal PLC

network Communication
RAM E-EPROM
module

Programming
tool CPU

power cord Input Output

Power supply
modules modules

Machine

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 Working of PLC

How a PLC works: internal PLC

network Communication
RAM E-EPROM
module

Programming
tool CPU

power cord Input Output

Power supply
modules modules

Central
processing unit Machine

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 Working of PLC

How a PLC works: internal PLC

network Communication
RAM E-EPROM
module

Programming
tool CPU

power cord Input Output

Power supply
modules modules

Working- and
Machine
program memory
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 Working of PLC

How a PLC works: internal PLC

network Communication
RAM E-EPROM
module

Programming
tool CPU

power cord Input Output

Power supply
modules modules

Program editor
Machine
and monitoring
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 Working of PLC

How a PLC works: internal PLC

network Communication
RAM E-EPROM
module

Programming
tool CPU

power cord Input Output

Power supply
modules modules

Sensor signal
Machine
input
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 Working of PLC

How a PLC works: internal PLC

network Communication
RAM E-EPROM
module

Programming
tool CPU

power cord Input Output

Power supply
modules modules

Actuator
Machine
command output
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 Working of PLC

How a PLC works: internal PLC

network Communication
RAM E-EPROM
module

Programming
tool CPU

power cord Input Output

Power supply
modules modules

Control
Machine
communication
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Working of PLC

How PLC works: processing cycle

Start PLC from E-EPROM

Read user program & Copy to RAM

Read input signals, store in table

Determine new output state of output module

processing cycle

Write output commands in table

Set output values on output module

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Relay vs. PLC
•More than 5 or 6 relays in a circuit will make it
• costlier
• more panel space consumption
• Limited functions
• limited logic, no math, no application specific instructions
• timers and counters will add up to the cost
• no communication possible (difficult to exchange data)
• Maintenance / Reliability
• mechanical devices wear out
• Wiring and designing
• time consuming
• difficult to document

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 •Troubleshooting
• requires skilled technician
• consumes a lot of time to diagnose the problem

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Advantages of PLCs

• Less wiring.
• Wiring between devices and relay contacts are done in the PLC
program.
• Easier and faster to make changes.
• Trouble shooting aids make programming easier and reduce
downtime.
• Reliable components make these likely to operate for years before
failure.

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 Programmable Logic Controller
(PLC)

• Classification of PLC
 Based on size (Number of I/Os)
 Micro
 Small
 Medium
 Large
 Very
 Based on memory size, instruction set size and
communication and networking capabilities

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03/24/2022 Process Automation (UEI751C) 51
 Programmable Logic Controller
(PLC)
• PLC Hardware Configuration
 Fixed: All the components – the input section,
CPU and associated memory, power supply and
output section built into one self contained unit.
 Modular: Comes as separate pieces – can select
power supply, processor, I/O modules and
assemblies called as chasis/racks/baseplates to
hold the pieces together

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 Programmable Logic Controller
(PLC)
• Fixed PLC
 Consist of fixed or built in input-output section

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 Programmable Logic Controller
(PLC)
• Modular PLC
 I/O points on plug in type
 removable units called I/O modules
 Consist of a chassis, rack or baseplate
 power supply, CPU, I/O modules are present on the chassis as
separate hardware items
 User can mix the input and output according to specific needs
Usually the chassis hold 4,5,7,8,10,13 or 16 I/O modules
Electrical connections between each module and CPU are
made by two mating plugs
The connection is established by means of backplane

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 Programmable Logic Controller
(PLC)

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 Digital and Analog PLC Interface
• Information flow from field device to PLC
memory – Processed by the user program –
Output from PLC memory to control field
device
• Understanding how the information is
represented and handled by the
programmable controller

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 Digital and Analog PLC Interface

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 Digital and Analog PLC Interface
• Digital Concept
 PLCs operate on digital circuits
 Digital circuits – A circuit is either on or off
 Discrete device – Device that provides two-state
signals as inputs to, or outputs from, a PLC

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 Digital and Analog PLC Interface

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 Digital and Analog PLC Interface
• Binary representation
 Computer uses group of bits called words
 Measure of processor capability – length of data
word on which it can operate
 Modern PLCs – 16 bit words

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 Digital and Analog PLC Interface
• A 16-bit word is composed of
 16 single bits or
 4 nibbles or
 2 bytes

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 Digital and Analog PLC Interface

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 Digital and Analog PLC Interface
• Correlation of 16-Bit Words to Input Signals
 A Standard input module might have 16 input
points
 Each input module corresponds to one 16-bit
word
 Each input screw terminal corresponds to like
numbered bit position in a 16-bit word
Each bit position will have either 1 or 0

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 Digital and Analog PLC Interface

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 Digital and Analog PLC Interface

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 Digital and Analog PLC Interface

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 Digital and Analog PLC Interface
• 24 point input module
Point 16 is word 1 bit 0
 Point 23 is word 1 bit 7

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 Digital and Analog PLC Interface
• 32 point input module

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 Digital and Analog PLC Interface
• Organization of data words
• Important to understand the organization to
know which input point is associated with
which bit in which word
• Data file: group of words containing like data

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 Digital and Analog PLC Interface

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 Digital and Analog PLC Interface
• Input status file
 Group of words in memory that are organized to
store input data
 Each input module in the chassis is mapped or
assigned a specific word in the input status file

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 Digital and Analog PLC Interface

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 Digital and Analog PLC Interface
• Output status file
 Group of words in memory that are organized to
store the on-off status of each output

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 Digital and Analog PLC Interface

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 Digital and Analog PLC Interface

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 Digital and Analog PLC Interface

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 Digital and Analog PLC Interface
• Input and output status file for fixed PLC
 Even though the hardware configuration is
different the interaction between the inputs and
outputs with the input and output status file
remains the same
 A 16 input fixed PLC will have one 16 bit word with
each bit corresponding to 1 input
 Three fixed PLCs of Allen Bradley SLC 500 family
 MicroLogix 1000
 MicroLogix 1200
 Micrologix 1500
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 Digital and Analog PLC Interface
 MicroLogix 1000 (20 inputs, 12 outputs)
 Support output four analog inputs and one analog
output
 Not expandable
 MicroLogix 1200 (24 inputs, 16 outputs)
Expandable upto 6 Allen Bradeley 1762 I/O modules
 MicroLogix 1500 (16 inputs, 12 outputs)
 Expandable upto sixteen Allen Bradeley 1769 I/O
modules

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 Digital and Analog PLC Interface
• For fixed PLC the CPU unit with fixed I/O is
called the base unit
• To maintain the consistency in addressing of
fixed PLC and modular PLC the I/O points that
comes along with CPU are addressed as slot
zero in the input and output status file

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 Digital and Analog PLC Interface

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 Digital and Analog PLC Interface

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 Digital and Analog PLC Interface

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 Digital and Analog PLC Interface
• Sixteen point I/O modules with decimal
addressing
 For modular PLC the addressing is dependent on
module type and the slot in which modules resides
 16 point input modules in slot 1,3,4 and 6. 16-
point output modules in slot 2 and 5
 Each screw terminals address is composed of
 Slot number
 Screw terminal number
 Designation as to whether I/O point is an input or output

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 Digital and Analog PLC Interface

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 Digital and Analog PLC Interface

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 Digital and Analog PLC Interface
• What is the address of screw terminal 9 on the
module in slot three?
• What is the address of screw terminal 0 on the
module in slot two?
• What is the address of screw terminal 12 on
the module in slot six?

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 Digital and Analog PLC Interface
• I/O interaction with input and output status
files
 Slot 1 – 8 point discrete input module
 Slot 3 – 32 point discrete input module
 Slot 4 – 16 point discrete in put module
 Slot 6 – 16 point discrete input module
 Slot 2 – 16 point discrete output module
 Slot 5 – 16 point discrete output module

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 Digital and Analog PLC Interface

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 Digital and Analog PLC Interface

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 Digital and Analog PLC Interface
• Fixed I/O addressing
 All I/O Screw terminals are addressed as slot 0
 Example: Fined PLC with 16 inputs and 12 outputs
 Address of input screw terminal 5
 Address of output screw terminal 11
• Fixed I/O addressing when I/O is expanded
 Only fixed SLC 500 PLC can be expanded into a
special two slot expansion chasis

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 Digital and Analog PLC Interface

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 Digital and Analog PLC Interface

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 Digital and Analog PLC Interface

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 Digital and Analog PLC Interface
• Analog I/O interface to PLC
 Voltage input or current input
 Used in applications concerned with continuous
process control such as temperature, pressure,
humidity, analog valves, load cells etc.
 Input and output voltage and current levels

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 Digital and Analog PLC Interface
 Input and output voltage and current levels
 +/- 10Vdc
 0 to 10Vdc
 +/- 5Vdc
 0 to 5Vdc
 1 to 5Vdc
 0 to 20mA
 4 to 20mA
 +/- 20mA
 Analog module transforms an analog voltage or
current level from a sensor or transmitter into a
discrete value
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 Digital and Analog PLC Interface
 ADC – transforms analog value into digital
equivalent
 Analog input and output connections are called
channels
 DAC – in the output module transforms the digital
value into equivalent analog signal

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 Digital and Analog PLC Interface

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 Digital and Analog PLC Interface

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 Digital and Analog PLC Interface
• Module Resolution
 The number of bits in the digital value that
corresponds to the full scale analog value
 Resolution is the smallest amount of change the
module can detect
A module with sixteen bit resolution can divide
the input signal into 32767 bits – 16 bit resolution

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 Digital and Analog PLC Interface

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 Introduction to Logic
• How logic functions are executed when
solving PLC programs
• To develop PLC programs – logic functions
 AND
 OR
 NOT

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 Introduction to Logic
• AND – Series logic
 The lamp, LAMP1, will illuminate only when SWITCH1 AND
SWITCH2 are ON

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 Introduction to Logic
• OR Logic
 Lamp will illuminate if SWITCH 1 OR SWITCH 2 is
closed

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 Introduction to Logic
• NOT Logic

Switch Light
Off On
On Off

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 Introduction to Logic
• Conventional ladder diagram
• Fundamental components used in electrical
machine control (Conventional Ladder diagram)
 Control transformer
 Fuses
 Switches
 Indicator lamps
 Relays

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 Introduction to Logic

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 Introduction to Logic

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 Introduction to Logic

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 Introduction to Logic

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 Introduction to Logic

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 Introduction to Logic

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 Introduction to Logic

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 Introduction to Logic
• PLC ladder for AND logic
A B C

• PLC ladder for OR logic

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 Introduction to Logic
• Ladder Programming
 A PLC ladder program is a planned set of instructions
resembling a hardwired ladder diagram. It consists of
a line (L) power rail and a neutral (N) power rail
between which one or more rungs are inserted
 Each individual rung contains one or more input
instructions on its left-hand (L power rail) side, and a
single output instruction or several output
instructions placed in parallel on its right-hand (N
power rail) side

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 Introduction to Logic

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 Introduction to Logic
• Each rung is a program statement
• Program statement – consists of condition
with some type of actions

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 Introduction to Logic
• Conventional ladder Vs PLC ladder
 Hardwired logic, PLC logic
 Symbols used
 Electrical continuity and logical continuity

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 Introduction to Logic
• Combinational Logic
 Ladder rungs will include some combinations of
AND, OR and NOT logic
 There must be at least one path of true logical
continuity before the output can be made true.

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 Introduction to Logic

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 Introduction to Logic

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 Introduction to Logic
• Pneumonic Programming

LOAD I1
AND I2
OUT O5

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 Introduction to Logic

LOAD I1
AND I2
AND I3
OUT O1

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 Introduction to Logic

LOAD I1
OR I2
OR I3
OUT O2
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 Introduction to Logic
• Priority of logic elements
LOAD I1
AND I2
OR I3
AND I4
OUT O7

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 Introduction to Logic

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 Introduction to Logic
• Each rung begins at the left power rail
• Start each rung with appropriate beginning instruction.
• Program the next element closest to one already
programmed. In case a series and a parallel logic element
are equidistant always program the parallel logic function
first. Continue following the rule until the output
instruction is reached
• Typically if two or more instructions are to be programmed
on a parallel branch, special instructions are used to
connect , or group, parallel instructions on that branch

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 Introduction to Logic
• LOAD I1 Group 1
LOAD I2 Group 2
AND INVERT I3
OR Block
OUT O2

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 Introduction to Logic
• Function Block Diagram

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 Introduction to Logic

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 Introduction to Logic

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 Introduction to Logic

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 Input Module
• Interface between the outside world and CPU
• Accept voltage/current and convert into
logical signal (0/1)
• Classification of input module
Discrete Module Analog Module
AC Type DC Type Single ended Differential
Sourcing Sinking
Type Type

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 Input Module
• Discrete Input Module
 AC Input Module
 24 VAC
 48 VAC
 120 VAC
 240VAC
 Common inputs
 Limit switches, proximity switches, photoelectric
switches, selector switches, relay contacts

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 Input Module

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 Input Module
• Discrete AC Input Module

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 Input Module
• Power conversion
 Consists of resistor and bridge rectifier
 Converts incoming AC signal to pulsating DC
 The pulsating DC is passed through filter to get a clean
debounced DC
• Threshold Detection
 Detects if the incoming signal has reached or
exceeded pre-determined value for a pre determined
time and whether it should be classified as valid on or
off
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 Input Module

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 Input Module
• Isolation
 Usually made up of an optical isolator , or a opto
coupler
 Separates high voltage signals from CPUs low
voltage control logic

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 Input Module

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 Input Module
• Logic Section
 Used to pass the DC signals from the optocoupler
to modules input address LED and then into input
status file

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 Input Module
• AC Input Module Specifications
 Voltage: This is the operating voltage at 47 to 63 MHz
 Inputs: The number of inputs the module has
 Points per common: Number of input points that share the
same common connection
 Backplane current draw: The amount of current drawn
from the PLCs power supply to operate the internal
electronics
 Maximum signal delay: Time it takes for the PLC to pick up
the field input signal, digitize it and store it in the PLC
memory

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 Input Module
 Nominal input current: Current drawn by the
input point at nominal input voltage
 Maximum inrush current: maximum input
current the module can handle
 Maximum off-state current: Maximum amount
off current, typically from leakage from a solid
state input device, that a module can accept while
remaining in off state

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 Input Module

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 Input Module
• Types of input devices
 Mechanical type
 Solid state type
• Mechanical Type
 Circuit continuity is either made or broken by
physically opening a set of contacts
 When open, the contacts have s physical air gap
thus infinite resistance
 No electrical power required to operate the device
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 Input Module
• Solid state type
 Electronic device which needs power to operate
 A small amount of current must continuously flow
through the device even in OFF state to keep the
internal electronics working
 Leakage current

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 Input Module

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 Input Module
• Excessive leakage current could possibly cause
the modules input point to turn on in error if
the modules maximum off state current is
exceeded

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 Input Module

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 Input Module

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 Input Module
• Considerations when connecting a solid state
device as input to the PLC
 Leakage current < maximum off-state current
 Voltage drop specification
 Power up delay

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 Input Module

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 Input Module

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 Input Module

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 Input Module
• DC input modules
 24 Vdc
 48 Vdc
 10-60 Vdc
 120 Vdc
 230 Vdc
• Typical inputs: proximity sensors, photoelectric sensors –
Usually have transistor switching
• Two categories of input devices: Devices with NPN
transistors(sinking) and devices with PNP
transistor(Sourcing)
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 Input Module
• Sourcing and Sinking

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 Input Module

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 Input Module

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 Input Module

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 Input Module

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 Input Module

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 Input Module

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 Input Module

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 Input Module
• Specifications of DC input module
• Considerations while connecting solid state
sensors to the DC input module
 Sink type or source type
 Leakage current<maximum off state current

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 Input Module

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 Input Module
• Three ways to eliminate the problem
associated with leakage current
 Carefully match the leakage current and
maximum off state current
 Using bleeder resistor
 Choose three wire input resistor

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 Input Module

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 Input Module

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 Input Module

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 Input Module
• Sensing of mild steel target at a distance of 8mm

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 Input Module

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 Input Module
• Analog Input Module
 Typical analog signals come from temperature,
pressure, position sensor
 Analog input modules convert analog signals to
digital word
 Accept either current or voltage input
 Usually signal levels: 0 to 10 V dc, -10 to +10 V dc,
0 to 5 V dc, 1 to 5 V dc, 0 to 20 mA, -20 to +20 mA,
4 to 20 mA

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 Input Module

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 Input Module

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 Input Module
• Examples

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 Input Module

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 Input Module

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 Input Module

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 Input Module

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 Input Module

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 Input Module

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 Input Module

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 Output Module
• Output module – connection between the outside
world and the Central Processing Unit(CPU)
• Common hardware field devices: motor starter
coils, pilot lights, solenoids, alarm bells, valves,
control relays etc.
• Three categories of output module
 Discrete
 Analog
 Specialty

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 Output Module
• Discrete output modules
 Acts as switch to control the field devices
 Two categories
 Solid state output switching
 Relay output switching

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 Output Module

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 Output Module
• Operating principles of output module
 Switching devices that carry out commands from
CPU
 Each output point contains a switching device
 The device is turned on or off according to the bit
value residing in that particular output status table
address

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 Output Module
• Signal flow from CPU to field device

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 Output Module
• Typical output module

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 Output Module
• Solid state output module switching
 AC Switching modules – use triac
 DC switching modules – use transistors
 Sinking modules
 Sourcing modules

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 Output Module

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 Output Module

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 Output Module
• Relay output modules
 Used to switch AC or DC loads
 Each output point is a electromechanical relay

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 Output Module

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 Output Module
• Module selection considerations
 Primary issues:
 Number of operations: Frequent switching – solid
state output, few switching – relay output
 Leakage current: in case of solid state switch
 Safe shutdown in case of failure: Solid state switch
tend to fail in shorted condition

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 Output Module
• Advantages of solid state switching
 Fast switching speed
 High reliability and infinite life
 low power required to energize
 No contact arching
 little or no switching noise
 No contact bounce
 can be hermetically sealed

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 Output Module
• Disadvantages of solid state switching
 Destroyed by an overload
 Tend to fail in on state
 Heat dissipation
 Expensive to purchase
 Possibility of false trips from electrical noise

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 Output Module
• Advantages of relay output switching
 Contact forgiving to a temporary overload
 Immune to false trip from electrical noise
 Definite on or off state with contacts physically
open
 No leakage
 Contact generate little heat
 inexpensive

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 Output Module
• Disadvantages of relay output switching
 Mechanical switching is slow
 Mechanical life is limited
 Require 50mA or more to energize
 Subject to contact arcing or welding
 Subject to contact bounce
 Cannot be completely sealed

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 Output Module
• Isolated output modules

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 Output Module
• Analog outputs
 Accept 16-bit output status word and convert to
an analog value through a DAC
 Analog signals are: 0 to 10 Vdc, -10 to +10Vdc, 0
to 5Vdc, 0 to 20 mA, -20 to +20mA, 4 to 20mA

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 Output Module

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