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OverviewThe 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 speci cations 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 speci c task,
connected together by networks for communication and monitoring. A
central control room is typically used for an entire plant.
The PLC SystemPLCs can be segmented by I/O count and scan rates.
They can also be classi ed 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 TypesI/O modules can be classi ed 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 speci
cations 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
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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 ampli ers (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 Ampli ers (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 VCommunication
Fieldbus IN
Electrical Isolation
Field Side Control Backplane
Isolated Power
Power Management: Exists onAll Modules
Group Isolated Analog Input Module
DigitalIsolation
DigitalIsolation
Controller Interface
Memory
AMP
AMP
Buffer
HART
ADCMUX
Protection
Protection VREF
V+
Temp
Flow
Optical
Pressure
Level
+
PLC: Analog Inputs
Design ConsiderationsDigital 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
bene t 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/OSN65HVS880 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/DACClocksOther
Power
RF/IF
ProcessorInterface
Amplifier
0 24 V24V
DC/DC Converter
DigitalInput
Serializer
Protection
Protection
Protection
Protection
Isolated Power
24 V
DC/DC Converter
Electrical Isolation
Field Side Control Backplane
24 V
DigitalIsolation
Controller Interface
Field InputsFrom Sensors
CommunicationFieldbus IN
CommunicationFieldbus OUT
Memory
TI signal chain solutions for analog inputsADS1248 (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, Ib precision op ampADS8319 16-bit,
500-ksps precision SAR ADCLMP7721 Ultra-low-bias current 3fA op
ampLMP90100 24-bit ADC + chopper stabilized PGA 1:128
LMP8671/2 2.5-nV/Hz 40V precision op amp
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Design ConsiderationsAnalog 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 solutionsDAC8718 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 ConverterIsolated PowerDC/DC Converter
24 VCommunication
Fieldbus IN
Electrical Isolation
Field SideControl Backplane
Power Management: Exists onAll Modules
Group Isolated Analog Output Module
DigitalIsolation
DigitalIsolation
ControllerInterface
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 V420 mA
InterfaceThere 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 signi cant 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
Devic
e (Fie
ld)
Level
Contr
ol
Level
Ente
rpri
se
Level
Offi
ce
Netw
ork
Contr
oller
Netw
ork
Fie
ld
Netw
ork
IntelligentSensors & 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 mAHART,
IO-Link,
RS-485
IEEE
802.15.4
IEEE802.11
Industrial Ethernet, RS-485,CAN, Other Fieldbuses
Ethernet
Actuator
PC
Network
Automation
Server
Comm
Module
TI interface products for PLCISO1176/76T (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)
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www.ti.com/automation
ProcessorTo 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 BenefitsSitara ARM Cortex-A8
processors with integrated industrial communications support
AM335xAM3517
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
RM42xRM46xRM48x
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 / F4xxxMSP430F5xxx / F6xxxMSP430FR57xx
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 I2C 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
Del no oating-point seriesConcerto 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
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www.ti.com/automation
PowerTo 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
ef ciency 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 PLCDescription Device Series
Key Benefits3.5-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 IQ Refer
to PMP5863
50-mA / 200-mA 4.7-V to 60-Vsynchronous step-down converters
TPS54062/1 Very small size; very low IQ High ef ciency,
synchronous solution
150-mA, LDO reg., ultra-low-power, IQ 500-nA with
pin-select-able, dual-level output voltage
TPS78001 Low IQ: 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 Vrms 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 (Del
no), 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 VRMS), high PRSS, low
drop-out linear regulator
TPS7A4700 Input voltage range: +3 V to +36 V Output voltage
noise: 4.17 VRMS (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 VRMS (10 Hz to 100 kHz) Power-supply ripple rejection: 72 dB (10
kHz)
High-power/high-ef ciency Power-over-Ethernet PD solution
TPS2378/9TPS23751/2/4
Integrates PoE interface and DC-DC controller 25-W operation,
high ef ciency 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 mm2) High ef ciency 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 ef ciency
across entire load range Small total solution footprint (
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SLYB180A
Visit for Industrial Automation solutions from
TIwww.ti.com/automation
TI offers best-in-class analog and embedded processing
semiconductor solutions includ ing precision
amplifiers, data converters, interface, isolation, clocking and
power management products, as well as
ARM-based processors and microcontrollers that cater to the
broad range of industrial applications.
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
manufacturer, TIs system-optimized hardware and software allow
customers to easily scale between
product lines to maximize investment, accelerate time to market
and enable differentiated products
across various industrial markets.
TI Worldwide Technical SupportInternetTI Semiconductor Product
Information Center Home Pagesupport.ti.comTI E2E Community Home
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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
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products and services before placing orders. TI assumes no
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The publication of information regarding any other companys
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2012 Texas Instruments IncorporatedPrinted in U.S.A. by
(Printer, City, State)
The platform bar, C2000, Concerto, DCS-Control, Delfi no, E2E,
MSP430, Sitara and SYS/BIOS are trademarks and Stellaris is a
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Die/Wafer SolutionsTI has expanded package options with the
additional availability of bare die to facilitate integrated
solutions for space-constrained applications which provide both
weight and power dissipation savings, while improving overall
system-level reliability. Learn more at www.ti.com/die
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