PLC Input and output I/O

modules and Power Supply

Module 4
 Syllabus
• PLC input output (I/O) modules and power supply: Introduction:
Classification of
• I/O, I/O system overview, practical I/O system and its mapping
addressing local
• and expansion I/O, input-output systems, direct I/O, parallel I/O
systems serial I/O
• systems. Sinking and sourcing. Discrete input module. Rectifier with
filter,
• threshold detection, Isolation, logic section, specifications of
discrete input module, types of analog input module, special input
modules, analog output module, I/O modules in hazardous
locations power supply requirements, power supply configuration,
filters.
 Introduction
• The CPU of a PLC executes the logic only.
• The input are to be taken from outside.
• Desired logic is implemented.
• The signals generated for final control are to be
sent to the real world outside the PLC.
• Input and Output Modules: Helps in the
Interaction of the CPU of a PLC with the outer
world.
• Commonly known as I/O modules
• Input modules:
• Receive signals from the field station.
• Convert them to CPU compatible information
• Pass them to the CPU of the PLC
• Output Modules:
• Convert and transmit the generated control
signals to compatible field devices.
• Depending on the type of signals I/O modules
also differ.
Classification of I/O modules
• Analog I/O

Analog Input
Analog Output
0-5 V
0-10 V
0-10V
4-20mA
4-20mA
0-25mA
Thermocouple
RTD
• First type conveys either switching on/off
information of a system or a specific condition
of a system.
• Discrete I/O modules handle two state (0/1)
digital signals.
• Analog I/O modules deal with continuously
variable analog signals.
• Parallel I/O indicate continuously changing
signals of flow, pressure, temperature etc.
• Special I/O modules accept variable input
signals like RTD , thermocouple.
Special Function Modules
I/O system overview
 I/O system overview
• In the system there is a rack.
• Slots are provided to house the control
processor module, power supply module and
I/O module.
• These are interconnected with one or more
programming devices.
• These are connected to the input and output
devices through a universal I/O system.
• Slots of the rack are provided with the self
locking mechanism.
• At the top of the module status indication
lamps and input/output marks are given.
• I/O system is the section of the PLC to which
all the field devices are connected.
Practical I/O system and its mapping
• Processor of the PLC works with the image of
the I/O stored in the I/O image memory.
• Input image table or input status file reflects
the status of the I/P terminal.
• The output image table or output status file
reflects the status of the output terminals.
• A standard input module has 16 input points.
• Each input terminal corresponds to one 16 bit
word of memory
• Input image table is the group of words in the
memory that are organized to store input data.
 Addressing local and Expansion I/O
• The local I/O provided by the CPU provides
fixed set of addresses.
• For a chain of expansion modules the
addresses of the point of the modules are
determined by the type of I/O.
• Its also determined by the position of the
module in the chain.
• Output module does not affect the addresses
of the points on an input module vice versa.
• Analog modules does not affect the addressing of
digital modules.
• Digital expansion modules always reserve I/O
status files in the increment of eight bits.
• If a module does not provide a physical point for
each bit of each reserved byte then it will be a
unused bit.
• These unused bits cannot be assigned to
subsequent modules in the I/O chain.
• For input modules the unused bits in reserved
bytes are set to zero with each input update
cycle.
• Analog expansion modules are always
allocated in words (16bit).
• If the module does not provide physical I/O
for each of these words these I/O words are
lost.
• These I/O words are not available for
assignment to subsequent modules in the I/O
chain.
 Input – output systems
1. Direct I/O
2. Parallel I/O systems
3. Serial I/O systems
 Direct I/O system
• Uses brute force for getting the I/O to and
from the PLC processor.
• There is one input signal, one output signal –
to the number of input and output processor
supports.
• Used in very small PLCs
• Cost is the principal advantage
• Flexibility is lost.
• Direct I/O systems are most cost effective
where the number of I/O points are low.
• When the number of I/O points is larger bus
oriented systems (parallel or serial) offer a
better cost performance ratio.
 Parallel I/O systems
• Originates from processors I/O interface
• Individual I/O modules are plugged into this
bus.
• Contain necessary circuit to decode the bus
signals
• Convert these signals to voltage levels that can
drive the necessary field loads.
• Each module will typically have a number of
input and output points on it.
• This multiplicity of I/O points is called
modularity of the I/O system.
• Modularities are of 4,8, 16 or 32.
• Adding more I/O points on a module reduce
the cost per I/O point.
• Reduces the amount of space required to
install a given number of I/O point.
• Communication takes place over a parallel bus
of multi conductor cable.
• Bus activity b/w I/O racks and processor board
controlled by control processor.
• Parallel I/O systems enter the halt operation
under the following conditions:
1. Control processor enter Stop mode.
2. I/O rack power supply detects the fact that
AC supply has fallen below a specific value.
3. When there is low AC line voltage detection.
 Serial I/O systems
• Parallel systems distance 15 m
• If a distance is 30 m long 2 PLCs are required.
• Serial I/O systems –serial data link (distance
300-3000m)
• Fewer wires
• Significant reduction in wiring cost
• If the number of serial I/O modules are used
they are connected to the processor through
serial link modules.
• Serial I/O star network
• Serial I/O multi drop network.
 Sinking and Sourcing
• Sinking and sourcing: Direction of current flow
through a field device
Why are they Required
Sourcing and Sinking in PLC interfacing
 Discrete Input Module
• The discrete input module is the most
common input interface used with PLCs.
Discrete
• Input signals from field devices can be either
AC or DC.
 Discrete DC Input Module
• Schematic diagram of a discrete dc input module
is shown in Fig. 5.24.
• A discrete input signal is received by the module
from field. devices isolated optically from the CPU
circuit.
• Common opto-isolator circuit is shown in Fig. 5.27.
• The signal is conditioned and sent to the
processor section and simultaneously to indicating
LEDs
 Discrete AC Input Module
• A discrete input module receives a signal of a
specific value representing the ON or OFF
state of a system.
• Common inputs include limit switches,
proximity switches, photoelectric switches,
selector switches, relay contacts and contact
closures from other equipment.
• The input module is considered as the load for
the field input device.
• The module's job is to convert the high-
voltage ac signal to the 5V DC level, with
which the PLC can work.
• Verify the input as a valid signal, isolate the
high-voltage field device signal from the
lower-voltage CPU signal
• Send the appropriate ON or OFF signal to the
CPU.
• The circuitry contained in an input module
consists of three parts: field signal conversion,
isolation, and logic as illustrated in Fig. 5.25.
 Rectifier with Filter
• The rectification section usually consists of a
bridge rectifier, which converts the incoming
AC signal to a pulsating DC signal.
• The DC signal is passed through filters to give
a conditioned DC input signal.
• The filtered DC signal goes on to the threshold
detector.
• Filtering and time delays are used to filter out
possible electrical noise that may be
interpreted as a false input pulse.
• To eliminate the possibility of faulty operation
due to electrical noise, a valid AC input signal
must:
1. Have a specific value
2. Must be present for a specific amount of
time before the input module allows the valid
signal to pass to the Subsequent section.
 Threshold Detection
• Threshold detection circuitry detects whether
the level of the input signal has exceeded a
predetermined set value.
• Depending on this it is classified as a valid ON
or OFF signal.
• A typical valid OFF state is between 0 and 20 or
30V AC
• And a valid ON state is between 80 and 130V
AC.
 Example of a threshold value

ON State 130 V

80V

20V

OFF State

0V

The signal area between 20 volts and 80 volts is called the undefined area.
Signals falling within this undefined area may be ON or OFF,.
Making them unstable and unreliable.
 Isolation
• The isolation section of the input circuit is usually made up of an
optical isolator, or optocoupler.
• This circuit essentially separates the high voltage signal circuit
from the low voltage CPU section.
• A commonly used opto-isolator circuit is shown in Fig. 5.27.
• It consists of a LED and a phototransistor.
• Once the LED is energised, it emits light to switch on a
phototransistor that is connected to the power circuit.
• Optical isolation protects the low-voltage CPU and its associated
circuitry by preventing spikes or high-voltage transients in the
input circuit from transferring to the low-voltage circuitry.
 Logic Section
• DC signals from the isolation section are used
by the logic section to pass the input signal to
the module's input address LED and the CPU.
• From there the input signal is passed on to
• the input status file via wires on the rack's
backplane called the data bus.
 Specifications of a Discrete Input Module
Item Meaning Typical Value for 24 V DC Typical Value for
24V DC
120/230V AC at
47-63. Hz
Points This is generally A 16-point input module — -
called points could have all the input points
common.It is the sharing one common, or it may
points sharing have two groups of 8 input
one points each group having its own
number of input separate common.
common
connection.
Rated This is the +24V DC at 4mA 120V at 6mA ,
voltage and operating voltage 230V at 9mA
current
Specified Voltage range on 0- +30V DC 264 V AC
operational which module
voltage can operate safely
range
 Discrete Output Modules
• Like discrete inputs, discrete outputs are used
most often.
• Discrete output modules act as switches to
control output field devices.
• They fall into two categories: solid-state only
switching and relay output switching.
• The schematic diagram of a discrete dc
output Module is shown in Fig. 5.28.
• Discrete output modules receive their operating power from the
power supply of the PLC, which comes from the backplane.
• A block diagram of a discrete output module is shown in Fig.
5.28.
• It is seen that the module consists of some potential free
contacts operated by signals from the CPU.
• Once this signal appears at the output terminals of the module,
the indicating LED glows.
• This signal is again isolated from the output power circuit by an
opto-isolator, amplified by the amplifier and interfaced with the
real world power circuit.
• Field output devices like coils, relays etc., powered by a power
supply external to the.
• PLC receive the signal to operate for final control action.
Operating Principles of Output Modules
Specifications of a Discrete Output Module

• A discrete output module is specified by all or

some of the following factors:
• Points, Nominal output voltage, specified
operational voltage range, absolute maximum
output voltage, absolute maximum reverse
input voltage, output current switching, carry,
field arrays, loop back thresholds.
Sourcing and Sinking output module
 Advantages and Disadvantages of Output
Modules
• The advantages and disadvantages of each type of output module
are given below. These have to be taken into account when an
output module is selected.
• Advantages of Solid-State Switching
• Fast switching speeds
• High reliability and almost infinite life
• Low power required to energize
• No contact arcing
• Little or no switching noise
• Positive switching and no contact bounce .
• Can be hermetically sealed, and is therefore suited to hostile
environments
• Disadvantages of Solid-State Switching:
• Solid-state switch may be destroyed by an
overload
• Solid-state devices tend to fail in the ON state
• Heat dissipation
• Expensive to purchase
• Possibility of false trips from electrical noise
 Types of Analog Input Modules
• Single ended input modules
• Differential ended input modules
 Special Input Modules
1. Resistance Temperature Detector Input Module
2. Thermocouple/millivolt input module
3. High Speed Encoder Input Module
4. Stepper Motor Control Module
5. Self Diagnostic Module
6. RS232 interface module
7. Remote I/O subscanners
8. Communication modules
 Analog Output Module
• Accepts 16 bit output status word
• Typical analog signals are 0 to 10 V DC, -10 to
+10V DC, 0 to 5V DC, 1V to 5V DC.
• 0 to 20mA, -20 to +20mA
• 4 to 20mA
• Example : speed of a DC motor to be varied.
I/O modules in Hazardous Location
 Power Supply Requirements
• Common AC Source
• Isolation from the power circuit
• Emergency Stops
• Safety Control systems
• Protection against excessive line voltage
variations
 Power Supply Configurations
• Rectifier unit
• Filter
• Regulator
 Filters
• Reduces the ripple voltage to a level that can
be used by the circuits using the power from
that power supply.
• Simple capacitive filter
• Simple Inductive filter
• Pi type filter