INPUT / OUTPUT MODULE

Ø The input modules are available to accept various voltages and currents and to automatically
convert input signal into a logical (typically 5 VDC) signal with which the CPU can work

Ø After solving the user program logic and sending the output signal to the output module by way of
the output status file, the output module, which is also available in various switching configuration,
controls the field output devices

Ø For example a low voltage 24 VDC control signal can be an input controlling 240 VAC output
device

Ø There are various ways to get information into the CPU from common hardware field device

1. Discrete I/O interface modules provide a method of getting two –state, discrete , or digital
signals into and out of the PLC

1. Ever-changing signals like temperature or pressure (called analog signals) can be interfaced to
the PLC using modules specifically designed to accept these variable signals. These modules
are called analog input or analog output modules
INPUT MODULES
Ø I/O modules are available as either input only, output only, or a combination of inputs and outputs
Ø Fig 1 shows a four-slot Allen Bradley SLC 500 modular chassis and an I/O module being inserted
Ø In the fig1 the self locking tabs, which will lock the module into the chassis

Ø An I/O module is made of the following features:-

Ø At the very top of the module is identification indicating whether this is an input, output, or
combination module

Ø Some manufacturers color-band the identifications portion of the module for further
identification

Ø Fig 2 illustrate an SLC 500 combination I/O module. Directly below the identification portion lie the
status indicators

Ø There will be one status indicator , or light emitting diode (LED), for each I/O point. These lights
the operator to the ON or OFF status of each point on that module

Ø Farther down the front of the module are the screw terminals for connecting the I/O wires to the
module

Ø Removable terminal blocks make wiring and changing the module easy and avoid the need for
Discrete Input Module

Ø The discrete input module is the most common input interface used with programmable controllers

Ø Discrete input signals from field devices can be either AC or DC

Ø Discrete input modules are selected according to the voltage levels with which they can work

Ø Typical input modules can accept +5 VDC, 10-30 VDC, 120 VAC, 120-240 VAC and 200-240 VAC
levels as input

Ø The most common modules types are listed below

Ø A 110 VAC input module will accept signals between 80 and 135 VAC.

Ø Common inputs include limit switches, photoelectric switches, selector switches, relay contacts, and
contact closures from other equipment

Ø Figure 3 illustrates wiring for a typical 110 VAC input module. Signals from line through the field
input device are wired to input screw terminals on the module

Ø The left module has its commons connected internally. All inputs will have the same voltage

Ø The right module is a 120 or 230 VAC input module. The module has two separate commons, which
allows the user to wire two different input voltage levels

Ø The input module is considered the load for the field input device. The module’s jobs are:-
Ø The circuitry contained in an input module is comprised of three parts :
power file conversion, isolation, and logic, as illustrated in fig 4.

Ø Alternating current enters the module (section1) and then flows to the power
conversion (section2).
2. Threshold Detection

Ø. This circuitry detects if the incoming signal has reached or exceeded a predetermined value for a
predetermined time, and whether it should be classified as a valid ON or OFF signal

Ø. Module specifications call this the valid ON/OFF state voltage range

Ø. A typical valid OFF state is between 0 and 30 VAC

Ø. A valid ON state will be between 80 and 132 VAC

Ø. The signal area between the upper voltage limit for a valid OFF state (20 volts) and the minimum
voltage for a valid ON state (80 volts) is called the undefined, or input state not guaranteed zero

Ø. Signals falling within this undefined area may be ON or OFF, making them unstable and unreliable
3. Isolation

Ø. The isolation section is usually made up of an optical isolator, or opto-coupler

Ø. In a 115 VAC module, isolation separates the high-voltage, 110 VAC input signal from the CPU,s
low-voltage control logic

Ø. The low-voltage control logic signals associated with the CPU will run from 5 to 18 VDC, depending
on the module manufacturer and the type of logic employed

Ø. Isolation is accomplished by the input signal energizing a light-emitting diode (LED), which
transmits a signal of light energy to a receiver in the form of a photo-conductive diode

Ø. This LED converts the electrical signal to an optical signal. The receiver usually a photo-transistor,
converts the optical signal back to an electrical signal

Ø. There is no actual physical or electrical coupling between the sending LED, its associated input
circuitry, and the optical receiver and its low-voltage, associated logic circuitry

Ø. Optical isolation protects the low-voltage CPU and its associated circuitry by preventing spikes or
high-voltage transient on the input from transferring into the low-voltage circuitry
AC Input Module Specifications
Module specifications provide important information during module selection, PLC hardware
configuration, troubleshooting, and input device selection

1. Voltage :- This is the operating voltage at 47 to 63 hertz (Hz) for the module

1. Inputs:- This indicates the number of inputs the module has

1. Points per Common:- This is the number of input points that share the same common connection

1. Backplane Current Draw:- Each module takes power from the PLC’s power supply to operate the
electronics on the module. This specification will be used when calculating power supply loading

1. Maximum Signal Delay:- Signal delay is the time it takes for the PLC to pick up the field input
signal, digitize it, and store it in memory. This specification is usually listed for a signal turning on
and for a signal turning off.

1. Nominal Input Current:- This is the current drawn by an input point at nominal input voltage

1. Maximum Inrush Current:- This is the maximum inrush current the module can handle
DC Input Modules
Ø DC sensors can drive electromechanical relays, counters, and solenoids in addition to solid-state
device

Ø A DC sensors will interface directly to a PLC without additional interface circuitry when using the
proper DC input module

Ø Common industrial sensing applications use discrete, solid-state sensors with transistor outputs for
interfacing to PLCs

Ø These sensing devices include inductive proximity sensors, capacitive proximity sensors, and
photoelectric sensors etc. Typical industrial sensors that fall into this category are 10-30 VDC
sensors

Ø The sensor’s transistor switch controls the signal that is input a PLC input module. Transistors are
solid-state switching devices that are available in two different polarities, NPN or PNP

Ø Solid-state input devices with NPN transistors are called “sinking input devices”, while input
devices with PNP transistors are called “sourcing input devices”.

Sinking And Sourcing

Fig6 Sinking and sourcing DC circuit. The switch is the source of the current that
the light sinks to ground
Ø Current flows from the positive terminal of the battery through the switch and onto the light, which
is the load
Ø Figure 7 illustrates the current flows from the positive side of the battery to the light. The light is
then source of the current as it passes it to the switch, which in turn sinks the current to ground
Ø fig 8 illustrate a sourcing input module, the load, with a sinking switch
Ø fig 9 sinking input module. Current flows from the positive side of the battery through the switch,
our sourcing input device. The switch is the source of current to the input module
DC Input Module Operation
Ø Except for the bridge rectifier circuit, the DC input module is very similar to the AC input module

Ø Since the input signal is already DC, no bridge rectifier is necessary. Resistors are used to drop the
incoming voltage before passing the signal on to the remaining electronics

Ø Fig 9 illustrates a simplified block diagram for a DC input module

Ø Typical analog signals comes from

Ø Simply, analog input modules