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Chapter 8
Output Modules
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Objectives (1 of 2)
• Describe the available types of output modules.
• Explain applications where analog output modules would be used.
• Define output module specifications from data sheets.
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Objectives (2 of 2)
• List the advantages and disadvantages of using relay-contact versus solid-state output switching.
• List the advantages and disadvantages of using solid-state versus relay-contact output switching.
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PLC Output Section
• The output section of a PLC system is the physical connection between the processor and the outside world.
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Output Classifications
• Output modules fall into three classifications.– Discrete– Analog– Specialty
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Discrete Outputs
• Motor starter coils
• Pilot lights
• Solenoids
• Alarms
• Valves
• Fans
• Control relays
• Start pushbuttons
• Stop pushbuttons
• Horns
• Start / stop signals to variable speed drives
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Operating Characteristics (1 of 2)
• Discrete output modules are simply switching devices that carry out commands from the processor.
• They receive their operating power from the PLC’s power supply.
• Power output point switches to control field devices are provided by the user.
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Operating Characteristics (2 of 2)
• Each output point contains a switching device, which is located inside the module.
• The switching device is turned on or off according to the bit value residing in that particular output module’s status table address.
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Three Basic Types of Output Modules
• Solid-state (triac) switching for AC loads
• MOSFET for DC loads
• Mechanical relay
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Basic Wiring for a 120 VAC
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Discrete Output Module Output Classifications
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Signal Flow from the CPU
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Block Diagram of a Typical Output Module
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Omron CQM1 Specifications
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Sourcing Output Module Specifications
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Relay Output Modules
• Relay output modules switch small mechanical relays.
• They are also known as contact or dry contact outputs.
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Relay Output Module Usage
• Switching small currents at low voltages
• Multiplex analog signals
• Interface control signals to variable drives
• Switching low voltage circuits where leakage current is a problem
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Simplified Single-Point Relay Output
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Relay Output Module Variations
• Combination input and relay output module
• Isolated relay outputs
• 8 or 16 outputs with shared commons
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Combination 120 VAC Input and Relay Output Module
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8-Point Relay Output Module
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AC Isolated Output Module
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Interposing Relays
• Most output modules switch between one-half and four amps.
• To switch higher current loads, a mechanical relay called an interposing relay is placed between the output point and the load.
• Output module switches the relay.
• Relay switches the load.
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Interposing Relay Switches Load That Exceeds Module Capability
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Choosing the Proper Output Module
• Solid-state versus mechanical output modules?
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Advantages to Solid-state Switching
• Fast switching speeds
• High reliability and almost unlimited life
• Low power to energize
• No contact arcing
• Little to no switching noise
• Positive switching, no contact bounce
• Can be sealed for hostile environments
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Disadvantages to Solid-state Switching
• May be destroyed on overload
• Tend to fail in the ON state
• Heat dissipation
• More expensive than mechanical relays
• Possible false trips from electrical noise
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Advantages to Relay Output Switching
• Contacts forgiving to temporary overload
• Immune to false trips from electrical noise
• Little voltage drop across contacts
• Definite ON or OFF state
• No leakage
• Contacts generate little heat
• Inexpensive
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Disadvantages to Relay Output Switching
• Mechanical switching slow
• Mechanical life limited
• May require up to 50 milliamps to energize
• Subject to contact arcing or welding
• Contact bounce
• Cannot be completely sealed
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Surge Suppression
• Electrical noise and microprocessor equipment do not play well together.
• Electrical noise is generated by many common electrical devices.
• Electrical noise can cause microprocessor devices to malfunction.
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Industrial Noise-generating Devices
• Electrical noise generated by– Motor starters– Relays and contactors– Solenoids– Clutches and brakes– Variable frequency drives
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Noise Reduction
• Surge suppression– MOVs on triac output devices– Diodes on DC output circuits
• Proper grounding and wiring practices– Follow manufacturer recommendations
• Communications cable proper installation– Proper cable selection, wire routing, and
termination
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Analog Output Modules
• They accept a 16-bit output status word, which the module converts to an analog value through a digital-to-analog converter.
• Analog output modules send out a varying current or voltage signal.
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Typical Analog Field Devices
• Temperature
• Pressure
• Position
• Valves
• Variable frequency drives
• Meters
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Typical Analog Outputs
• Analog output signals– 0 to 10 volts DC– -10 to +10 volts DC– 0 to 5 or 1 to 5 volts DC– 4 to 20 milliamps– 0 to 20 milliamps– -20 to +20 milliamps
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Analog Module Configurations
• Analog output information is sent to the field device by way of an output channel.
• Analog modules are– All inputs– All outputs– Combination of input and output channels
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Analog Output Signals Represent Values
• A binary output signal from 0 to 32767 from the output status table could be converted to a 0 to 10 V DC output signal to control an analog field device.
• Analog data format is determined by module and module configuration.
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Local Versus Remote I/O
• Local analog modules in an SLC 500 system automatically receive the binary value from the output status table.
• Remote I/O analog signals require block transfers.
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Analog Input Modules and the Output Status Table
• Each analog channel will be represented by an entire word in the output status table.
• A two-channel analog output module will have two words in the output status table to represent the binary representation of the analog voltage or current.
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Analog Data Is Represented as Whole Word Data
• Analog signals are not digital signals represented as 1s and 0s.
• Analog information is represented as a 16-bit signed integer in the data table.
• Each channel will require one word.
• Data table will reserve one word for each channel.
• This is part of the I/O configuration process.
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Output Word Assignment
• 1746-NO4V is a four-channel analog voltage output module.
• Four words will be assigned to the output status table as part of the I/O configuration.
• Module in slot 4 will have words O:4.0 through O:4.3, one for each channel.
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1746-NO4V Input Status Table Words