Allen-Bradley 1203-GD1 Parts list manual

Getting
Started
Manual
Allen-Bradley
Bulletin 1203
Remote I/O
Communications
Module
Catalog Numbers
1203-GD1
1203-GK1
1336-GM1

Because of the variety of uses for the products described in this
publication, those responsible for the application and use of this
control equipment must satisfy themselves that all necessary steps
have been taken to assure that each application and use meets all
performance and safety requirements, including any applicable laws,
regulations, codes and standards.
The illustrations shown in this guide are intended solely for purposes
of example. Since there are many variables and requirements
associated with any particular installation, Allen-Bradley does not
assume responsibility or liability (to include intellectual property
liability) for actual use based upon the examples shown in this
publication.
Allen-Bradley publication SGI-1.1, Safety Guidelines for the
Application, Installation, and Maintenance of Solid-State Control
(available from your local Allen-Bradley office), describes some
important differences between solid-state equipment and
electromechanical devices that should be taken into consideration
when applying products such as those described in this publication.
Reproduction of the contents of this copyrighted publication, in
whole or in part, without written permission of Allen-Bradley
Company, Inc., is prohibited.
Throughout this manual we use notes to make you aware of safety
considerations:
!ATTENTION: Identifies information about practices
or circumstances that can lead to personal injury or
death, property damage or economic loss.
Attention statements help you to:
•identify a hazard
•avoid the hazard
•recognize the consequences
Important: Identifies information that is critical for successful
application and understanding of the product.
PLC, PLC–2, PLC–3, and PLC–5 are registered trademarks of Allen–Bradley Company, Inc.
PLC–2/30, PLC–5/10, PLC–5/15, PLC–5/25, PLC–5/30, PLC–5/40, PLC–5/40L, PLC–5/60L, and PLC–5/250 are trademarks
of Allen–Bradley Company, Inc.
SCANport is a registered trademark of Allen–Bradley Company, Inc.
SLC 500, SLC–5/02, and PLC–5/15 are registered trademarks of Allen–Bradley Company, Inc.
DH+ is a registered trademark of Allen–Bradley Company, Inc.
Important User
Information

Summary of Changes
Publication 1203–5.1 – July, 1997
Summary of Changes
We would like to call your attention to the following changes to the
1203-5.1 manual which have occurred since the previous version
published in April, 1996. All references to page, table, and figure
numbers refer to the December publication. Page, table, and figure
numbers in the July, 1997 publication may not match the page, table,
and figure number references mentioned here due to omissions or
inclusions and, likewise, text and graphics shifting somewhat from
page to page.
•Page 1–1 was updated to include the 1336 IMPACT and 1397
drives.
•Figure 1.1 was changed to reflect a change in LED colors.
•Figure 1.2 was changed to reflect a change in LED colors.
•Figure 4.1 was changed to reflect a change in LED colors.
•Table 4.A was changed to reflect a change in LED colors.
•Table 5.A was changed to identify the column headings more
clearly.

soc–ii Summary of Changes
Publication 1203–5.1 – July, 1997

Preface
Who Should Use this Manual? P–1. . . . . . . . . . . . . . . . . . . . . . . . . . .
Purpose of this Manual P–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents of this Manual P–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SafetyPrecautions P–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Firmware Support P–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLC Product Compatibility P–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terms and Abbreviations P–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Common Techniques Used in this Manual P–3. . . . . . . . . . . . . . . . . . .
Allen–BradleySupport P–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Local Product Support P–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Product Assistance P–4. . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 1
ChapterObjectives 1–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AdapterDescription 1–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCANport Device Compatibility 1–1. . . . . . . . . . . . . . . . . . . . . . . . . . .
ConfigurationSwitches 1–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Datalinks 1–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SafetyPrecautions 1–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 2
ChapterObjectives 2–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting the Module Configuration Switches 2–1. . . . . . . . . . . . . . . . . .
Switch SW3 2–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch SW2 2–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch SW1 2–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting the Remote I/O Module 2–9. . . . . . . . . . . . . . . . . . . . . . . . .
Connecting the Remote I/O Cable 2–12. . . . . . . . . . . . . . . . . . . . . . . . .
Connecting the TerminationResistor 2–14. . . . . . . . . . . . . . . . . . . . . . .
Connecting the SCANport Link 2–16. . . . . . . . . . . . . . . . . . . . . . . . . . .
1305 Drive 2–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1336 PLUS (7.5 – 500HP) and 1336 FORCE 2–16. . . . . . . . . . . . . . .
SMP 3 2–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SMC Dialog Plus 2–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting the Power Supply 2–18. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 3
ChapterObjectives 3–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Programmable Controller Data Table Use 3–1. . . . . . . . . . . . . . . . . . .
Data Transfer Through the Communications Module 3–3. . . . . . . . . . . .
Table of Contents
Overview
Installation
Configuration and
Interfacing

ii
Publication 1203–5.1 – July, 1997
Chapter 4
ChapterObjectives 4–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TroubleshootingTable 4–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 5
ChapterObjectives 5–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ProductSpecifications 5–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Programmable Controller Compatibility 5–2. . . . . . . . . . . . . . . . . . . . .
Troubleshooting
Specifications

Preface
Publication 1203–5.1 –– July, 1997
Preface
Read this preface to familiarize yourself with the rest of the manual.
This preface covers the following topics:
•who should use this manual
•the purpose of this manual
•safety precautions
•firmware support
•product compatibility
•terms and abbreviations
•conventions used in this manual
•Allen–Bradley support
Use this manual if you are responsible for designing, installing,
programming, or troubleshooting control systems that use the
Bulletin 1203 remote I/O communications module. You must have
previous experience with and a basic understanding of electrical
terminology, configuration procedures, required equipment, and
safety precautions.
To efficiently use this communications module, you must be able to
program and operate an Allen-Bradley programmable controller. In
particular, you must be familiar with remote I/O concepts and
configuration and be able to program block transfer instructions.
This manual provides you with the information you need to apply the
remote I/O communications module that is available for products
that include the SCANporttcommunications port. This manual
describes the procedures for installing, configuring, and
troubleshooting the remote I/O communications module. Block
transfer instructions are explained in a separate software
programming manual.
For information on specific product features, refer to the product
manual.
Important: Read this manual in its entirety before installing,
operating, servicing, or initializing the remote I/O
communications module.
Who Should Use this
Manual?
Purpose of this Manual

P–2 Preface
Publication 1203–5.1 –– July, 1997
Contents of this Manual
This manual contains the following information:
Chapter: Title: Contents:
Preface Describes the purpose, background, and scope of this
manual as well as an overview of this product.
1 Overview Provides an overview of the adapter features,
configuration information, and diagnostic information.
2 Installation
Provides the procedures you need to mount the Bulletin
1203 remote I/O communications module, connect the
power, and configure the switches, as well as providing
cabling and hardware information.
3Configuration and
Interfacing Provides information such as addressing, information transfer, and sample programs.
4 Troubleshooting Provides information about the LED indications and
fault descriptions.
5 Specifications Provides the environmental, electrical, and
communications specifications.
Please read the following safety precautions carefully.
!ATTENTION: Only personnel familiar with
SCANport devices and the associated machinery
should plan or implement the installation, start-up,
configuration, and subsequent maintenance of this
remote I/O communications module. Failure to comply
may result in personal injury and/or equipment
damage.
!ATTENTION: This module contains ESD
(Electrostatic Discharge) sensitive parts and
assemblies. Static control precautions are required
when installing, testing, servicing, or repairing this
assembly. Component damage may result if ESD
control procedures are not followed. If you are not
familiar with static control procedures, reference
Allen-Bradley Publication 8000-4.5.2, Guarding
against Electrostatic Damage, or any other applicable
ESD protection handbook.
This manual supports communication module firmware versions
1.xx and 2.xx (the xx designator may vary). Features that work with
specific firmware versions will be denoted as such.
Safety Precautions
Firmware Support

P–3Preface
Publication 1203–5.1 –– July, 1997
This adapter is designed to be used with the following Allen-Bradley
programmable controllers:
•PLC-2/30with SD2 (communications module version 1.02 or
later)
•PLC-3
•SLC 500twith 1747-SN scanner
•PLC-5/10t, PLC-5/15t, PLC-5/25tfamily
•PLC-5/30t, PLC-5/40t, PLC-5/40Lt, PLC-5/60t,
PLC-5/60Ltfamily, PLC-5/80t
•PLC5/250t
•PLCscanner modules and subscanners.
This adapter was tested with the current revision level of the PLC
processors listed. Earlier versions of the processors may not be
compatible.
The following terms and abbreviations are specific to this product.
For a complete listing of Allen–Bradley terminology, refer to the
Allen–Bradley Industrial Automation Glossary.
In this manual, we refer to the:
•remote I/O communications module as communications module
•variable frequency ac drive (1305, 1336 FORCE, or 1336 PLUS)
as the drive or SCANport device
•The programmable logic controller as the programmable
controller
•Allen–Bradley remote input/output network as remote I/O
•earth ground as Gnd
The following conventions are used throughout this manual:
•Bulleted lists provide information, not procedural steps.
•Numbered lists provide sequential steps or hierarchical
information.
•Italic type is used for emphasis and chapter names.
We also use this convention to call attention to helpful information.
PLC Product Compatibility
"
Terms and Abbreviations
Common Techniques Used in
this Manual
"

P–4 Preface
Publication 1203–5.1 –– July, 1997
Allen–Bradley offers support services worldwide, with over 75
Sales/Support Offices, 512 authorized Distributors and 260
authorized Systems Integrators located throughout the United States
alone, plus Allen–Bradley representatives in every major country in
the world.
Local Product Support
Contact your local Allen–Bradley representative for:
•sales and order support
•product technical training
•warranty support
•support service agreements
Technical Product Assistance
If you need to contact Allen–Bradley for technical assistance, please
review the information in the Troubleshooting chapter first. If you
are still having problems, then call your local Allen–Bradley
representative.
Allen–Bradley Support

Chapter 1
Publication 1203–5.1 –– July, 1997
Overview
Chapter 1 covers the following information:
•a description of the communications module
•SCANport device compatibility
•configuration switches
•datalinks
•safety precautions
The remote I/O communications module is an optional interface
device designed to provide a direct, digital link between an
Allen-Bradley programmable controller and any device that uses the
SCANporttcommunication port. The current list of products that
use the SCANport communications interface includes: 1305, 1336
PLUS, 1336 FORCE, 1336 IMPACT, 1397, and SMP3 and SMC
Dialog Plus. The board connects to these products through the
SCANport peripheral interface.
The adapter is available in both Open style (Figure 1.1) and Enclosed
(Figure 1.2) type configurations. The Open style module mounts
inside certain drives, depending on drive size (refer to Table 1.A).
You can use the Enclosed module with any compatible SCANport
device that is mounted outside the drive package.
Table 1.A Remote I/O Configurations
Designation Enclosure Power Supply Source Used With
Open Style Open PC board Supplied by drive 1336 PLUS➀
1336 FORCE➁
Enclosed IP30 24V ac/dc separately supplied or
120/240V ac separately supplied
1305
1336 PLUS
1336 FORCE
SMP3
SMC Dialog Plus
Other SCANport products
➀7.5 hp and higher sizes only
➁7.5 hp and higher sizes with standard adapter board only
The remote I/O communications module does not support version
1.xx (the .xx designator may vary) of the 1305 drive. If you try to
use the remote I/O communications module with a version 1.xx
1305, the remote I/O communications module will continually reset
itself, resulting in the red adapter fault status LED and the amber
SCANport status LED both flashing simultaneously indicating an
error condition. Firmware revision 2.xx or higher on the 1305 is
required to support remote I/O communications and block transfer.
Chapter Objectives
Adapter Description
SCANport Device
Compatibility

1–2 Overview
Publication 1203–5.1 –– July, 1997
Figure 1.1
Open Style Communications Module
SW1
Front View
SW2SW3
Remote I/O Connector
Adapter Fault
Status (Red)
SCANport Status
(Green)
Adapter Health
(Green)
Remote I/O Status
(Green)
Remote I/O Active
(Green) J4
181818
Block Transfer Enable
Logic Command / Status Enable
Analog Reference / Feedback Enable
Datalink A-D enable
Truncate last datalink Starting Quarter
Baud Rate
Rack Fault
Hold Last State
Last Rack
Rack Address

1–3Overview
Publication 1203–5.1 –– July, 1997
Figure 1.2
Enclosed Style Communications Module
Front View
SW1
Remote I/O Status (Green)
Remote I/O Active (Green)
Connect
Power Supply Here Adapter Health (Green)
SCANport Status (Green)
Adapter Fault Status (Red)
Remote I/O
Connector
SCANport
Communication
Cable Connector
Bottom View
1
Switch SW3
– Block Transfer Enable
– Logic Command/
Status Enable
– Analog Reference/
Feedback Enable
– Datalink A-D enable
– Truncate last datalink
Switch SW1
– Rack Address
SW2818SW3 18
Switch SW2
– Starting Quarter
– Baud Rate
– Rack Fault
– Hold Last State
– Starting Quarter
.
.
.

1–4 Overview
Publication 1203–5.1 –– July, 1997
Figure 1.3
Typical Programmable Controller/SCANport Device Interconnection
SCANport
Communications
Module
PLC
.
.
.
1305*
Micro
Drive
1336 PLUS
Open Style
RIO
Adapter
Remote I/O Link
.
Other Remote I/O Devices
ÁÁÁ
ÁÁÁ
ÀÀ
ÀÀ
Panel View Operator Terminal
*NOTE:Refer to Page 1–1 for compatibility
requirementsofSCANport devices
SCANport
Communications
Module
SMP 3
Communications
Module
SMC Dialog Plus

1–5Overview
Publication 1203–5.1 –– July, 1997
The remote I/O communications module contains three DIP switches
SW1, SW2, and SW3 (Figure 1.1 and Figure 1.2). Switches are set
On or Off as detailed in Figure 1.4. For a detailed explanation of
switch configuration, refer to Chapter 2, Installation.
Figure 1.4
ConfigurationSwitch
Side View of Typical Switches
Open
8
Closed (On)
1234
5
67
OPEN
Open Open (Off)
Rocker Switch
Open
Open
Slide Switch
Switch Designation as
shown in this manual
OFF (OPEN)
ON
Datalinks are a SCANport mechanism for transferring additional
information between a programmable controller and a SCANport
device. Each datalink switch on the adapter reserves two words of
the programmable controller I/O image table. The 1305, 1336
PLUS, and 1336 FORCE drives support this mechanism. For
additional details, refer to Chapter 3, Configuration and Interfacing.
Configuration Switches
Datalinks

1–6 Overview
Publication 1203–5.1 –– July, 1997
Please read the following safety precautions.
!ATTENTION: This board contains ESD
(Electrostatic Discharge) sensitive parts and
assemblies. Static control precautions are required
when installing, testing, servicing, or repairing this
assembly. Component damage may result if you do not
follow ESD control procedures. If you are not familiar
with static control procedures, refer to Allen-Bradley
publication 8000-4.5.2, Guarding Against Electrostatic
Damage, or any other applicable ESD Protection
Handbook.
!ATTENTION: Servicing or configuring the RIO
boards on drives larger than 3hp involves opening the
1336 drive cabinet which creates the potential to come
in contact with other drive components. Energized
industrial control equipment can be hazardous. Severe
injury or death can result from electrical shock, burn,
or unintended actuation of controlled equipment.
Recommended practice is to disconnect and lock out
all control equipment from power sources, and allow
stored energy in any capacitors to dissipate. If you
must work near energized equipment, you must follow
the safety related work practices of NFPA 70E,
Electrical Safety Requirements for Employee
Workplaces.
Safety Precautions

Chapter 2
Publication 1203–5.1 –– July, 1997
Installation
Chapter 2 provides information to help you:
•set the module configuration switches
•mount the remote I/O module
•connect the remote I/O cable
•connect the termination resistor
•connect the SCANport link
•connect the power supply
Read this chapter completely before you attempt to install or
configure your remote I/O communications module. Double check
all connections and option selections before you apply power.
Important: Switch selections take effect only on power–up. If you
change selections after power is applied, cycle the
power to use the new settings.
This publication describes switches as being either on or off. If the
switch assembly has the word OPEN printed on it, the word OPEN
corresponds to OFF (O).
When you change the adapter board configurations, keep in mind the
addressing conventions of the type of processor that you are using. In
all cases, each remote I/O device must have a unique address that the
processor can recognize.
Important: This adapter is not compatible with complementary I/O
configurations because the adapter uses both output and
input image words for proper drive control.
!ATTENTION: When you make changes to the switch
settings, use a blunt, pointed instrument such as a ball
point pen. Do not use a pencil because the lead
(graphite) of the pencil may damage the switch
assembly.
ATTENTION: Failure to check connections and
switch settings for compatibility with your application
when configuring the communications module, could
result in personal injury and/or equipment damage due
to unintended or undesirable operation of the drive or
process equipment.
Chapter Objectives
Setting the Module
Configuration Switches

2–2 Installation
Publication 1203–5.1 –– July, 1997
Switch SW3
Set switch SW3 first. The settings on this switch determine how the
SCANport device uses the data contained in the programmable
controller I/O image table. SW3 also establishes the minimum rack
size that this communications module requires.
The switches are labeled in the same orientation as they appear on
the board.
Table 2.A, SW3 Image Table Map, and Figure 2.2, SW3 Flowchart,
are included to help you set the DIP switches properly. It may also
be helpful to color in the final switch settings in Figure 2.1 as a
visual record of your SW3 settings. Chapter 3 contains several
examples of how to fill in the worksheet and set these DIP switches.
Figure 2.1
Configuration Switch SW3 Settings
J1
SW3
Block
Transfer
Off
Datalink A
Transfers
On
Logic
Command/Status
On
Off
Reference/
Feedback
On
Off
On
Off
Datalink B
Transfers
Datalink C
Transfers
On
Off
On
Off
On
Off
Datalink D
Transfers
81234567
OPEN
Truncate➀➁
Last Datalink
➀IMPORTANT: Only available on communications modules with version 1.02 or later firmware.
➁All datalinks are two words, the truncate function will delete the last datalink word. (If “Datalink B” is the last used,
“Data in B2” and “Data Out B2” will be truncated.)
Open Style Enclosed Style
Off
On
Not
Enabled
Enabled
Off (Open)
On
"

2–3Installation
Publication 1203–5.1 –– July, 1997
Table 2.A
SW3 Image Table Map
RESERVED FOR: Minimum
Ri
S
tart
A
t
Gp
Output Image Input Image
R
equ
i
red
Rack Size➀
S
tart
A
t
Group
R
0
1/4
R
ack
0
, 2, 4, or 6
lf R
0
Ha
lf
R
ack
0
, 2, or 4
R
0
3/4
R
ack
0
or 2
ll R
0 nly
Fu
ll
R
ack
0
o
nly
➀Use this to select settings for switch SW2, switches 1 and 2
How to use Table 2.A:
1. Use Figure 2.2 to set DIP switch SW3 and fill out Table 2.A.
2. Use minimum rack size shown in Table 2.A to set DIP switch
SW2-1 and SW2-2.
Figure 2.2
SW3 Flowchart
Will block transfer or block transfer RIO pass thru
be used?
1. Block Transfer
YES
1. Write “Block Transfer” in word 0 of both the input
and the output image
2. Set SW 3-1 to on
Will the SCANport device be controlled by (Start/Stop
etc.) or will the Logic Status by monitored by the PLC?
2. Logic Command
NO
NO 2. Move to step 2
YES
1. Write “Logic Cmd” in the output image and “Logic
Status” in the input image of the next available word
2. Set SW3-2 to on
Will a reference or feedback be provided
from/to the programmable controller?
3. Reference/Feedback
NO
YES
1. Write “Reference” in the output image and
“Feedback” in the input image of the next available
word
2. Set SW3-3 to on
NOTE: For detailed information on block transfer
messages refer to the 1203-5.0 Reference Manual.
Step
Step
Step
1. Set SW3-1 to off
2. Move to step 3
1. Set SW3-2 to off
2. Move to step 4
1. Set SW3-3 to off

2–4 Installation
Publication 1203–5.1 –– July, 1997
Figure 2.2
SW3 Flowchart continued
Will Datalink Group B be used?
Step 5. Datalink B Transfer
YES
NO
1. Write “Datalink B“ in the output and input image
of the next two available words
2. Set SW3-5 to on
Will Datalink Group C be used?
Step 6. Datalink C Transfer
YES
NO
1. Write “Datalink C” in the output and input image
of the next two available words
2. Set SW3-6 to on
Will Datalink Group D be used?
Step 7. Datalink D Transfer
YES
NO
1. Write “Datalink D” in the output and input image
of the next two available words
2. Set SW3-7 to on
Step 9. Calculate minimum rack size
Refer to Table 2.A on page page 2–3.
1. Record the minimum rack size in Table 2.A on page 2–3.
2. Use the minimum rack size to set Dip switches SW2-1 and SW2-2.
Will the last Datalink be one word
(truncate last Datalink) ?
Step 8. Truncate Last Datalink
YES
NO
1. Cross out the last word of the last Datalink group
used in the output and input image table
2. Set SW3-8 to on
2. Move to step 6
1. Set SW3-5 to off
2. Move to step 7
1. Set SW3-6 to off
2. Move to step 8
1. Set SW3-7 to off
2. Move to step 9
1. Set SW3-8 to off
Will Datalink Group A be used?
4. Datalink A Transfer
YES
NO
1. Write “Datalink A” in the output and input image
of the next two available words
2. Set SW3-4 to on
Step
2. Move to step 5
1. Set SW3-4 to off