Overview

The Programmable Logic Controller (PLC) is the

workhorse of Industrial Control systems. It uses
digital and analog I/O modules to interface to
sensors, actuators and other equipment. These I/O
modules must meet stringent electrical
specications and designers face challenges in
condi tioning and converting these signals. In
addition, increasing levels of embedded
processing and connectivity can be seen on these
modules. Variations of the PLC include the
Programmable Automation Controller (PAC) which
has more integration and processing functions to
tackle more complex operations and the
Distributed Control System (DCS) which is used
extensively in process control. The DCS uses
distributed controllers, each performing a specic
task, connected together by networks for
communication and monitoring. A central control
room is typically used for an entire plant.
The PLC System
PLCs can be segmented by I/O count and scan
rates. They can also be classied as brick type
versus modular PLCs. A small or brick PLC has a
xed number of connections for inputs and
outputs. Modular PLCs have a chassis (also called
a rack) into which are placed modules with
different functions. The processor and selection of
I/O modules is customized to t the application. A
modular PLC consists of the Central Processing
Unit (CPU), a power supply and various I/O
modules. The CPU performs the main controller
functions like scanning data and running control
sequences. The power supply unit converts line
power to 24 volts. The I/O modules are used to
measure data from sensors and to control various
actuators. Together, the input and output modules
along with the central controller form a control loop.
I/O Module Types
I/O modules can be classied as analog input (AI),
analog output (AO), digital input (DI) and digital
output (DO). They are usually cate go rized into 2-,
4-, 8- and 16-channel modules. I/O modules need
to meet stringent electrical specications such as
the IEC 61000-4 family of Electro Magnetic
Compatibility (EMC) tests for surge, ESD (Electro-
static Discharge) and EFT (Electrically Fast
Transients). They also need short-circuit and over-
load protection. All these modules include isolation
between the control side and the eld side via
DC-DC converters and isolation on digital commu-
nication between the eld devices and the digital
backplane. Communication over the digital back-
plane is done by a variety of interfaces (RS-485,
CAN, Ethernet, etc.) and industrial eldbuses
(PROFIBUS

, DeviceNet, CANopen

, Modbus,
EtherCAT

, Ethernet I/P, PROFINET

, SERCOS,
POWERLINK, etc.). On the following pages we
discuss solutions from TI for these various I/O types.
I/O
Modules
Power
Supply
Module
CPU
Includes backup
power
220/110 Volt
Prop. digital bus
24-Volt
power bus
4 to 64 channels
is typical
Can be
integrated
with CPU
Multi-
Channel
Analog
In
Multi-
Channel
Analog
Out
Multi-
Channel
Digital
In
Comm.
Module
(Fieldbus,
Ethernet)
Industrial Automation Solutions
Programmable Logic Control (PLC)
TIs PLC system solutions speed the design cycle with the
right devices, software, tools and support.
www.ti.com/automation
2H 2012
Analog input modules capture and measure signals
such as temperature, pressure, ow, level, vibration
and motion. These parameters are transmitted from
equipment such as sensors and other eld devices
on the factory oor in the form of current or voltage.
Current loops typically range from 420 mA while
voltage inputs can be single ended or differential
ranging from 05V, 010V, 5V and 10V.
The system accuracy is determined by the
Analog to Digital Converter (ADC) resolution with
thermocouple applications needing up to 24 bits.
Delta sigma ADCs are a good choice with some
products having a built-in PGA and MUX. Some
products also offer ratio-metric measurement with
built-in current sources for RTD excitation and
voltage biases for ungrounded thermocouples.
Slow changing variables like temperature,
pressure, level and ow need lower sampling
rates (up to 2 kSPS) while other applications
and systems with higher channel counts need
larger sampling speeds (several 100 kSPS). SAR
ADCs are a good choice for these applications.
Simultaneous sampling architectures are used
for modules used in condition monitoring, motion
control and power automation.
Signal conditioning considerations include
high-input impedance when interfacing to sensors
with low-source impedance which is achieved
with input buffers and instrumentation ampliers
(INA). Other considerations are large common-
mode voltage range and common-mode rejection
of interference from motors, AC power lines and
other sources which inject noise on the analog
inputs. Since the inputs could be signals from
thermocouples and other low-level sensors, low
offset voltages as well as minimal drift of the
offset voltage over temperature is needed to
maintain accuracy. Precision bipolar op amps are
used extensively. Differential amps can be used
when the common mode range is greater than
the power supply rails. Finally, Programmable
Gain Ampliers (PGA) can be used when the input
voltage range can vary over multiple sensor types.
www.ti.com/automation
DC/DC Converter Isolated Power DC/DC Converter
24 V
Communication
Fieldbus IN
Electrical Isolation
Field Side Control Backplane
Isolated Power
Power Management: Exists on
All Modules
Group Isolated Analog Input Module
Digital
Isolation
Digital
Isolation
Controller Interface
Memory
AMP
AMP
Buffer
HART
ADC MUX
Protection
Protection
VREF
V+
Temp
Flow
Optical
Pressure
Level

+
PLC: Analog Inputs
Design Considerations
Digital input modules capture and measure digital
input signals from a wide variety of sensors like
proximity switches, limit switches and push
button switches. Inputs typically are 024V with
tolerances up to 30V. The signals from DC sensors
used in PLC digital input (DI) modules are typically
of a higher voltage and are usually isolated
through optocouplers before going into a shift
register to be serialized. Instead, digital input
serializers can be used to serialize a large number
of digital inputs allowing higher channel densities
in PLC I/O modules. The isolation is then limited to
the SPI interface as a number of serializers can be
daisy chained. They also provide the benet of
sensing higher voltages, adjustable current limits
and programmable de-bounce times. Other
functions that are integrated into these products
are temperature sensing and voltage regulation.
TI solutions for Digital I/O
SN65HVS880 18V 30V industrial
8-channel digital input serializer
SN65HVS881 10V 34V industrial
8-channel digital input serializer with parity
PLC: Digital I/O
LEGEND Logic
ADC/DAC
Clocks
Other
Power
RF/IF
Processor
Interface
Amplifier
0 24 V
24V
DC/DC Converter
Digital
Input
Serializer
Protection
Protection
Protection
Protection
Isolated Power
24 V
DC/DC Converter
Electrical Isolation
Field Side Control Backplane
24 V
Digital
Isolation
Controller Interface
Field Inputs
FromSensors
Communication
Fieldbus IN
Communication
Fieldbus OUT
Memory
TI signal chain solutions for
analog inputs
ADS1248 (temperature measurement and
universal inputs)
4 differential or 7 single-ended inputs, 24-
bit, single-cycle settling
Low-noise PGA, temperature sensor,
burnout detection
50-/60-Hz simultaneous rejection,
up to 2kSPS
Dual matched current sources for
RTD excitation
PGA280 + ADS1259
Zero drift high-voltage PGA + low-noise,
24-bit, 14-kSPS ADC
Input signals from 10s of mV to 15V
Allows input signal diagnostics
OPA2188 36-V zero-drift, rail-to-rail
precision op amp
OPA211 1.1-nV/Hz

36-V, low power,

precision op amp
OPA320 20-MHz, 0.9-pA, I
b
precision op amp
ADS8319 16-bit, 500-ksps precision SAR ADC
LMP7721 Ultra-low-bias current 3fA op amp
LMP90100 24-bit ADC + chopper
stabilized PGA 1:128
LMP8671/2 2.5-nV/Hz

40V precision op amp

Design Considerations
Analog output modules are used to drive and con-
trol actuators and other machines to form part of
an overall control system. Current-loop outputs
typically range from 420 mA while voltage
outputs range from 05V, 010V, 5V and 10V.
The linearity, settling time, response and
accuracy is determined by the DAC used. Resistor
string-based DACs are small, inexpensive and
inherently monotonic. For higher resolution and for
applications requiring higher linearity like open-
loop valve control, R-2R DACs are a good choice.
Finally, for achieving the fastest settling times and
speeds, R-2R multiplying DACs should be used.
Selecting the right reference and pairing it with
the right buffer can impact system performance.
Considerations for references include initial tem-
perature drift and source/sink current capability.
The output must be picked based on speed,
output voltage level and power. TIs XTR industrial
drivers are excellent for implementing 420 mA
current loops. Some products allow the designer
to make the output programmable to be either
a voltage or current. Newer products integrate
the DAC and XTR to minimize board space and
optimize power.
TI signal chain solutions
DAC8718 family
16-/14-/12-bit family of 8-channel bipolar
16.5V DACs
Wide voltage range of 16.5V with up to
6 gain eliminates need for external gain
circuitry
10-s settling time, 4 nV-s glitch energy
12- and 14-bit serial and parallel options
provide exible upgrade / downgrade path
DAC8562 family
16-/14-/12-bit family of dual-channel,
low-power and low-voltage DACs
Integrated precision reference (4 ppm/C
drift), ultra-small package (33 mm)
Wide temperature range (-40C to 125C)
XTR300
Industrial analog current/voltage output
driver
User-selectable: voltage or current output
Design exibility
Separate driver and receiver channels
Digital output selection, error ags, and
monitor pins
OPA140 11-MHz, precision, low-noise, RRO,
JFET op amp
REF5020 + OPA365 precision voltage
reference + high-speed, single-supply rail-
to-rail op amp
DAC161S055 16-bit rail-to-rail output DAC
with external voltage reference
DRV110 current driver for solenoid loads
PLC: Analog Outputs
Isolated Power
DC/DC Converter Isolated Power DC/DC Converter
24 V
Communication
Fieldbus IN
Electrical Isolation
Field Side Control Backplane
Power Management: Exists on
All Modules
Group Isolated Analog Output Module
Digital
Isolation
Digital
Isolation
Controller Interface
Memory
AMP
AMP
Buffer
HART
DAC
Protection
Protection
ffer
AMP Protection
VREF
To Field Acutators
I/V Driver
420 mA
Voltage Driver
05 V, 010 V, 5 V, 10 V
Current Driver
05 V, 010 V, 5 V, 10 V
420 mA
Interface
There are a number of eldbus options both
serial (RS-485, DeviceNet, PROFIBUS

, CAN,
etc.) and Ethernet based. Extended cable reach
and diagnostics to debug wire breaks provides
system designers signicant value. Integrated
digital isolation on the interface transceivers is
highly desirable to reduce board space. In
addition, the interface between the DAC and the
controller can be digitally isolated either by using
optocouplers or TI isolators built with capacitive
technology.
PLC: Connectivity
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Intelligent
Sensors & Actuators
Sensor
Sensor
Sensor Sensor
Actuator
Actuator
PLC
HMI
CNC, Machine
Vision, Others
DCS/SCADA
PLC
PLC
PLC/PAC
Comm
Module
Comm
Module
Comm
Module
Comm
Module
Sensors & Actuators
Digital/Analog
Data
Acquistion
RTU
Drives
Gateway
Wireless
Sensors
420 mA
HART,
IO-Link,
RS-485
IEEE
802.15.4
IEEE
802.11
Industrial Ethernet, RS-485,
CAN, Other Fieldbuses
Ethernet
Actuator
PC
Network
Automation
Server
Comm
Module
TI interface products for PLC
ISO1176/76T (isolated RS-485 PROFIBUS
transceiver): Reduced components and board
space; Life span > 25 years @ 125C; Hot
pluggable without data corruption
TLK105/TLK106/TLK110 (10/100 industrial
Ethernet PHY): Low and deterministic latency
for real time; Extended cable reach (up to
150 m); Cable diagnostics (TLK106/TLK110);
32-pin QFN packages (TLK105/TLK106)
ISO1050 (isolated CAN transceiver): Inte-
grated CAN and isolation for easy system
integration; Reduced loop time improves
timing margin; Lower power than optocouplers
ISO7420E/20FE (low-power dual-channel,
digital isolator): Signaling rate above 50 Mbps;
Low propagation delay: 7 ns; Low power
consumption: 2.5 mA per ch @ 25 Mbps
SN65HVD255/6/7 (Turbo CAN transceiver):
Fast loop times with up to 2-Mbps data rate;
Next generation for HVD251 and HVD1050;
Special features: I/O level shifting (HVD256);
bus redundancy (HVD257)
www.ti.com/automation
Processor
To support the processor, development platforms
and software tools in addition to support which
quickens time to market are highly desired.
Connectivity options ranging from Ethernet ports to
UARTs to simple SPI ports are required. Ethernet
enables integration of eld devices to the
corporate enterprise network. Most industrial
control applications need simple, low-cost PLCs
with lots of digital I/O and integrated functions.
These include fault diagnostics, watch dog timers,
low power, multiple SPI ports, UARTs, integrated
analog peripherals like ADCs and PWM outputs
which perform similar functions to DACs. MCUs
(Micro Controller Units) are a good choice for
these applications. For applications which push
capabilities and need higher loop rates along with
advanced control algorithms to handle multiple
functional domains like logic, PID control and
motion, higher-performance MPUs (Micro
Processing Units) are needed. TI provides
solutions to address all these needs.
TI processors for PLC
Sitara AM335x ARM Cortex-A8 Processor
Multiple industrial communication
standards integrated with application
processor
Two development tool options:
$99 USD Industrial Communications
Engine (ICE); $895 USD Industrial
Development Kit (IDK)
Robust software options including:
SYS/BIOS real-time kernel and
application stacks for industrial
communication standards
Includes parts listed to the left
PLC: Processor
Description Device Series Key Benefits
Sitara ARM

Cortex-A8
processors with integrated
industrial communications
support
AM335x
AM3517
Integrated industrial communications support
including: EtherCAT

, PROFIBUS

, Ethernet/IP,
PROFINET

, POWERLINK, SERCOS-III, CANOpen

,
and more, with scalable performance
TMS570 ARM Cortex-R4F-based
microcontroller for safety-critical
applications up to 160 MHz and
2-MB Flash
TMS570LS2x Support for safety-critical applications up to
IEC 61508 SIL-3
Three integrated CAN controllers
Powerful Cortex-R4F oating-point CPU
Up to 2 MB of integrated Flash memory
RM4x ARM Cortex-R4-based
microcontroller for safety-critical
applications up to 220 MHz and
3-MB Flash
RM42x
RM46x
RM48x
Support for safety-critical applications up to
IEC 61508 SIL-3
Three integrated CAN controllers
Powerful Cortex-R4 CPU
From 384 KB up to 3 MB of integrated Flash
memory
MSP430 16-bit ultra-low-
power microcontroller family. Up
to 25 MHz, 0.5-kB 512-kB NVM
MSP430F2xxx / F4xxx
MSP430F5xxx / F6xxx
MSP430FR57xx
10 24-bit ADC / op amps / DACs
Fast / ULP FRAM non-volatile memory
Low-cost, easy-to-use tools
Stellaris

ARM Cortex-M4F-
based MCUs up to 80 MHz and
256-kB Flash
LM4Fx Up to 120 GPIOs that can drive over 600 mA
Up to 8 UARTs, 4 SPI, and 6 I
2
C
Two integrated CAN controllers and USB OTG
C2000 32-bit real-time MCUs
up to 300 MHz, including dual-
core C28x + ARM Cortex-M3
devices with up to 1.5 MB of
Flash
Delno oating-
point series
Concerto oating-
point C28x + ARM
Cortex-M3
IEC61131-3 programming with CoDeSys
Integrated real-time control peripherals coupled
with integrated communications interfaces
Support for Power Line Communications
standards
www.ti.com/automation
Power
To protect against transients and ground loops,
the eld side which interfaces to sensors is
electrically isolated from the control side. This is
done on a per channel basis or by isolating groups
of channels from each other and from the control
side. The design can be customized for perfor-
mance and cost by using a DC-DC converter and
discrete components or pre-built isolated DC-DC
converter modules can be used. Other consider-
ations include high efciency and integration
along with smaller packages. Picking a DC-DC
converter with a large input range will protect
against supply transients. Finally, using LDOs with
good PSRR (power supply rejection ratio) to supply
the precision analog circuitry will reduce the
power supply ripple and preserve system
accuracy and resolution.
PLC: Power
TI power management for PLC
Description Device Series Key Benefits
3.5-V to 60-V input,
0.5/1.5/2.5/3.5-A,
DC-DC converters
TPS54060A/
160A/260/
360
12-/24/48-V support plus transients
Small size and low I
Q
Refer to PMP5863
50-mA / 200-mA 4.7-V to 60-V
synchronous step-down converters
TPS54062/1 Very small size; very low I
Q
High efciency, synchronous solution
150-mA, LDO reg., ultra-low-
power, I
Q
500-nA with pin-select-
able, dual-level output voltage
TPS78001 Low I
Q
: 500nA
150-mA, Low-dropout regulator with pin-selectable
dual-voltage level output
2-W, 3.3/5-Vin isolated DC/DC
converter
TPS55010 No optocoupler required
Primary side feedback allows input/output voltage
combinations with the same transformer
36-V, 150-mA high voltage,
ultra-low-noise LDOs
TPS7A4901/
TPS7A30xx
Stable with 2.2-F ceramic capacitor
Low noise with 15.4 V
rms
and 72-dB PSRR
Reduces noise from switchers generating Vout
Dual, 500-mA low-dropout regula-
tors and triple voltage rail monitor
TPS75005 Optimized to supply TIs C2000 MCU series:
F2833x (Delno), F2823x, F281x, and
F280x/F2801x
Window comparator for over and
under voltage detection
TPS3700 Wide supply voltage range: 1.8 V to 18 V
Adjustable threshold: Down to 400 mV
Open-drain outputs for over- and under-voltage
detection
+3-V to +36-V input, 1-A low
noise (4 V
RMS
), high PRSS, low
drop-out linear regulator
TPS7A4700 Input voltage range: +3 V to +36 V
Output voltage noise: 4.17 V
RMS
(10 Hz to 100 kHz)
Power supply ripple rejection: 82 dB (100 Hz),
55 dB (10 Hz to 10 MHz)
3-V to 36-V input, 1-A low
noise, high PRSS, low drop-out
linear regulator
TPS7A3301 Input voltage range: 3 V to 36 V
Output voltage noise: 16 V
RMS
(10 Hz to 100 kHz)
Power-supply ripple rejection: 72 dB (10 kHz)
High-power/high-efciency
Power-over-Ethernet PD solution
TPS2378/9
TPS23751/2/4
Integrates PoE interface and DC-DC controller
25-W operation, high efciency
Robust process to withstand surges and
over-currents
4.5 to 40-V input, 15-W negative
output voltage power module
TPS84259 Small 9112.8-mm QFN package
Meets Class B radiated emissions
Frequency synchronization
7-V to 50-V input, 2.5-A step-
down power module
TPS84250 Small 9112.8-mm QFN package
Meets Class B radiated emissions
Frequency synchronization
17-V supply, 1-A step-down con-
verter, DCS-Control topolo gy,
pin-selectable frequency, adj.
soft-start, power good
TPS62150 Small solution footprint (80 mm
2
)
High efciency across entire load range
Fast AC line and load transient response
28-V supply, 0.5-A step-down
converter with SNOOZE mode,
DCS-Control topology, power good
TPS62175 Ideal for powering Stellaris

processors
High efciency across entire load range
Small total solution footprint (<60 mm
2
)
100-V, 600-mA synchronous step-
down regulator with integrated
high-side and low-side MOSFETs
LM5017 Wide 9-V to 100-V input range
Integrated 100-V, high- and low-side switches
Constant on-time control
4.5-V52-V PWM controller for
isolated yback, boost or SEPIC
TPS40210 Small MSOP10 or SON10 (33-mm) packages
Choose MOSFET to optimize performance
Refer to PMP4626
Precision current limiter LMP8646 Provides circuit protection and current limit
Supports any switching or linear regulator with an
available feedback node
Simple design with adjustable gain and bandwidth
SLYB180A
Visit for Industrial Automation solutions from TI www.ti.com/automation
TI offers best-in-class analog and embedded processing semiconductor solutions includ ing precision
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These solutions are comple mented by TIs software, design tools, reference designs and support,
which simplify and accelerate design cycles. As the worlds largest industrial semiconductor
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B090712
Important Notice: The products and services of Texas Instruments
Incorporated and its subsidiaries described herein are sold subject to TIs
standard terms and conditions of sale. Customers are advised to obtain
the most current and complete information about TI products and services
before placing orders. TI assumes no liability for applications assistance,
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2012 Texas Instruments Incorporated
Printed in U.S.A. by (Printer, City, State)
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