VIET NAM NATIONAL UNIVERSITY – HCMC

HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY

DEPARTMENT OF CONTROL ENGINEERING & AUTOMATION
FACULTY OF ELECTRICAL AND ELECTRONICS ENGINEERING


CLASS TT01 --- SEMESTER 242

DATE: 08/03/2025

REVIEW QUESTIONS AND PROBLEMS CHAPTER 6

Instructor: PhD. NGUYỄN TRỌNG TÀI

STUDENTS PERFORMED
No Name Student ID Process Note
1 Bùi Phan Xuân Bách 2251002 100% 6.1, 6.5, 6.9, 6.13, 6.17
2 Huỳnh Hữu Lộc 2251028 100% 6.2, 6.6, 6.10, 6.14, 6.18
3 Nguyễn Trí Ngọc 2251037 100% 6.3, 6.7, 6.11, 6.15, 6.19
4 Đỗ Chí Hiếu 2251013 100% 6.4, 6.8, 6.12, 6.16, 6.20

Hồ Chí Minh City, 2025

6.1. Explain how the status of a digital input signal 230 V is stored in the memory of
a PLC.

First, the 230V AC input signal passes through isolation circuitry (optocouplers) that
converts it to a safe internal voltage. The signal is conditioned into a binary state: presence
of 230V becomes a logical "1", absence becomes a logical "0". This binary value is stored
as a single bit in the PLC's Input Image Table, a dedicated memory area that holds the status
of all inputs. Every digital I/O has an address that defines its position in the specific I/O
module, as well as its position in the I/O mapping memory. Consequently, the PLC updates
this memory during each scan cycle, maintaining consistent input states throughout
program execution.

6.2. What is the so-called “scanning cycle” of a PLC? Is the time duration of scanning
cycle a constant or variable parameter and why?

A scan cycle in a PLC is the process the PLC follows to read inputs, execute the control
program, and update outputs. It consists of three main steps: input scan, program execution,
and output scan. During the input scan, the PLC reads the status of all in put devices. Then,
in the program execution step, the PLC runs the control logic based on the input statuses.
Finally, during the output scan, the PLC updates the status of all output devices according
to the executed program. This cycle repeats continuously, ensuring real-time control and
monitoring of the automated system. Understanding the scan cycle is crucial for designing
efficient PLC programs and troubleshooting issues effectively. The scan cycle is the
repetitive process that a PLC follows to read inputs, execute logic, and update outputs. This
fundamental operation allows PLCs to monitor and control automated industrial processes
continuously. The primary purpose of the scan cycle is to ensure that the PLC responds to
input conditions in a timely manner and executes actions that are reflective of the current
state of the system, thus maintaining efficiency and safety in automated operations.

The scan cycle time in a PLC can be either constant or variable depending on the PLC type
and configuration
Variable Scan Time which is the most common:

In most modern PLCs, the scan time varies based on the complexity of the program being
executed. Each scan may take a different amount of time because:

- Different program paths may be executed based on input conditions

- Some instructions take longer to process than others
- Subroutines or function blocks may not be executed in every scan
- Communication tasks may interrupt the main program execution

Constant Scan Time:

Some PLCs can be configured for constant scan time operation. The PLC intentionally
waits until a predefined time has elapsed before starting the next scan. Even if program
execution finishes early, the PLC waits until the fixed scan time is reached. This provides
deterministic behavior which can be beneficial for:

- Time-sensitive applications requiring consistent response times

- Simplifying calculations for time-based functions
- Systems where predictable timing is critical

6.3. Describe the advantages, if there are any, of using a modular PLC instead of a
compact PLC in an industrial application.

The use of a modular PLC in an industrial application offers several advantages over a
compact PLC:

Customization Modular PLCs enable engineers to create a PLC system tailored to the
precise demands of a specific application because of the wide array of I/O modules and
special purpose modules.

- Flexibility and expandability Modular PLCs are expandable, unlike compact PLCs,
which have a fixed number of I/O.
- Space Since PLCs are digital devices, they have a comparatively small volume as well
as dozens of timers, counters, and hundreds of auxiliary relays; thus, their volume is
incomparably less than that of a conventional industrial automation enclosure with an
equivalent number of auxiliary equipment.
- Easy Automation Modification Alterations can be made by directly changing the
corresponding program.

Compact PLCs, conversely, are more appropriate for small-scale automation tasks because
they are non-expandable and have a set number of inputs and outputs.

6.4. One of the PLC’s advantages is the easy detection of equipment faults. The figure
shows the conventional automation circuit of a pump (C2) which has been translated
in a program and runs in a PLC. Suppose that the float level switch has been damaged
and its contact remains open, although the liquid level in the tank is above the float
switch. Explain why the detection of this fault will be easier in the case of
programmable automation.

In PLC programming there is always a close-loop between the plants and the controller to
make sure everything works correctly. PLC can be programmed to check the condition
such as:

- The water level is higher than the float switch but the switch doesn’t close

- The pump(C2) doesn’t run even though all the conditions are satisfied
When detecting the error, the sensor will feedback to the controller then the system will
warn the technician. 1 advantage of the PLC is it can record the system data; it will help
the supervisor to check the error more quickly.

6.5. What type of digital output (DO) module do you have to select for the activation
of a solid-state output device in order to avoid operating problems due to leakage
current?

We should use Relay Output Module to ensure complete isolation when OFF and prevents
accidental activation of solid-state devices due to leakage current. It is also suitable for
solid-state devices like SSRs (Solid-State Relays) or optocouplers, which are sensitive to
leakage current.

6.6. The figure shows a typical simplified electric circuit of a digital input module.
Describe the operations that take place inside the module between the input signal
and the logic signal which is transferred to a CPU.

This circuit converts a 220V AC input signal into a 5V DC logic signal suitable for a CPU.

Input Protection

The initial resistors (R) limit the input current and protect against voltage spikes or surges
in the 220V AC signal. This helps prevent damage to downstream components.
AC to DC Conversion

A bridge rectifier (four diodes arranged in a diamond pattern) converts the AC input into
pulsating DC. This ensures that the following components receive current in a single
direction, regardless of the AC polarity.

Filtering and Voltage Division

After rectification, a resistor network (three resistors marked R) serves to:

- Filter the pulsating DC, making it more stable.

- Reduce the voltage to a safer level before passing it to the optocoupler.

Electrical Isolation via Optocoupler

The optocoupler (shown with an LED and a phototransistor) provides galvanic isolation
between the high-voltage input side and the low-voltage logic side. When sufficient current
flows through the LED inside the optocoupler, it emits light, activating the p hototransistor
on the output side. This ensures that no direct electrical connection exists between the 220V
AC signal and the low-voltage CPU, protecting the system from electrical noise and surges.

Signal Conditioning for CPU Input

The final resistor and LED on the logic side serve two functions:

- The resistor acts as a pull-up resistor, ensuring a stable logic signal.

- The LED serves as a status indicator, showing when the input is active.

When the phototransistor conducts, it creates the appropriate 5V DC logic level that the
CPU reads as a HIGH (1) signal. If the input AC signal is absent, the optocoupler remains
off, and the CPU reads a LOW (0) signal.

6.7. The classical scanning cycle of three steps (input scanning, program execution,
and output updating) is interrupted when the user program contains instructions for
a peripheral read–write. For example, an instruction for a direct-in-the-module
reading of an input will give the result shown in the figure. In your opinion, when is
the scanning cycle faster? When the user program contains instructions for
peripheral read–write, or included no instructions?

Without peripheral read–write instructions: The scanning cycle follows its normal
sequence (inputs → processing → outputs), ensuring a predictable and streamlined
execution.

With peripheral read–write instructions: The scanning cycle is interrupted for direct input
readings. While this allows for real-time responsiveness, it introduces delays in completing
the overall scanning cycle because the PLC must process the read –write operation
separately.
=> Thus, the scanning cycle is faster when the user program does not include peripheral
read–write instructions, as there are no additional interruptions that delay the standard
sequence of execution.

6.8. An analog valve for flow control accepts an analog signal of –10 V DC up to +10
V DC from an analog output of a PLC. The PLC controls the liquid flow based on a
proper algorithm. The analog output uses 12 bits for a digital value representation
and 1 bit for sign. Complete a three-column table which will give (for each opening
position of the valve from 0% up to 100% in steps of 10%) the corresponding voltage
value and its digital representation that is created by the analog output of the PLC.

The problem state voltage signal change from -10V to 10V and the PLC use 12 bit to
change to digital value but 1 bit use for sign. So, the effective range for positive and
negative value is

211 = 2048

The digital values range from -2047 to 2048, zero is included. The voltage increases from
-10V at 0% valve to 10V at 100%

The relationship between the voltage and its corresponding digital representation can be
expressed as:

VoltageValue
DigitalValue =  2047
10V
 Digital Value (12-bit
Valve Opening (%) Voltage (V)
representation)

0% -10.0V -2047

10% -8.0V -1638

20% -6.0V -1228

30% -4.0V -819

40% -2.0V -409

50% 0.0V 0

60% 2.0V 409

70% 4.0V 819

80% 6.0V 1228

90% 8.0V 1638

100% 10.0V 2047

6.9. In a liquid flow pipe network, a flow valve, similar to that of problem 6.8, has
been inserted and permits the flow of 100 L/min when it is at its maximum opening.
What will be the stored digital value of the analog output adjusted for 60 L/min flow?

VoltageValue
As demonstrated in Problem 6.8, using the formula: DigitalValue =  2047
10V

We calculate the digital value when it is maximum opening (at 10V) is: 2047
Since the output adjusted for 60L/min is 60% of valve’s opening, look at the table on
problem 6.8, the digital value is: 409

6.10. A small industrial process is controlled via a modular PLC. The automation task
controls a system with 32 digital inputs, 28 digital outputs, 4 analog inputs, and 4
analog outputs. Given that peripheral equipment is not required due to the small
dimensions of the industrial building, determine the required local equipment by
selecting the PLC from the three available in the market, which will have the major
number of empty places for future installation of I/O modules. The technical
characteristics of the three available PLCs are shown in the table. Please create a
diagram showing the structure and interconnection of the equipment units.

The digital inputs and outputs are further categorized as follows:

- 32 DI = 20 DI with nominal voltage 230 V AC + 12 DI with nominal voltage 24 V

DC
- 28 DO = 16 DO with nominal voltage 230 V AC + 12 DO with nominal voltage 24
V DC

The power supply, CPU and communication modules each occupy a single place in
the installation rack of any PLC.
6.11. In the technical characteristics catalog of a digital input module with a nominal
operating Vvoltage of 24 V DC, it is written, “Input current for signal ‘1’ = 8.5 mA at
24 V DC” Explain what exactly expresses this magnitude (8.5 mA) and if it has any
possible importance.

This magnitude (8.5 mA) expresses the current that the digital input module draws when
the input signal is in the ON state (logic '1'), with a voltage of 24 V DC.

Importance of this magnitude:

- Determining the load on the sensor or switching device: The sensor or switching device
providing the input signal must be capable of supplying this current (8.5 mA) at 24 V DC
to reliably activate the digital input module. If the sensor cannot supply this current, the
input signal may be unreliable.
- Power supply considerations: The total current drawn by all the digital input modules
must be considered when designing the power supply for the PLC system.
- Fault detection: Monitoring the input current can help in detecting faults in the input
circuit. A significant deviation from the specified current may indicate a problem with the
sensor, wiring, or the input module itself.

6.12. In a PLC with many digital I/Os and a large executed program, the scanning
cycle duration is 50 msec. The digital input device connected to the PLC is an SPST
contact output of a sensor which opens and closes with frequency 100 Hz. Explain if
it is possible to count the number of ON/OFF changes of the sensor output during a
time interval of 1 hour.

We can see that the PLC scanning cycle is 50ms while the sensor changing cycle is 10ms.
So, if we try to count for the changing time in 1 hour there will be some error. For example,
in 50ms the sensor has change 5 cycles on/off but the PLC only scan in the 6th cycle of the
sensor. As a result, the PLC cannot count correctly the number of changing states of the
sensor. If we want it to count, we have to use interrupt module to indicate every time the
sensor change state or use a high-speed module (HSC- high speed counter)

6.13. Four machines, C1–C4, operate according to the automation circuit shown in
the figure, either manually through buttons Starti/Stopi and the rotational switch RSi
in place M or automatically through command from the digital Outputi of the PLC
and the rotational switch RSi in place A. In order to accomplish this operation, a
digital output module is available from the manufacturer that defines the connection
in the diagram shown in the figure (module view). Design how the outputs of the PLC
will be connected to the conventional automation circuit in order for the desired
operation to be achieved. Note that the conventional circuit may be modified suitably
to facilitate the connection to PLC, but it will not affect the desired operation.
Each machine (C1-C4) needs to be controlled by a corresponding PLC digital output. The
rotational switches (RS1-RS4) allow selecting between manual ("M") and automatic ("A")
operation. When RSi is in "M" (Manual Mode) → Start i/Stop i buttons control the machines.
When RSi is in "A" (Auto Mode) → PLC output commands the machines.

Therefore, these are the I/O connection list:

Power Connections:
- Connect terminal L1 to the power supply (R)
- Connect terminal C to the neutral (N)
PLC Output Connections:
- Connect PLC output 0 to the "A" terminal of rotational switch RS1 (for machine C1)
- Connect PLC output 1 to the "A" terminal of rotational switch RS2 (for machine C2)
- Connect PLC output 2 to the "A" terminal of rotational switch RS3 (for machine C3)
- Connect PLC output 3 to the "A" terminal of rotational switch RS4 (for machine C4)

And the "Digital output 4 PLC command" shown in the diagram will now be replaced by
outputs 0-3 from the PLC module.
6.14. Write the differences between a PLC and a general-purpose computer from a
hardware and software point of view.

Feature
Hardware PLC General-Purpose Computer
differences

Specialized microcontroller Powerful general-purpose

Processing Unit or processor designed for CPU optimized for multi-
real-time control and tasking and complex
automation. computations.

Uses non-volatile memory Uses RAM, HDD, SSD, and

Memory (EEPROM, Flash) to store other storage media,
programs permanently even requiring an OS for
after power loss. operation.
Has built-in digital and Uses USB, HDMI, Ethernet,
analog I/O modules for and other general interfaces
I/O Interfaces direct connection to sensors, for peripherals like a
actuators, and industrial keyboard, mouse, and
devices. display.
Designed for harsh Designed for office or home
Durability environments (high environments, more
temperature, humidity, sensitive to extreme
vibration, dust). conditions.
Uses industrial-grade power
Power Supply Uses a standard AC power
supplies (typically 24V DC
supply (110V/220V AC).
or 120/240V AC).

Expandable with external

Modular design allows easy peripherals like graphics
Expandability expansion with additional cards and external storage
I/O modules. but not specialized for real-
time control.
 Feature
Software PLC General-Purpose Computer
differences
Uses firmware or a real-time Uses general-purpose OS
Operating System operating system designed (Windows, Linux, macOS)
for deterministic control. for various applications.
Uses ladder logic, structured
Uses high-level
text, function block diagram,
Programming programming languages like
instruction list, or sequential
Languages C, Python, Java, JavaScript
function charts optimized for
for software development.
automation.
Designed for deterministic Not designed for strict real-
execution of control loops, time performance, processes
Real-Time Processing
ensuring real-time tasks based on priority
performance. scheduling.
Runs industrial automation Runs general-purpose
programs for machine applications like web
S0oftware Applications
control, robotics, and browsers, word processors,
process monitoring. and entertainment software.
Has a graphical user
Typically programmed via
interface (GUI) for
User Interface dedicated PLC programming
multitasking and user-
software with minimal GUI.
friendly interaction.
6.15. Write the basic differences between a digital input module and an analog input
module of a PLC.

Feature Digital Input Module (DI) Analog Input Module (AI)

Signal Type Discrete (ON/OFF, 0 or 1) Continuous (e.g., voltage,

current)

Data Conversion Direct detection of signal Requires ADC for signal

presence processing
Detects events (e.g., switch Measures physical variables
Applications
press, valve open) (e.g., temperature, pressure)

Memory Storage Single-bit value Multi-bit word

Wiring Simple two-wire connection Shielded cables to reduce noise

Verify signal accuracy and ADC

Troubleshooting Check voltage and PLC input bit
conversion

6.16. The manufacturer of a digital output module with nominal operating voltage of
24 V DC gives a connection pattern of the output devices as shown in diagram (e) of
the figure. Which one of the four connections (a, b, c, or d) of the output devices
realized by a technician (shown in the figure) has a faulty connection? Explain your
answer.

Which one of the four connections (a, b, c, or d) of the output devices realized by a
technician (shown in the figure) has a faulty connection? Explain your answer.
The faulty connection is the circuit C. Because the digital output module of the
manufacturer gives us is a sink output so it needs the operating voltage of 24 V DC, but in
C there is no operating voltage which could lead to no load can operate. A deeper analyzing
is the connection a,b,c is non-isolated supply output and d is isolated supply output.

6.17. The activation of the power relay C from a PLC is performed via a power
transistor or a triac which are in the digital output module. Suppose that the power
transistor or triac has been burned and is at short-circuit status. What problem arises
concerning the function of the button STOP which must stop the operation of power
relay C, and how it can be addressed?

If the power transistor or triac in the digital output module has burned out and is in a short-
circuit state, this creates a serious problem: The burned transistor/triac creates a permanent
connection between the power supply and relay C, this means the re lay C will remain
energized regardless of the STOP button position. Even when you press the STOP button,
it cannot interrupt the current flowing through the short -circuited path. Therefore, the
manual emergency stop function becomes ineffective, creating a safety hazard.
There are some solutions to address it:

1. Install a Master Contactor: Place a master contactor or circuit breaker before both the
PLC output and the manual control circuit that can cut power to the entire circuit.
2. Redundant Stop Circuit: Implement a redundant emergency stop circuit that disconnects
power upstream of both the PLC and the relay.

Monitoring Circuit: Add a monitoring circuit that can detect abnormal current flow then
send a feedback signal to the PLC to detect if the output remains ON despite being
commanded OFF.

6.18. A modular type PLC is going to control a small system with 8 digital inputs, 8
digital outputs, and 1 analog input. What structural units (modules) do you have to
buy in order to implement the PLC-based automation system?

Required structural units for the PLC-based automation System:

Core Components

1. CPU/Processor Module

- The brain of the system that executes the control program

- Must have sufficient processing power, memory, and communication capabilities

- Manages data flow between all modules

2. Power Supply Module

- Converts AC mains power (120V/240V AC) to required DC voltage (typically 24V

DC)

- Powers the PLC system and modules

- Must be correctly sized for the total power requirements

3. Rack/Backplane/Base Module
 - Physical frame that houses and connects all modules

- Provides the communication bus between modules

- Select appropriate size to accommodate current needs and potential expansion

I/O Modules

4. Digital Input (DI) Module - 8 channels

- Processes 8 digital input signals from field devices (sensors, switches, buttons)

- Choose appropriate voltage rating (24V DC or 120V AC) based on field devices

- Provides electrical isolation between field devices and PLC

5. Digital Output (DO) Module - 8 channels

- Controls 8 digital output devices (relays, solenoids, indicator lights)

- Select appropriate type (relay, transistor, or triac outputs) based on load

requirements

- Consider current ratings and switching frequency needs

6. Analog Input (AI) Module - minimum 1 channel

- Converts analog signals to digital values the CPU can process

- Select appropriate signal type (0-10V, 4-20mA) based on the sensor

- May include multiple channels for future expansion

Optional Components

7. Communication Module

- Enables connectivity to HMI panels, SCADA systems, or other networks

- Common protocols include Ethernet/IP, Modbus, PROFIBUS, or RS485

- Required if remote monitoring or integration with other systems is needed

8. Programming Device/Software

- Not part of the physical PLC structure but essential for system configuration

- Needed to develop, test, and upload the control program to the PLC

- Often includes monitoring and diagnostic capabilities

6.19. Which is the maximum time delay that may happen between the activation of a
digital input and the activation of a digital output which depends logically on the first?

The maximum time delay between the activation of a digital input and the activation of a
digital output that depends on it is related to the PLC's scanning cycle duration. The
scanning cycle consists of reading inputs, executing the user program, and updat ing the
outputs. Therefore, the time delay is equal to the duration of the scanning cycle.

6.20. The operation of the electromechanical equipment of a road tunnel is going to

be controlled via a central PLC. The electromechanical equipment includes general
purpose lighting, acoustic and luminous signaling, a ventilation system, a fire safety
system, and a large number of sensors and meters. Although the machinery is
relatively distributed along the whole length of the tunnel, they may be grouped in the
three points as shown in the figure. The kind and number of I/O devices are also
indicated in the figure. Configure and design the I/O hardware system in detail,
selecting the PLC placement first. In particular, determine the local and peripheral
hardware, the kind and number of required I/O modules, the communication pattern
between I/O modules and CPU, and the method of grouping I/O points and modules,
giving the corresponding diagrams. The technical characteristics of the PLC are:

a. Each digital module contains 8 I/O points.

b. Each analog module contains 4 I/O points.

c. The maximum cable length for peripheral equipment is 900 m.

d. The maximum cable length for local equipment is 30 m.

e. The maximum cable length between a digital I/O module and digital I/O devices is
100 m.

f. Each installation rack may contain up to 6 I/O modules.

The automation and control system of the road tunnel will have a central selector
switch for selecting the manual or automatic operation of the system. All handling
and indicating devices must be installed at one of the two ends of the tunnel (on a
control panel) independently of the PLC location. All digital inputs and outputs have
the same nominal operating voltage of 24 V DC.
 At three points

Equipment Point 1 Point 2 Point 3 Total

Motors DS (Direct
5 0 5 10
Starting)
Motors IR (Inversible
3 0 3 6
Rotation)

Two-speed motors 2 0 2 4

Lighting control
32 32 32 96
outputs

Sirens 4 4 4 12

Alarm buttons 12 12 12 36

Photocells 12 12 12 36

Flow and level

3 3 3 9
switches

Analog inputs 8 8 8 24

Analog outputs 2 2 2 6

The most optimal point to place the PLC is point 2 because distance to Point 1 and Point 3
is 1 km, which is within the 900m remote I/O limit. So, it is possible to use remote I/O for
data transmission.

Digital I/O Modules Calculation

• Each digital I/O module has 8 points.

• Total Digital Inputs = Photocells (36) + Alarm buttons (36) + Flow & level switches
(9) = 81 points.
 • Total Digital Outputs = Motors DS (10) + Motors IR (6) + Two-speed motors (4) +
Sirens (12) + Lighting control outputs (96) = 128 points.

• Total Digital I/O points = 81 + 128 = 209 points.

• Required Digital I/O modules = 209 / 8 = 27 modules.

Analog I/O Modules Calculation

• Each analog I/O module has 4 points.

• Total Analog Inputs = 24.

• Total Analog Outputs = 6.

• Total Analog I/O points = 24 + 6 = 30 points.

• Required Analog I/O modules = 30 / 4 = 8 modules.

Rack estimation and classification

• Each PLC rack can hold up to 6 modules.

• Total Digital (27) + Analog (8) = 35 modules.
• At least 6 racks are required.

Digital Outputs Analog Outputs

Station Digital Inputs (DI) Analog Inputs (AI)
(DO) (AO)

32 (Lighting) + 5
12 (Photocells) + 3
(Motors DS) + 2
(Flow/Level) + 4
Station 1 (Motors IR) + 3 8 2
(Alarm Buttons) =
(Two-speed Motors)
19
+ 4 (Sirens) = 46
12 (Photocells) + 3
(Flow/Level) + 4 32 (Lighting) + 4
Station 2 8 2
(Alarm Buttons) = (Sirens) = 36
19
 Digital Outputs Analog Outputs
Station Digital Inputs (DI) Analog Inputs (AI)
(DO) (AO)

32 (Lighting) + 5
12 (Photocells) + 3
(Motors DS) + 2
(Flow/Level) + 4
Station 3 (Motors IR) + 3 8 2
(Alarm Buttons) =
(Two-speed Motors)
19
+ 4 (Sirens) = 46

Station 1 (Total: 19 DI, 46 DO, 8 AI, 2 AO)

• DI: 3 modules (24 DI > 19 needed)

• DO: 6 modules (48 DO > 46 needed)

• AI: 2 modules (8 AI is enough)

• AO: 1 module (4 AO > 2 needed)

• Total modules = 12 → 2 racks (since each rack can hold 6 modules)

Station 2 (Total: 19 DI, 36 DO, 8 AI, 2 AO)

• DI: 3 modules (24 DI > 19 needed)

• DO: 5 modules (40 DO > 36 needed)

• AI: 2 modules (8 AI is enough)

• AO: 1 module (4 AO > 2 needed)

• Total modules = 11 → 2 racks.

Station 3 (Total: 19 DI, 46 DO, 8 AI, 2 AO)

• DI: 3 modules (24 DI > 19 needed)

• DO: 6 modules (48 DO > 46 needed)

• AI: 2 modules (8 AI is enough)

• AO: 1 module (4 AO > 2 needed)

• Total modules = 12 → 2 racks.