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IO Module Installation and Configuration Manual

INTRODUCTION

This manual provides step-by-step guidance for the installation of I/O modules in the Saksham PLC system. It is intended to help users safely and accurately complete the mechanical setup of I/O hardware components.

In this section, we will focus exclusively on:

  • Installation of the T-BUS (Terminal Bus)
  • Mounting of I/O Modules (AI, AO, DI, DO)

Hardware Components to be Installed

  • T-BUS
  • Modules

Installation of T-BUS

  • ✅ A T-BUS is a small connector that goes under each PLC module.
  • ✅ It carries signals between the modules.
  • ✅ It saves wiring effort and makes the system neat and easy to expand.

Why TBUS is Important?

Feature Without T-BUS With T-BUS
Communication Manual connections or wiring Shared via T-BUS pins
Installation Time Slower and error-prone Fast and tool-free
Panel Appearance Messy and hard to manage Clean and organized
Future Expansion Complicated re-wiring needed Just slide in another module on T-BUS

Installation Steps OF T-BUS

Step 1: Insert the First T-BUS Connector

  • Take a T-BUS connector and place it on the DIN rail.
  • Hook one side of the T-BUS onto the top edge of the DIN rail.
  • Then press down gently until it clicks into place.
  • The metal pins should face upward – these will connect with your modules.

📝 Tip: You don’t need to use any screws. It simply clips on.

Step 2: Add More T-BUS Connectors (Max. 9 T-BUS)

  • Place a second T-BUS connector right next to the first one.
  • Make sure the ends of both connectors touch each other – there should be no gap.
  • Repeat this for all the modules you plan to install (one T-BUS per module).

✅ Check: All T-BUS connectors should be aligned and form one straight line.

Step 3: Double-Check Alignment

Look from the top to ensure all T-BUS pieces are:

  • Tightly placed on the DIN rail
  • Perfectly connected end-to-end
  • No connectors are loose or misaligned

🛑 Warning: Misalignment can prevent modules from getting signal.

Step 4: Secure the Ends (Optional)

  • Once all T-BUS connectors are in place, you can install END CLAMP at both ends.
  • The DIN RAIL on which the module rack is to be mounted should be installed using a panel isolator, and the DIN RAIL should be connected to the panel's power earth. This enhances the safety of the module.

This helps to:

  • Keep the T-BUS in place
  • Maintain a neat finish

Step 5: Done

Your T-BUS installation is now complete.
You can now begin placing the modules on top of the T-BUS.

TBUS Image

🧯 Safety Tips

  • Handle T-BUS connectors gently — avoid bending the pins.
  • Don’t leave gaps between T-BUS connectors.
  • Only use T-BUS connectors compatible with your PLC system.

Installation Steps OF IOs

Step 1: Install the IM Module (Interface Module)

Start by fixing the IM module on the leftmost side of the DIN rail.

This is always the first module to be installed.

How to install:

  • Place the IM module on the left side of the DIN rail.
  • Align it properly with the rail and press it in.
  • You’ll hear a click when it locks in place.
  • Make sure it is firmly attached and not loose.

IOs Module Installation

Step 2: Install I/O Modules to the Right of IM

Once the IM module is in place, install all other I/O modules on the right side of it.

You can install them in any order – Digital Input, Digital Output, Analog Input, etc.

How to install:

  • Take the next I/O module.
  • Line it up with the IM module (side-to-side connection).
  • Also align it with the DIN rail below.
  • Push it in until it clicks and locks into place.
  • Repeat this for all remaining I/O modules.

Final Check

Make sure:

  • All modules are tight and properly connected.

  • There are no gaps between modules.

  • Each module is locked firmly on the DIN rail.