• Input interface module accept signals from the

machine or process devices and convert them

into signals that can be used by the controller.

• Output interface module convert controller

signals into external signals used by the
control the machine or process.
 I/O section
• Provides an interface between the hardwired
components in the field and the CPU.
• It consists of :
 I/O rack
 Individual I/O modules
 I/O module
• Typical PLC has rooms for several I/O modules.

• Slot in the PLC can hold any type of I/O module.

• Input interface allows status info regarding

processes to be communicate to the CPU and thus
allows the CPU to communicate operating signals
through the Output interface to the process
devices under its control.
Chassis
 Chassis
• The frame or enclosure of a modular PLC.

• It’s the physical hardware assembly that

houses devices such as I/O modules,
processor module and power supply.

• Sizes: 4,8,12,16…slots
• An I/O chassis is a single, compact enclosure
for the processor, power-supply modules,
remote and extended-local I/O adapter
modules, and I/O modules.

• The left-most slot of the I/O chassis is reserved

for the processor or adapter module.
 Rack
• Logical rack is an addressable unit consisting of
128 I/O points and 128 O/P points.

• A rack uses 8 words Input image table and 8

words output image table.

• A word in the output image table file and its

corresponding word in the input image table file
are called an I/O group.
Inptu and Output image table
• Benefit of the PLC system is the ability to locate
the I/O modules near the field devices to
minimize the amount of wiring required.

• Each remote rack requires a unique state number

to distinguish one from others.

• Remote racks are linked to the local rack through

communication module.
Remote I/O
 Communication cable
Fiber optic cables:
• To connect CPU and I/O rack
• Distance grater than 20 miles with no voltage drop.
• It will not pick up noise caused by adjacent high
power lines or equipments in the industry.
Coaxial cable:
• Greater than 20 miles but more susceptible to this
type of noice.
Allen bradley PLC 5 family and SLC 500
addressing format
Slot:
• Physical location of the I/O module.
• Combination of rack number and slot number
when using expansion racks.

Word and bit:

• Used to identify the actual terminal
connection in a particular I/O module
Analog I/O
• The design of a PLC determines whether the
system is capable of being addressed flexibly or
whether it is rigid in its addressing method.

• Flexible addressing schemes allow PLC system

designers to create control logic software
without having to follow a sequential I/O
assignment, resulting in a randomly addressed
and installed I/O system.
• Incase of small PLCs, the system contains one
rack and therefore has I/O addressing fixed by
the manufacturer.

• Addressing labeling various greatly from

manufacturer to manufacturer.
Typical combination I/O module
• I/O module can be placed anywhere in the
rack, but they are normally grouped together
for ease of wiring.

• I/O modules can be 8,16,or 32 point cards.

• Standard I/O module has 8 inputs or outputs.

• High density module may have up to 32 input
or output.
• It have at least 4 common points.
Disadvantage:
It cant handle as much current per output.
 Discrete I/O Modules
• The most common type of I/O interface module is the
discrete type.

• This type of interface connects field input devices of

the ON/OFF nature such as Selector switches,
pushbutton and limit switch.

• Likewise output control is limited to devices such as

lights, small motor, solenoids and motor starters that
require simple ON/OFF switching.
• In this type of input or output, each bit
represents a complete information element in
itself and provides the status of some external
contact or advises of the presence or absence
of power in a process circuit.

• Each discrete I/O module is powered by some

Field-supplied voltage source.
• They receive their module voltage and current
for proper operation from the backplane of
the rack enclosure into which they are
inserted.

• The relatively higher currents required by the

loads of an output module are supplied by
user-supplied power.
 Common ratings for discrete I/O interface
modules.
INPUT INTERFACE OUTPUT INTERFACE
12v ac/dc/24 v ac/dc 12-48 v ac
48 v ac/dc 120 v ac
120 v ac/dc 230 v ac
230 v ac/dc 120 v ac
5 v dc (TTL level) 230 v ac
5v dc (TTL level)
24 v dc
AC discrete input module
AC input module
• When push button is closed, 120 v ac is applied to the
bridge rectifier through resistor R1 and R2.
• Low dc voltage applied across the LED of the optical
isolator.
• Zener diode sets the minimum level of voltage that
can be detected.
• Light from the LED strikes the photo transistor, it
switches into conduction and the status of the push
button is communicated in logic or low level dc
voltage to the processor.
• Optical isolator not only separates the higher
ac input voltage, also prevent damage to the
processor due to line voltage transients.

• It helps reduce the effect of electrical noise,

common in the industrial environment, which
cause erratic operation of the processor.
Typical input module wiring connection
Input module performs 4 tasks:
1. Sense when a signal is received from a sensor
2. Convert the input signal to the correct
voltage level for the particular PLC.
3. Isolate the PLC from fluctuation
4. Send a signal to the processor indicating
which sensor originated the signal.
AC discrete output module
• Triac has low and high resistance levels.
• In it OFF state –HIGH resistance, a small
leakage current of a few milliamperes still
flows through the triac.
• O/P also has LED indicators to indicate the
status.
 ALLEN BRADLEY module
Color TYPE OF I/O

Red AC INPUT/OUTPUT

Blue DC INPUT/OUTPUT

Orange RELAY OUTPUT

Green SPECIALTY MODULE