Series of PLCs A U T O M AT I O N P E O P L E

USER MANUAL
32-Point 24 VDC Input Module
The digital input module accepts 24 VDC inputs from various 4632
24VDC INPUT
input devices like push buttons, proximity switches, limit 32 IP
switches. It can be used for sink or source type of interface.
The module receives input signal which is optically isolated,
filtered and matched in order to transmit it to the Processor I .0
.1
Module. .2
.3
On the front side, green LEDs indicate individual input status. .4
LED glows if the respective input is sensed by the module as .5
.6
ON. The I/O label is provided on the front side for I/O .7
identification. Under the front door, a removable 38-pin I .0
.1
terminal block is provided for wiring of field input devices. This .2
is easily removable by unscrewing two screws which facilitates .3
.4
wiring and module replacement without removing a single wire. .5
The module can be inserted in any of the I/O slots. .6
.7
I .0
.1
.2
Technical specifications .3
.4
.5
Number of inputs 32 .6
.7
Voltage Rating 24 VDC(18 to 30 VDC including ripple) I .0
.1
Type of Inputs Sink /Source (in group of 8 inputs) Type 2 digital .2
Indication for inputs 3 mm green LED for each input provided on .3
.4
digital side .5
.6
ON Voltage 18 VDC Minimum .7

OFF Voltage 5 VDC Maximum

Current per input 6 mA (maximum) at 24 V DC Figure 1 : Front view
ON to OFF (15-20ms)
Filter time (RC filter)
OFF to ON (15-20ms)
Optical (1.5 KV from bus)
Isolation
No isolation between channels
Back-plane current 200 mA with all inputs ON
IO point consumption 32 input points
Connection Removable 38-pin terminal block
Dimension (W x H x D) 42mm x 190mm x 120mm
Ordering code 4632

1
 Module wiring
The inputs in groups of consecutive eight inputs can be connected for source or
sink type of operation. The terminal numbers 9, 18, 27, 36 are common points for
the respective group inputs. The figure 2 shows how to connect source type of
input devices. The figure 3 shows how to connect sink type of input devices. The
Figure 4 shows the block diagram of input section.
PNP
● ●
Front shield plate
●

Terminal block fixing

●

●
●

●
●

●
screw
● ● 01
02
+ –
24VDC – 03
– – 04
Supply 05
– 06
● ● 09
07
– 08
– 09
– 10
–
– 11
–
–
12
13 Connection details
–
18
14
15
label
16
– 17
– 18
– 19
– 20
– 21
–
– 22
– 23 LED Status
indication
24
27
25
– 26
– 27
– 28
– 29
– 30
– 31
–
– 32 38 pin removable
33
36
34 terminal block
Recommended wires 36
35

1-1.5 mm2 (AWG 20-16) SOURCE / SINK

INPUT Terminal block fixing
screw
Figure 2 : Connecting source type of input devices
NPN
● ●

● ● ●

● ● ●
● ● 01
02
– 24VDC – 03
–
+ Supply – 04
05
– 06
● ● 09
07

Figure 3 : Connecting sink type

of input devices

Figure 4 : Input section block diagram

2
 Installation
Refer printed manual PD-2002-052 Nexgen 5000 PLC Installation Manual to know
• the installation of the module in the PLC rack.
• the installation of entire PLC system and safety precautions to be followed.
• the wiring inside the control panel and outside the control panel.
The latest manual in pdf format ED-2002-052 along with all the related manuals are
available on the website:
www.messungautomation.com/download/manual

Precautions
The input switching ON and OFF with high frequency can not be
connected to the digital input modules. The input should remain ON or
OFF for the duration equal to the filter time of digital input plus maximum
PLC scan time to detect it as ON or OFF in the input scan.
The user should take care to avoid over voltage even in case of DC. The
application of AC voltage to 24 V DC input module may damage
individual inputs of the module or the entire module permanently.
A bleeder resistor may have to be connected externally between the input
and common point if the OFF state leakage current of the sensor is
excessive and causes uncertainty in level determination at input circuit.
This resistor is to be used of a value and wattage such that the input low
remains below the low level value given in specifications sheet when the
input in not activated.

3
 Troubleshooting
Diagnostic Flowchart
The following flow chart illustrates various possibilities of faults with digital input
module and corrective action to be taken.
Input device is ON

LED on input module is ON, but application LED on input module is OFF
program executes as if it is OFF

Probable reason Recommended action Probable reason Recommended action

1. Input is forced Unforce the input. Forcing is 1. Input circuit is Check input sensor specifica-
to zero indicated by blinking 'ON' LED not compatible tions. Check the module
on Processor module. specifications. Check for the
2. Application Check the application proper sink / source type of
program fault requirement and the connections for DC inputs.
application program. 2. Low voltage at Input device may be faulty.
3. Input circuit Try spare input channel if any input Replace it. Input supply may
faulty or replace module be faulty. Adjust it if possible
or replace it.
3. Incorrect Check the input device
wiring connections.
4. Open circuit Input device may be faulty.
Replace it. Check wiring for
open circuit if any.
Figure 5 : Diagnostic flow chart if 5. Input switching Check the input filter time
input device is ON frequency is specification & maximum
high PLC scan time.

Input device is OFF

LED on input module is OFF but application LED on input module is ON

program executes as if it is ON

Probable reason Recommended action Probable reason Recommended action

1. Input is forced Unforce input. Forcing is 1. Input device Check input device specifica-
to one indicated by blinking 'ON' LED OFF state tions. Check module specifi-
on Processor module. leakage cations.If required, use proper
2. Application Check the application current high. bleeder resistor between input
program fault requirement and the and common. If input device
application program. is faulty replace it
3. Input circuit Try spare input channel if any 2. Incorrect Check the input device
faulty or replace module wiring connections.
3. Short Circuit Input device may be faulty.
Replace it. Check wiring for
any short circuit if any.
4. Input circuit Try spare input channel if any
Figure 6 : Diagnostic flow chart if
damaged or replace the module.
input device is OFF

4
 User safety guidelines
This manual provides information for the use of I/O Module. The manual has been written to
be used by trained and competent personnel. The definition of such a person or persons is as
follows:
a) DESIGN ENGINEER Any engineer who is responsible for the planning, design, and
construction of automatic equipment using the product associated with this manual
should be of a competent nature, trained and qualified to the local and national standards
required to fulfill the role.. These engineers should be fully aware of all the aspects of safety
with regards to automated equipment.
b) COMMISSIONING/SERVICE ENGINEER. Any engineer who is responsible for the
commissioning, use and maintenance of automatic equipment using the product
associated with this manual should be of a competent nature, trained and qualified to the
local and national standards required to fulfill the role. This includes being completely
familiar with all the associated documentation for the said system. Maintenance to be
carried out in accordance to the established safety practices.
c) OPERATORS. The personnel using the completed equipment should be trained to use
the product in a safe and coordinated manner in compliance to established safety
practices. They should be also familiar with documentation, which is relevant to the actual
operation of the equipment.
Note : The term-completed equipment refers to a third party constructed device, which
contains or uses the product associated with this manual.

Warning !
The specifications of product and contents of manual are subject to change without
notice. This manual has been prepared taking utmost care; the performance of the
final equipment depends on many other parameters beyond any control of Messung
Systems. Messung systems does not assume any responsibility/liability of any
damage to life or property that might result due to any malfunction due to design,
use, of the equipment using this component.

Revisions :
Edition Date Version Description
January 2004 1.0 First release

5
NEXGEN PLC I/O Module
32-Point 24 VDC Input Module (4632)
Document No.: PD-2002-005 V.1.0 A U T O M AT I O N P E O P L E
Published January, 2004
MESSUNG SYSTEMS
EL-2, J-Block, MIDC Bhosari,
Pune - 411026 (INDIA)
Tel. : (+91)-20-2712 0807, 2712 2807.
Email : [email protected]
PRINTED IN INDIA WEB : www.messungautomation.com