Chapter 4: Input/Output Modules and Installation

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Input/Output Modules
Learning objectives

Understand

Wiring of typical sensors and actuators to PLC I/O modules Surge protection for certain types of devices Typical control cabinet layout Typical installation wiring

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Input/Output Modules
Overview

Input/Output (I/O) Modules provide Physical Interface between

PLC Processor and Field Devices:

Switches, Lamps Valves etc

Common Characteristics of I/O Modules

Removable Terminal Blocks (Retractable)

Wiring is connected to the terminal block T Terminal i l block bl k is i plugged l d into i t the th module d l Isolates field wiring from the PLC internal circuitry

Isolation

PLC power supply provides low-voltage power unlike a typical field wiring

Diagnostic Indicators

Discrete Input modules display an indicator for each input channel that is on Discrete Output modules display an indicator for each output channel that is on o

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Input/Output Modules
Isolation between I/O and PLC
Isolation Barrier
L1 (Line) Fuse L1 (Line) (Li )

PLC Processor Power S l Supply

Output Device Neutral

Neutral

Input Module
L1

Output Module
Neutral

I/O modules provide isolation between field wiring and PLC internal circuitry:

Ground loops Noisy electrical signals Fault on I/O wiring

Isolation prevents events from interfering with the PLC and causing a module failure

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Input/Output Modules
Sinking & Sourcing

What is Sinking g and Sourcing? g

The flow of current (power) when the I/O device is active

An Output Device is designated as Sourcing if current flows OUT when the output device is active An Output Device is designated as Sinking if current flows IN when the output device is active

Computer Aided Manufacturing TECH 4/53350

Input/Output Modules
Sinking & Sourcing

What is Sinking g and Sourcing? g

The flow of current (power) when the I/O device is active

An Input Device is designated as Sourcing if current flows OUT when the output device is active An Input Device is designated as Sinking if current flows IN when the output device is active

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Input/Output Modules
Sinking & Sourcing
A Sourcing field Sensor is usually connected t d to t a PLC input i t why? h ?

Sourcing Field Sensor

Current

Sinking PLC Input

Sinking Field Sensor

Current

Sourcing PLC Input

Sourcing PLC Output

Current

Sinking Field Device

Sinking PLC Output

Current

Sourcing Field D i Device

Arrows indicate the direction of the current flow

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Input/Output Modules
Focus Primarily concern with sinking PLC inputs and sourcing PLC outputs t t since i th that t is i th the majority j it of ft types of f connections.

Note that most discrete sensors can be purchased in either a sinking or sourcing configuration. Make sure you specify if th the correct t one!! !!

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Discrete Input Modules

A Discrete Input module senses status of devices with only two states on/off, on/off open/closed, open/closed running/stopped

Types of discrete inputs

Switches - many kinds Pushbutton Li it Limit Level Proximity R l contacts Relay t t

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Discrete Input Modules Standard Discrete Input Voltages 120 v AC/DC (can ( handle h dl either) ith ) 220 v AC/DC 10 - 30 v DC 10 - 30 v AC 20 - 60 v DC

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Discrete Input Modules

Discrete Input p Module Block Diagram g

Powered from the field

Powered from PLC

Threshold detector

Senses when input device is on When input device voltage > minimum-on-state voltage devised is sensed to be on When device voltage < maximum-off state voltage devised is sensed to be off

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Discrete Input Modules

Discrete Input Module Block Diagram

Powered from the field

Powered from PLC

Optical Isolator

Provides electrical isolation between field wiring and the PLC internal circuitry

Light-Emitting Diode & Photoelectric transistor S it h Cl Switch Closed d Current C t flow fl th through h LED Generates G t Light Li ht Light Li ht T Triggers i current t fl flow th thru Photoelectric Ph t l t i transistor Sensed by PLC digital logic

Circuitry to the LHS of isolator powered from the field Circuitry to the RHS powered from internal PLC voltage source

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Discrete Input Modules

Discrete Input Module Block Diagram

P Powered d from f the th field fi ld

P Powered d from f PLC

Noise and Dist Disturbance rbance

Capacitors and Resistors are typically used to form simple noise filter

B id Rectifier Bridge R tifi

Converts AC to full-wave rectified DC

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Discrete Input Modules AC Inputs

L1 (Line)
I/O Module Term. Strip

L2 (Load)

Black (120 VAC)

White (120 VAC)

Com
Some modules need this connection for balancing

AC Inputs

Power flows into the Input Module when the field device is on

Hence the Input Module is characterized as a Sinking Module

There is a least one common per module. Some modules have a common for every 4 input channels Why would you need more than one common?

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Discrete Output Modules

Discrete Output Modules:

Used to turn real-world output deices either on or off Can be used to control any two state device Available in AC and DC versions Available in various voltage ranges and current capabilities

Examples of Discrete Devices Controlled by PLC

Indicator Lamps, Alarm Lamps Motor Starters, , Electric Valves, , Electric Fans Control Relays, Heater Relay

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Discrete Output Modules

Standard Discrete Output p Voltages g

120 v AC 220 v AC 12 - 48 v AC 120 v DC 220 v DC 12 - 48 v DC

AC Di Discrete t Output O t t Modules M d l handle h dl only l Ac A Signals Si l DC Discrete Output Modules handle only DC Signals Relay output Modules handle both Ac and DC signals

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Discrete Output Modules Block Diagram

Optical Isolator

Provides electrical isolation between PLC and internal circuitry and field wiring Circuitry on LHS of Optical Isolator powered by internal PLC voltage Circuitry on RHS of Optical Isolator powered from the field

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Discrete Output Modules AC Outputs

L1 (Line)
I/O Module Term. Strip

L2 (Load)

Common

AC Signals

Output Modules that handle Ac signals are Sourcing Modules

Power flows out of the Module when the Switch (Triac ) is ON

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Input/Output Modules Wi i Wiring

Best to sketch the diagram g on a p piece of p paper p before wiring

Easier to visualize the whole picture Start the sketch with one input first

S Suppose you h have many i inputs t t to wire? i ?

If you figure out the first, the rest will follow

Next simply add second input third input etc

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Input/Output Modules Si ki I Sinking Input M Module d l Wi Wiring i

Suppose:
One Input Power Supply Wiring Terminals Input 0 Input 1 Input 2 Input 3 Common

Wire this simple circuit

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Input/Output Modules Wi i i Wiring in a Si Simple l Ci Circuit i

Input 0 I Input t1 Input 2 Input 3 Common

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Input/Output Modules Wi i Addi Wiring Additional i l Input I D Device i

Input 0 I Input t1 Input 2 Input 3 Common

Wiring an additional input device

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Input/Output Modules Wi i three-wire Wiring h i Sensor S

Connect 3-wire sourcing g sensor

OUT TPUT

Sourcing Sensor output is positive

Sourcing g Sensor

Input 0 Input 1 Input 2 Input 3 Common

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Input/Output Modules Th Three-wire i Sensor S Wi Wiring i

Complete Wired Circuit OUT TPUT

Sou c g Sourcing Sensor Input 0 Input 1 Input 2 Input 3 Common

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