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Let's now take a look at how the input circuits of a plc work. This will give us a better understanding of how we should wire them up. Bad
Register things can happen if we wire them up incorrectly!
Typically, dc input modules are available that will work with 5, 12, 24, and 48 volts. Be sure to purchase the one that fits your needs based
upon the input devices you will use.
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We'll first look at how the dc inputs work. DC input modules allow us to connect either PNP (sourcing) or NPN (sinking) transistor type
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devices to them. If we are using a regular switch (i.e. toggle or pushbutton, etc.) we typically don't have to worry about whether we wire it as
Your email NPN or PNP. We should note that most PLCs won't let us mix NPN and PNP devices on the same module. When we are using a sensor
Friends (photo-eye, prox, etc.) we do, however, have to worry about its output configuration. Always verify whether it's PNP or NPN. (Check with
name the manufacturer when unsure)
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email The difference between the two types is whether the load (in our case, the plc is the load) is switched to ground or positive voltage. An NPN
type sensor has the load switched to ground whereas a PNP device has the load switched to positive voltage.
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Below is what the outputs look like for NPN and PNP sensors.

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On the NPN sensor we connect one output to the PLCs input and the other output to the power supply ground. If the sensor is not powered
from the same supply as the plc, we should connect both grounds together. NPN sensors are most commonly used in North America.
Many engineers will say that PNP is better (i.e. safer) because the load is switched to ground, but whatever works for you is best. Just
remember to plan for the worst.
On the PNP sensor we connect one output to positive voltage and the other output to the PLCs input. If the sensor is not powered from the
same supply as the plc, we should connect both V+'s together. PNP sensors are most commonly used in Europe.

Inside the sensor, the transistor is just acting as a switch. The sensors internal circuit tells the output transistor to turn on when a target is
present. The transistor then closes the circuit between the 2 connections shown above. (V+ and plc input).

The only things accessible to the user are the terminals labeled COMMON, INPUT 0000, INPUT 0001, INPUTxxxx... The common terminal

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either gets connected to V+ or ground. Where it's connected depends upon the type of sensor used. When using an NPN sensor this
terminal is connected to V+. When using a PNP sensor this terminal is connected to 0V (ground).
A common switch (i.e. limit switch, pushbutton, toggle, etc.) would be connected to the inputs in a similar fashion. One side of the switch
would be connected directly to V+. The other end goes to the plc input terminal. This assumes the common terminal is connected to 0V
(ground). If the common is connected to V+ then simply connect one end of the switch to 0V (ground) and the other end to the plc input
terminal.

The photocouplers are used to isolate the PLCs internal circuit from the inputs. This eliminates the chance of any electrical noise entering the
internal circuitry. They work by converting the electrical input signal to light and then by converting the light back to an electrical signal to be
processed by the internal circuit.

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Now that we understand how dc inputs work, let's take a close look at ac inputs. An ac voltage is non-polarized. Put simply, this means that
Register there is no positive or negative to "worry about". However, ac voltage can be quite dangerous to work with if we are careless. (Remember
when you stuck the knife in the toaster and got a shock? Be careful) Typically, ac input modules are available that will work with 24, 48,
110, and 220 volts. Be sure to purchase the one that fits your needs based upon the input devices (voltage) you will use.

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name OUCH... use care!!
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Find It AC input modules are less common these days than dc input modules. The reason being that today's sensors typically have transistor
outputs. A transistor will not work with an ac voltage. Most commonly, the ac voltage is being switched through a limit switch or other switch
type. If your application is using a sensor it probably is operating on a dc voltage.

We typically connect an ac device to our input module as shown above. Commonly the ac "hot" wire is connected to the switch while the
"neutral" goes to the plc common. The ac ground (3rd wire where applicable) should be connected to the frame ground terminal of the plc.(not
shown) As is true with dc, ac connections are typically color coded so that the individual wiring the device knows which wire is which. This
coding varies from country to country but in the US is commonly white (neutral), black (hot) and green (3rd wire ground when applicable).
Outside the US it's commonly coded as brown (hot), blue (neutral) and green with a yellow stripe (3rd wire ground where applicable).
The PLCs ac input module circuit typically looks like this:

The only things accessible to the user are the terminals labeled COMMON, INPUT 0000, INPUTxxxx... The common terminal gets connected
to the neutral wire.
A common switch (i.e. limit switch, pushbutton, toggle, etc.) would be connected to the input terminals directly. One side of the switch would
be connected directly to INPUT XXX. The other end goes to the ac hot wire. This assumes the common terminal is connected to neutral.
Always check the manufacturers specifications before wiring, to be sure AND SAFE.
The photocouplers are used to isolate the PLCs internal circuit from the inputs. This eliminates the chance of any electrical noise entering the
internal circuitry. They work by converting the electrical input signal to light and then by converting the light back to an electrical signal to be
processed by the internal circuit.

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One last note, typically an ac input takes longer than a dc input for the plc to see. In most cases it doesn't matter to the programmer
because an ac input device is typically a mechanical switch and mechanical devices are slowwwwww. It's quite common for a plc to require
that the input be on for 25 or more milliseconds before it's seen. This delay is required because of the filtering which is needed by the plc
internal circuit. Remember that the plc internal circuit typically works with 5 or less volts dc.

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By now we should have a good understanding of how the inputs are used. Next up is the output circuits.
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One of the most common types of outputs available is the relay output. A relay can be used with both AC and DC loads. A load is simply a
fancy word for whatever is connected to our outputs. We call it a load because we are "loading the output" with something. If we connected
no load to the output (i.e. just connect it directly to a power supply) we would certainly damage the outputs. This would be similar to replacing
this site to a friend the lightbulb in the lamp you're using to read this with a piece of wire. If you did this, the lamp would draw a tremendous amount of current
from the outlet and certainly pop your circuit breaker or blow your fuse or your brains. (Take our word. Please don't try it! Extremely
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dangerous!)
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Friends Some common forms of a load are a solenoid, lamp, motor, etc. These "loads" come in all sizes. Electrical sizes, that is. Always check the
name specifications of your load before connecting it to the plc output. You always want to make sure that the maximum current it will consume is
Friends within the specifications of the plc output. If it is not within the specifications (i.e. draws too much current) it will probably damage the output.
email When in doubt, double check with the manufacturer to see if it can be connected without potential damage.
Send It Now Some types of loads are very deceiving. These deceiving loads are called "inductive loads". These have a tendency to deliver a "back
current" when they turn on. This back current is like a voltage spike coming through the system.
A good example of an inductive load that most of us see about 6 months per year is an air conditioning unit. Perhaps in your home you have
Find It an air conditioner. (unless you live in the arctic you probably do!) Have you ever noticed that when the air conditioner "kicks on" the lights dim
for a second or two. Then they return to their normal brightness. This is because when the air conditioner turns on it tries to draw a lot of
current through your wiring system. After this initial "kick" it requires less current and the lights go back to normal. This could be dangerous
to your PLCs output relays. It can be estimated that this kick is about 30 times the rated current of the load. Typically a diode, varistor, or
other "snubber" circuit should be used to help combat any damage to the relay. Enough said. Let's see how we can use these outputs in the
"real plc world".

Shown above is a typical method of connecting our outputs to the plc relays. Although our diagram shows the output connected to an AC
supply, DC can be used as well. A relay is non-polarized and typically it can switch either AC or DC. Here the common is connected to one
end of our power supply and the other end of the supply is connected to the load. The other half of our load gets connected to the actual plc
output you have designated within your ladder program.

The relay is internal to the plc. Its circuit diagram typically looks like that shown above. When our ladder diagram tells the output to turn on,
the plc will internally apply a voltage to the relay coil. This voltage will allow the proper contact to close. When the contact closes, an external
current is allowed to flow through our external circuit. When the ladder diagram tells the plc to turn off the output, it will simply remove the
voltage from the internal circuit thereby enabling the output contact to release. Our load will than have an open circuit and will therefore be off.
Simple, isn't it?
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 Try our online PLC Simulator- FREE. Click here now to try it.
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The next type of output we should learn about is our transistor type outputs. It is important to note that a transistor can only switch a dc
Register current. For this reason it cannot be used with an AC voltage.
We can think of a transistor as a solid-state switch. Or more simply put, an electrical switch. A small current applied to the transistors
"base" (i.e. input) lets us switch a much larger current through its output. The plc applies a small current to the transistor base and the
this site to a friend transistor output "closes". When it's closed, the device connected to the plc output will be turned on. The above is a very simple explanation
of a transistor. There are, of course, more details involved but we don't need to get too deep.
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Your email We should also keep in mind that as we saw before with the input circuits, there are generally more than one type of transistor available.
Friends Typically a plc will have either NPN or PNP type outputs. The "physical" type of transistor used also varies from manufacturer to
name manufacturer. Some of the common types available are BJT and MOSFET. A BJT type (Bipolar Junction Transistor) often has less switching
Friends capacity (i.e. it can switch less current) than a MOS-FET (Metal Oxide Semiconductor- Field Effect Transistor) type. The BJT also has a
email slightly faster switching time. Once again, please check the output specifications of the particular plc you are going to use. Never exceed the
manufacturers maximum switching current.
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Shown above is how we typically connect our output device to the transistor output. Please note that this is an NPN type transistor. If it
were a PNP type, the common terminal would most likely be connected to V+ and V- would connect to one end of our load. Note that since
this is a DC type output we must always observe proper polarity for the output. One end of the load is connected directly to V+ as shown
above.
Let's take a moment and see what happens inside the output circuit. Shown below is a typical output circuit diagram for an NPN type output.

Notice that as we saw with the transistor type inputs, there is a photocoupler isolating the "real world" from the internal circuit. When the
ladder diagram calls for it, the internal circuit turns on the photocoupler by applying a small voltage to the LED side of the photocoupler. This
makes the LED emit light and the receiving part of the photocoupler will see it and allow current to flow. This small current will turn on the
base of the output transistor connected to output 0500. Therefore, whatever is connected between COM and 0500 will turn on. When the
ladder tells 0500 to turn off, the LED will stop emitting light and hence the output transistor connected between 0500 and COM will turn off.

One other important thing to note is that a transistor typically cannot switch as large a load as a relay. Check the manufacturers
specifications to find the largest load it can safely switch. If the load current you need to switch exceeds the specification of the output, you
can connect the plc output to an external relay. Then connect the relay to the large load. You may be thinking, "why not just use a relay in the
first place"? The answer is because a relay is not always the correct choice for every output. A transistor gives you the opportunity to use
external relays when and only when necessary.

In summary, a transistor is fast, switches a small current, has a long lifetime and works with dc only. Whereas a relay is slow, can switch a
large current, has a shorter lifetime and works with ac or dc. Select the appropriate one based upon your actual application needs.
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