ED-2002-013 16-Point 24 VDC Input Plus 8 Point 24 VDC Outpu

Messung Systems NEXGEN PLC I/O Modules
NEXGEN Series of PLCs

16- Point 24 VDC Input +
8- Point 24 VDC Output Module (4425)
Document No.:ED-2002-013
Version: 1.0
Published July 2002
MESSUNG SYSTEMS
EL-2, J- Block MIDC Bhosari,
Pune – 411026.(INDIA)
Tel: (+91)-020-712 0807, 712 2807.

Email : marketing@ms.messung.com
WEB: www.messung.com
16 I + 8 DO Module Published July 2002

Document No.: ED-2002-013/V1.0 Page 1 of 17
NEXGEN PLC I/O Modules Messung Systems
Revision
Version Date Description
16-Point 24 VDC Input + 8-Point 24 VDC Output

1.0 July 2002
Module (4425) (NEXGEN Series of PLCs)
Published July 2002 16 I + 8 DO Module

Page 2 of 17 Document No.: ED-2002-013/V1.0
INDEX
1. 16-Point 24 VDC Input + 8-Point DC Output Module .....................................................5

1.1 Module Specifications .................................................................................................5
2. Module Wiring.................................................................................................................7
3. Troubleshooting..............................................................................................................9
3.1 Input Section ...............................................................................................................9
3.2 Output Section ..........................................................................................................10
3.3 Diagnostic Flowchart.................................................................................................11
INDEX OF FIGURES
Figure 1 : Front View of the Module ..........................................................................................5

Figure 2 : Field Connections for the Module .............................................................................7
Figure 3 : Input Section with NPN type of Input Device ............................................................9
Figure 4 : Input Sction with PNP type of Input Device...............................................................9
Figure 5 : Output Section ........................................................................................................10
Figure 6 : Diagnostic Flow Chart if Input Device is ON ..........................................................11
Figure 7 : Diagnostic Flow Chart if Input Device is OFF ........................................................12
Figure 8 : Diagnostic Flow Chart if LED on Output Module is ON. .........................................13
Figure 9 : Diagnostic Flow Chart if LED on Output Module is OFF.........................................14

Guidelines for the Safety of the user and protection of I/O Module
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.
Notes on Symbols used in this Manual

The following symbols will be used throughout this manual to highlight points of information
regarding the users personal SAFETY and protection of the unit's integrity. The meaning of the
symbols must be clearly understood and due cognizance be taken of the associated note
where these symbols appear. The symbols and their descriptions are given ahead for ready
reference
HARDWARE RELATED
1 Indicates that the identified danger WILL cause physical and property damage.
Indicates that the identified danger could POSSIBLY cause physical and property
2
damage.
3 Indicates a point of further interest or explanation.

1. 16-Point 24 VDC Input + 8-Point DC Output Module

This is NEXGEN PLC family I/O module. This is 16-point
digital input and 8-point digital output module. The module
4425 accepts 24 VDC inputs. It can be used for sink or source
type of interface. The module provides 24 VDC output
MIXED IO-DC
16 IP – 8 OP through solid state MOSFET type of devices. It provides
source type of output.
The digital input section receives signals from various

sensors like push buttons, proximity switches, limit switches.
GROUP ERROR 0 These signals are then optically isolated, filtered and
GROUP ERROR 1 matched in order to transmit them to the Processor Module.
The digital output section receives commands from the

Processor module in order to switch ON or OFF various field
actuators and elements like relays, contactors, solenoid
valves.
1.1 Module Specifications

The technical specifications are given in table.
Number of inputs 16
Voltage Rating 24 VDC
(18 to 30 VDC including ripple)
Type of Inputs Sink / Source as per connections
(in groups of 8 inputs)
Indication for inputs 3 mm green LED for each input
provided on digital side
ON Voltage 18 VDC Minimum
OFF Voltage 5 VDC Maximum
Current per input 6 mA (maximum) at 24 VDC
Filter time ON to OFF 15-20 ms
(RC filter) OFF to ON 15-20 ms
Input Isolation Optical (1.5 KV from internal bus)
Module specifications continue on next page
Figure 1 : Front View of the Module

Module specifications continue.
Number of outputs 8
24 VDC (18-30 VDC external
Voltage rating
supply)
Type of Output Source (in groups of 4)
Output device MOSFET
3 mm Red LED for each channel at
Indication for output
digital side.
ON Voltage 22 VDC Minimum
OFF Voltage 1.5 VDC Maximum
OFF to ON 0.1 ms
Response time
ON to OFF 0.4 ms
1.5 Amp
Maximum 4 Amp per group,
Current per output
Maximum 8 Amp per module
(Outputs can be used in parallel)
9 Amp at 25 ºC
Inrush current
5 Amp at 150 ºC
10 µΑ at 24 VDC
OFF state leakage current
(Resistive Load of 24 Ω)
• Reverse voltage
• Over voltage above 47 VDC
• Short circuit at output device
Output protections
side (electronic protection)
• Fast demagnetization for
inductive loads
• NO 24 V SUPPLY
Fault Indications • GROUP ERROR 0
• GROUP ERROR 1
Output Isolation Optical (1.5 KV from internal bus)
Input and output Isolation Optical (1.5 KV from internal bus)
Back-plane current 220 mA (All inputs and outputs ON)
18–30 VDC (100 mA) including
External power supply
ripple (For driving output circuit)
IO point consumption 16 Input points + 8 Output points
Length of I/O signal cables 100 Meter maximum
Ordering code 4425

2. Module Wiring
The front side of the module is provided with green LEDs for individual inputs
and red LEDs for individual outputs. Green LED glows when input is sensed
by the Processor as ON. Red LED glows if the Processor puts ON the
output. Below the front door, 38-pin terminal block is provided for wiring of
field inputs and outputs. This is easily removable which facilitate wiring. This
module can be inserted in any of the I/O slots.
GND +24 VDC
+24 VDC GND
Figure 2 : Field Connections for the Module

For inputs, two separate common points (terminal numbers 9 and 18) each
for group of consecutive eight inputs are provided. Input devices can be
connected for sink or source type of operations. This can be done in group of
eight inputs. In figure 2 last eight inputs are connected for sink type of
operation where ground is switched to input point of module and +24 VDC is
conncted to common point on terminal number 18.
The inputs are protected against transients by a filter and optical isolation
circuitry inside input module. But it is always better to take certain care
regarding wiring of inputs to reduce the effect of electrical noise such as
inductive switching. All the input modules of same type should be grouped
together.
User should take care to avoid over voltage. User should avoid application of
high AC voltage to 24 VDC input module. Such cases damage input module
permanently.
This module provides source type of outputs.Two +24VDC common points

(terminal numbers 27 and 36), each for group of consecutive four outputs are
provided. Connect output devices (load less than 1.5 Amp) to output points
as shown in figure 2 with other terminals of output devices connected to
ground.
Ensure that total load in a group at a time should not exceed 4 Amps and
total load on a module at a time should not exceed 8 Amp.
Filtered 24 VDC supply is required for working of output stage of module.

This is connected to terminal numbers 37 and 38.
The module 24 V supply ground and output devices ground should be

commom.The terminal number 37 should be shorted to common ground
point of output load devices.
Two orange LEDs are provided as GROUP ERROR 0 & GROUP ERROR 1
indications. One indication is provided for first four outputs and other for
remaining four outputs. If any single output is put ON by the processor,
corresponding error LED glows
If load connected to output point is less than 300 mA or

If total load current of a group exceeds permissible limit.

3. Troubleshooting
This section explains the input and output section of 16 Point DC Input + 8-
Point DC output module and diagnostic flowchart.
3.1 Input Section

The figure below shows input section of 24 VDC input along with the
connection of PNP and NPN type of input device. The term 'sourcing' and
'sinking' applicable to input modules refer to the manner in which input
devices are wired.
In figure 3, NPN type of input device is connected for source type of

operation. In this connection, ground is switched to input terminal and
positive potential is connected to input module. The input module is said to
be providing current to input device. As input module is providing current, it is
said to be sourcing.
+5V
R3
NPN type of
LED
Input device Input R1
To digital circuit
R2
COM OptoIsolation
5 V GND
_ +
24 VDC
Field Supply
Figure 3 : Input Section with NPN type of Input Device
In figure 4, PNP type of input device is connected for sink type of operation.
In this connection, positive potential is switched to input terminal and ground
is connected to input module. The input device is said to be providing current
to input module. As input module is receiving current, it is said to be sinking.
+24 VDC +5V

PNP type of R3
Input device
LED
Input R1
To digital circuit
R2
COM OptoIsolation
5 V GND
24 V GND
Figure 4 : Input Sction with PNP type of Input Device

3.2 Output Section

The figure below shows output section of DC output.
+5V
+24 V
24 VDC Supply for
output devices
R1 R2 DC Switching
LED Device
(MOSFET)
Control & Error

Detection Circuit Output device like
From digital circuit Opto Isolation relay/ contactor/
solenoid valve, etc
Output
24 VDC GND
+5V +24 V
DC to DC 24 VDC Supply
Converter for Module
GND 0V
Figure 5 : Output Section

The module provides source type of output. The output device is connected
to output point and other terminal of device is connected to ground.

3.3 Diagnostic Flowchart
The following flow chart illustrates various possibilities of faults with digital
input 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 to Unforce the input. 1. Input circuit is not Check input
zero Forcing is indicated by compatible specifications. Check
blinking 'ON' LED on module specifications.
Processor module. Check for proper sink /
2. Application Check for the effect of source type of
program fault (JMP), (MCR) / (ME) connections for DC
instructions, etc. inputs.
3. Input module Replace the module 2. Low voltage at Input device may be
faulty input faulty. Replace it. Source
voltage may be faulty.
Adjust it if possible or
replace it.
3. Incorrect wiring Check the input device
connections. check
'common' connection.
4. Open circuit Input device may be
faulty. Replace it. Check
wiring for open circuit if
any.
5. Input switching Check the input
frequency is high specification &
application requirement.
Figure 6 : Diagnostic Flow Chart if Input Device is ON

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
to one indicated by blinking 'ON' OFF state leakage specifications. Check
LED on Processor current high. module specifications.
module. If input device is faulty
2. Application Check application replace it
program fault program 2. Incorrect wiring Check the input device
3. Input circuit Try spare input channel connections.
damaged if any or replace module 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
damaged any or replace the
module.
Figure 7 : Diagnostic Flow Chart if Input Device is OFF

The following flow charts illustrate various possibilities of faults with digital
output and corrective action to be taken.
LED on Output module is ON.
Output device is energized but not working Output device is not energized.
as per application requirement.

1. Output is forced Unforce output. 1. Low / no voltage Check output device
to one Forcing is indicated by across output specifications. Check
blinking ‘ON’ LED module specifications.
on Processor module. Check source voltage.
2. Output circuit Check output 2. Incorrect wiring Check output device
incompatibility specifications. connections. Check
Check for sink /source common connection
type of connections for 3. Open circuit Output device may be
DC outputs. faulty. Replace it. Check
3. Application Check for the effect of wiring for open circuit, if
program fault (JMP), (MCR)/(ME) any.
instructions, double 4. Output switching Check output
output updation frequency is high specification &
through coil or functions, application need.
etc. 5. Output circuit Try spare output
4. Output circuit Try spare output damaged channel if any or replace
damaged channel the module
if any or replace module.
5. Output device Check output device
faulty operation.
Figure 8 : Diagnostic Flow Chart if LED on Output Module is ON.

LED on Output module is OFF
Output device is de-energized but not Output device is energized.

working as per application requirement.

1. Output is forced Unforce output. Forcing 1. Output device is Check output device
to zero, is indicated by blinking incompatible specification. Check
'ON' LED on Processor module specifications.
module. If output device is
2. Output circuit Check output faulty, replace it.
incompatibility specifications. 2. Incorrect wiring Check output device
Check for sink I source connections.
type of connections for 3. Output OFF state Check output device
DC outputs. leakage current may specifications. Check
3. Application Check for the effect of drive output device module specification.
program fault (JMP), (MCR) / (ME) Check output module
instructions, double specification. If required
output updation connect dummy load
through coil or across output device
functions. etc 4. Short circuit Output device may be
4. Output circuit Try spare output faulty. Replace it.
damaged channel if any or Check wiring for any
replace module. short circuit, if any.
5. Output device Check output device 5. Output circuit Try spare output
faulty operation. damaged channel if any or
replace the module
Figure 9 : Diagnostic Flow Chart if LED on Output Module is OFF
In addition to the flow charts, for diagnostic purpose, two orange LEDs
(GROUP ERROR) are provided. One indication is provided for first four
outputs and other for remaining four outputs. If any single output in a group is
made ON by processor, corresponding error LED glows
• If load connected to output point is less than 300 mA. This condition may
not be error, but just an indication of low load.
• If total load current of a group exceeds permissible limit. This is error
condition and corrective action is required.



MESSUNG SYSTEMS
EL – 2, J - Block, MIDC, Bhosari,
PUNE – 411 026. INDIA
Tel. – (+91) –020 – 712 0807, 712 2807
Fax. – (+91) –020 –712 0391
NEXGEN PLC I/O Modules

16- Point 24 VDC Input + 8- Point 24 VDC Output Module (4425)
Document No.:ED-2002-013


ED-2002-013 16-Point 24 VDC Input Plus 8 Point 24 VDC Outpu

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Messung Systems NEXGEN PLC I/O Modules

NEXGEN Series of PLCs

8- Point 24 VDC Output Module (4425)

Published July 2002

Tel: (+91)-020-712 0807, 712 2807.

16 I + 8 DO Module Published July 2002

Version Date Description

16-Point 24 VDC Input + 8-Point 24 VDC Output

Published July 2002 16 I + 8 DO Module

1. 16-Point 24 VDC Input + 8-Point DC Output Module .....................................................5

Figure 1 : Front View of the Module ..........................................................................................5

16 I + 8 DO Module Published July 2002

Notes on Symbols used in this Manual

3 Indicates a point of further interest or explanation.

Published July 2002 16 I + 8 DO Module

1. 16-Point 24 VDC Input + 8-Point DC Output Module

The digital input section receives signals from various

The digital output section receives commands from the

1.1 Module Specifications

Module specifications continue on next page

Figure 1 : Front View of the Module

16 I + 8 DO Module Published July 2002

Module specifications continue.

Published July 2002 16 I + 8 DO Module

GND +24 VDC

+24 VDC GND

Figure 2 : Field Connections for the Module

16 I + 8 DO Module Published July 2002

This module provides source type of outputs.Two +24VDC common points

Filtered 24 VDC supply is required for working of output stage of module.

The module 24 V supply ground and output devices ground should be

If load connected to output point is less than 300 mA or

Published July 2002 16 I + 8 DO Module

3.1 Input Section

In figure 3, NPN type of input device is connected for source type of

Figure 3 : Input Section with NPN type of Input Device

+24 VDC +5V

Figure 4 : Input Sction with PNP type of Input Device

16 I + 8 DO Module Published July 2002

3.2 Output Section

Control & Error

Figure 5 : Output Section

Published July 2002 16 I + 8 DO Module

3.3 Diagnostic Flowchart

LED on input Module is ON , but application LED on Input Module is OFF

Probable reason Recommended action Probable reason Recommended action

Figure 6 : Diagnostic Flow Chart if Input Device is ON

16 I + 8 DO Module Published July 2002

Input device is OFF

LED on input Module is OFF but application LED on Input Module is ON

Probable Reason Recommended Action Probable reason Recommended action

Figure 7 : Diagnostic Flow Chart if Input Device is OFF

Published July 2002 16 I + 8 DO Module

LED on Output module is ON.

Probable reason Recommended action Probable reason Recommended action

Figure 8 : Diagnostic Flow Chart if LED on Output Module is ON.

16 I + 8 DO Module Published July 2002

LED on Output module is OFF

Output device is de-energized but not Output device is energized.

Probable reason Recommended action Probable reason Recommended action

Figure 9 : Diagnostic Flow Chart if LED on Output Module is OFF

Published July 2002 16 I + 8 DO Module

16 I + 8 DO Module Published July 2002