Allen-Bradley 1746-NIO4I User manual

SLC ™ 500
4-Channel Analog
I/O Modules
(Catalog Numbers 1746-NI4,
1746-NIO4I, 1746-NIO4V,
1746-NO4I, and 1746-NO4V)
User Manual
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Important User Information
Solid state equipment has operational characteristics differing from those of
electromechanical equipment. Safety Guidelines for the Application,
Installation and Maintenance of Solid State Controls (Publication SGI-1.1
available from your local Rockwell Automation sales office or online at
http://www.ab.com/manuals/gi) describes some important differences
between solid state equipment and hard-wired electromechanical devices.
Because of this difference, and also because of the wide variety of uses for
solid state equipment, all persons responsible for applying this equipment
must satisfy themselves that each intended application of this equipment is
acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for
indirect or consequential damages resulting from the use or application of
this equipment.
The examples and diagrams in this manual are included solely for illustrative
purposes. Because of the many variables and requirements associated with
any particular installation, Rockwell Automation, Inc. cannot assume
responsibility or liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to
use of information, circuits, equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without
written permission of Rockwell Automation, Inc. is prohibited.
Throughout this manual we use notes to make you aware of safety
considerations.
WARNING Identifies information about practices or circumstances
that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property
damage, or economic loss.
IMPORTANT Identifies information that is critical for successful
application and understanding of the product.
ATTENTION Identifies information about practices or circumstances
that can lead to personal injury or death, property
damage, or economic loss. Attentions help you:
•identify a hazard
•avoid a hazard
•recognize the consequence
SHOCK HAZARD Labels may be located on or inside the drive to alert
people that dangerous voltage may be present.
BURN HAZARD Labels may be located on or inside the drive to alert
people that surfaces may be dangerous temperatures.
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Publication 1746-UM005B-EN-P - June 2004
Summary of Changes
The information below summarizes the changes to this manual since
the last printing.
To help you find new and updated information in this release of the
manual, we have included change bars as shown to the right of this
paragraph.
For information on: See:
SCP (scale with parameters) instruction available with SLC™
5/05 6-3, 6-9, 6-15, 6-21
Change in Impedance to ANL Com specification for NI4
Series B module A-1
Change in Impedance Channel to Channel specification for
NI4 Series B module A-1
Change in Input Impedance specification for NI4 Series B
module A-4
Change in resistance value for NI4 Series B module Appendix D
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iPublication 1746-UM005B-EN-P - June 2004
Table of Contents
Preface
Who Should Use this Manual. . . . . . . . . . . . . . . . . . . . . . . P-1
Purpose of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
Related Documentation . . . . . . . . . . . . . . . . . . . . . . . . P-2
Common Techniques Used in this Manual . . . . . . . . . . . . . P-3
Your Questions or Comments on this Manual . . . . . . . . P-3
Chapter 1
Overview
How to Use Analog. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Types of Analog Modules . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1746-NI4 Analog Input Module. . . . . . . . . . . . . . . . . . . 1-2
1746-NIO4I and NIO4V Analog Combination Modules. . 1-2
1746-NO4I and NO4V Analog Output Modules . . . . . . . 1-2
Chapter 2
Quick Start for Experienced Users
Required Tools and Equipment . . . . . . . . . . . . . . . . . . . . . 2-1
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Chapter 3
Installing and Wiring Your Analog
Module
European Union Directive Compliance . . . . . . . . . . . . . . . 3-1
EMC Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Determining Your Power Requirements for a Modular
Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Determining Your Power Requirements for a Fixed
Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Configuring Your Module . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Switch Settings for the 1746–NI4. . . . . . . . . . . . . . . . . . 3-5
Switch Settings for the 1746-NIO4I and -NIO4V. . . . . . . 3-5
External Power Switch for the 1746-NO4I and -NO4V . . 3-6
Choosing a Slot in the Chassis . . . . . . . . . . . . . . . . . . . . . . 3-6
Installing Your Module . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Removing the Analog Module Terminal Block. . . . . . . . 3-7
Wiring Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
System Wiring Guidelines. . . . . . . . . . . . . . . . . . . . . . . 3-9
Grounding Your Cable. . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Determining the Cable Length . . . . . . . . . . . . . . . . . . . 3-10
Wiring the Analog Module. . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Labeling and Installing the Terminal Block. . . . . . . . . . . . . 3-12
Grounding the Foil Shields and Drain Wires. . . . . . . . . . . . 3-12
Wiring Schematics for 2, 3, and 4-Wire Analog Input
Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Wiring Schematic for Single-ended Analog Input
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Minimizing Electrical Noise on Analog Modules . . . . . . . . . 3-15
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Table of Contents ii
Chapter 4
Module Operation and System
Considerations
Interface between the Module and the Processor . . . . . . . . 4-1
Entering Module ID Codes . . . . . . . . . . . . . . . . . . . . . . 4-1
Addressing Analog Modules . . . . . . . . . . . . . . . . . . . . . 4-2
Bit Level Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Processor Update of Analog Data . . . . . . . . . . . . . . . . . 4-5
Monitoring the Input and Output Data . . . . . . . . . . . . . 4-5
Converting Analog Input Data . . . . . . . . . . . . . . . . . . . 4-6
Converting Analog Output Data . . . . . . . . . . . . . . . . . . 4-7
System Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Safe State for Outputs . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Retentive Programming Option. . . . . . . . . . . . . . . . . . . 4-9
Retentive Analog Output Example . . . . . . . . . . . . . . . . 4-10
Non-Retentive Analog Output Example. . . . . . . . . . . . . 4-11
During a Mode Change or Power Cycle . . . . . . . . . . . . 4-11
Input Out-of-Range Detection. . . . . . . . . . . . . . . . . . . . 4-11
Response to Slot Disable . . . . . . . . . . . . . . . . . . . . . . . 4-13
Input Response to Slot Disable. . . . . . . . . . . . . . . . . . . 4-13
Output Response to Slot Disable . . . . . . . . . . . . . . . . . 4-13
Input Channel Filtering . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Chapter 5
Testing Your Module
Testing the SLC 500 System . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Start-up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Inspect the Analog Module. . . . . . . . . . . . . . . . . . . . . . 5-2
Disconnect Prime Movers (Motion Devices) . . . . . . . . . 5-2
Power Up the SLC 500 System . . . . . . . . . . . . . . . . . . . 5-3
Testing Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Testing Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Chapter 6
Programming Examples
Addressing, Out-of-Range Detection, and Scaling of Analog
Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Calculating the Linear Relationship . . . . . . . . . . . . . . . . 6-2
Calculating the Out-of-Range Flag Using the Scale
Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Using Standard Math . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Using the Scale (SCL) Instruction . . . . . . . . . . . . . . . . . 6-6
Using Scale with Parameters (SCP) Instruction. . . . . . . . 6-7
Addressing and Scaling Outputs. . . . . . . . . . . . . . . . . . . . . 6-8
Calculating the Linear Relationship . . . . . . . . . . . . . . . . 6-8
Using Standard Math . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Using the Scale with Parameters (SCP) Instruction. . . . . 6-12
Scaling Offset when > 32,767 or < -32,768 . . . . . . . . . . . . . 6-14
Calculating the Linear Relationship . . . . . . . . . . . . . . . . 6-14
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Calculating the Shifted Linear Relationship . . . . . . . . . . 6-15
Using Standard Math . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Using the Scale with Parameters (SCP) Instruction. . . . . 6-18
Scaling and Range Checking and Analog Inputs and
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Calculating the Linear Relationship . . . . . . . . . . . . . . . . 6-21
Using Standard Math Instructions . . . . . . . . . . . . . . . . . 6-22
Scaling and Range Checking of Analog Inputs and
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Using SCL Instruction. . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Using the Scale with Parameters (SCP) Instruction. . . . . 6-26
Chapter 7
Maintenance and Safety
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Safety Considerations When Troubleshooting. . . . . . . . . . . 7-2
Appendix A
Specifications
Analog Modules Specification . . . . . . . . . . . . . . . . . . . . . . A-1
General Specifications for NI4, NIO4I, NIO4V, NO4I, and
NO4V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
General Analog Input Specifications for NI4, NIO4I, and
NIO4V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Current-Loop Input Specifications for NI4, NIO4I, and
NIO4V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Voltage Input Specifications for NI4, NIO4I, and NIO4V . . . A-4
Current Output Specifications for NIO4I and NO4I . . . . . . . A-5
Voltage Output Specifications for NIO4V and NO4V. . . . . . A-6
Appendix B
Two’s Complement Binary
Numbers
Positive Decimal Values . . . . . . . . . . . . . . . . . . . . . . . . A-1
Negative Decimal Values . . . . . . . . . . . . . . . . . . . . . . . A-2
Appendix C
Optional Analog Input Software
Calibration
Calibrating an Analog Input Channel . . . . . . . . . . . . . . . . . A-1
Calculating the Software Calibration . . . . . . . . . . . . . . . A-2
Appendix D
Module Input and Output Circuits
Index
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Table of Contents iv
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1Publication 1746-UM005B-EN-P - June 2004
Preface
Read this preface to familiarize yourself with the rest of the manual. It
provides information concerning:
•who should use this manual
•the purpose of this manual
•related documentation
•conventions used in this manual
•Rockwell Automation support
Who Should Use this
Manual
Use this manual if you are responsible for designing, installing,
programming, or troubleshooting control systems that use SLC 500
4-Channel Analog I/O Modules.
You should have a basic understanding of electrical circuitry and
familiarity with relay logic. If you do not, obtain the proper training
before using this product.
Purpose of this Manual
This manual describes the procedures you use to install, wire, and
troubleshoot your 4-channel analog I/O module. This manual:
•explains how to install and wire your module
•gives you an overview of the SLC 500 programmable controller
system
Refer to your programming software user documentation for more
information on programming your SLC 500 programmable controller.
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2 Preface
Related Documentation
The following documents contain additional information concerning
Rockwell Automation products. To obtain a copy, contact your local
Rockwell Automation office or distributor.
For Read this Document Document Number
In-depth information on the SLC Instruction Set. SLC 500 Instruction Set Reference Manual 1747-RM001
A description on how to install and use your Modular SLC 500
programmable controller. SLC 500 Modular Hardware Style User Manual 1747-UM011
A description on how to install and use your Fixed SLC 500
programmable controller. SLC 500 Fixed Hardware Style Installation & Operation Manual 1747-6.21
A description on how to install 4-channel analog I/O modules SLC 500 4-Channel Analog I/O Modules
Installation Instructions 1746-IN008
Information on reducing electrical noise. System Design for Control of Electrical
Noise GMC-RM001
In-depth information on grounding and wiring Allen-Bradley®
programmable controllers. Allen-Bradley Programmable Controller Grounding and Wiring Guidelines 1770-4.1
A description of important differences between solid-state
programmable controller products and hard-wired electromechanical
devices.
Application Considerations for Solid-State
Controls SGI-1.1
An article on wire sizes and types for grounding electrical
equipment. National Electrical Code - Published by the National Fire Protection Association of Boston, MA.
A glossary of industrial automation terms and abbreviations. Allen-Bradley Industrial Automation
Glossary AG-7.1
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Preface 3
If you would like a manual, you can:
•download an electronic version from the internet at:
–www.theautomationbookstore.com
–http://ab.com/manuals
•order a printed manual by:
–contacting your local distributor or Rockwell Automation
representative
–visiting www.theautomationbookstore.com
–calling 1.800.963.9548 (USA/Canada) or 001.330.725.1574
(Outside USA/Canada)
Common Techniques Used
in this Manual
The following conventions are used throughout this manual:
•Bulleted lists such as this one provide information, not
procedural steps.
•Numbered lists provide sequential steps or hierarchical
information.
•Italic type is used for emphasis.
Your Questions or Comments on this Manual
If you find a problem with this manual, or you have any suggestions
for how this manual could be made more useful to you, please
contact us at the address below:
Rockwell Automation
Automation Control and Information Group
Technical Communication, Dept. A602V
P.O. Box 2086
Milwaukee, WI 53201-2086
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4 Preface
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1Publication 1746-UM005B-EN-P - June 2004
Chapter 1
Overview
This chapter describes how analog is used and provides two
application examples of analog. The types of available analog
modules and their related specifications are also described.
How to Use Analog
Analog refers to the representation of numerical quantities by the
measurement of continuous physical variables. Analog applications
are present in many forms. The following application shows a typical
use of analog.
In this application the processor controls the amount of fluid placed in
aholding tank by adjusting the percentage of the valve opening. The
valve is initially open 100%. As the fluid level in the tank approaches
the preset point, the processor modifies the output to degrade closing
the valve 90%, 80%, adjusting the valve to maintain a set point.
Types of Analog Modules
The following sections provide an overview of the various analog
modules.
Level Sensor CPU
Analog Input
Analog Output
Valve
Analog I/O
Module
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1-2 Overview
1746-NI4 Analog Input Module
The 1746-NI4 Analog Input module contains 4 analog input channels
that are user selectable per channel for voltage or current to support a
variety of monitoring and controlling applications
1746-NIO4I and NIO4V Analog Combination Modules
The NIO4I and NIO4V Analog Combination I/O modules provide two
input and two output channels in a single slot module. The
1746-NIO4I module contains two current or voltage inputs (user
selectable per channel), and two current outputs. The 176-NIO4V
module contains two current or voltage inputs (user selectable per
channel) and two voltage outputs.
1746-NO4I and NO4V Analog Output Modules
The NO4I and NO4V Analog Output Modules provide 4 analog output
channels. The NO4I module contains four current outputs. The NO4V
module contains four voltage outputs. Both of these modules support
a variety of monitoring and controlling applications.
For more specification information, refer to Appendix A.
Catalog 1746- Input Channels per
Module Output Channels per Module Backplane Current Draw External 24V dc Power Supply Tolerances
5V (max.) 24V (max.)
NI4 4 differential, voltage or
current selectable per
channel, not individually
isolated
NA 35 mA 85 mA NA
NIO4I 2 differential, voltage or
current selectable per
channel, not individually
isolated
2 current outputs, not
individually isolated 55 mA 145 mA NA
NIO4V 2 differential, voltage or
current selectable per
channel, not individually
isolated
2 voltage outputs, not
individually isolated 55 mA 115 mA NA
NO4I NA 4 current outputs, not
individually isolated 55 mA 195 mA 24 ±10% at 195 mA max.
(21.6 to 26.4V dc)(1)
NO4V NA 4 voltage outputs, not
individually isolated 55 mA 145 mA 24 ±10% at 145 mA max.
(21.6 to 26.4V dc)(1)
(1) Required for some applications if SLC 24V power is not readily available.
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1Publication 1746-UM005B-EN-P - June 2004
Chapter 2
Quick Start for Experienced Users
This chapter can help you to get started using analog. The procedures
are based on the assumption that you have an understanding of SLC
500 products. You should understand electronic process control and
be able to interpret the ladder logic instructions required to generate
the electronic signals that control your application.
Because it is a start–up guide for experienced users, this chapter does
not contain detailed explanations about the procedures listed. It does,
however, reference other chapters in this book where you can get
more information.
If you have any questions or are unfamiliar with the terms used or
concepts presented in the procedural steps, always read the
referenced chapters and other recommended documentation before
trying to apply the information.
This chapter:
•tells you what tools and equipment you need
•lists preliminary considerations
•describes when to configure the module
•explains how to install and wire the module
•discusses system power–up procedures
Required Tools and
Equipment
Have the following tools and equipment ready:
•small blade screwdriver
•an adequate length of communication cable (Belden™8761) for
your specific application. (See chapter 3, Installing and Wiring
Your Analog Module for maximum cable distances.)
•programming equipment
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2-2 Quick Start for Experienced Users
Procedures
1. Check the contents of shipping box. Reference
Unpack the shipping box making sure that the contents include:
•Analog I/O module (Catalog Number 1746-Series)
•installation instructions (publication 1746-IN008)
If the contents are incomplete, call your local Allen–Bradley representative for assistance.
2. Determine your power requirements for the modular controller. Reference
Review the power requirements of your system to see that your chassis supports placement of the
analog module.
•For modular style systems, calculate the total load on the system power supply using the
procedure described in the SLC 500 Modular Hardware Style User Manual (publication
1747-UM011) or the SLC 500 Family System Overview (publication 1747-SO001).
•For fixed SLC 500 controllers, refer to the SLC 500 Fixed Hardware Style Installation &
Operation Manual (publication 1747-6.21).
Chapter 3
(Installing and
Wiring Your
Analog Module)
Appendix A
(Specifications)
Catalog Number Backplane Current Draw External 24V dc Power
Supply Tolerance
5V (max.) 24V (max.)
1746-NI4 35 mA 85 mA NA
1746-NIO4I 55 mA 145 mA NA
1746-NIO4V 55 mA 115 mA NA
1746-NO4I 55 mA 195 mA 24 ±10% at 195 mA max.
(21.6 to 26.4V dc)(1)
1746-NO4V 55 mA 145 mA 24 ±10% at 145 mA max.
(21.6 to 26.4V dc)(1)
(1) Required for some applications if SLC 24V power is not readily available.
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Quick Start for Experienced Users 2-3
3. Configure the module using the DIP switches (analog inputs only). Reference
Each analog input channel can be configured for either voltage or current. Locate the DIP
switches on your module and set them for your application. Chapter 3 (Installing and
Wiring Your
Analog Module)
ON Configures channel for current input
Off Configures channel for voltage input
123 4
N
O
Switch 1 = Channel 0
Switch 2 = Channel 1
Switch 3 = Channel 2
Switch 4 = Channel 3
Current
Voltage
12
N
OSwitch 1 = Channel 0
Current
Voltage
Switch 2 = Channel 1
Sw 1
External
Backplane
24V dc
Power
Selector
1746-NI4
1746-NIO4I,NIO4V
1746-NO4I, NO4V
_
_
4. Install your module. Reference
When selecting a slot for an analog module, position the module:
•in a slot away from ac or high voltage dc modules
•in the chassis closest to the bottom of the enclosure where the SLC 500 system is
installed
•away from the chassis power supply if installed in a modular system
Chapter 3
(Installing and
Wiring Your
Analog Module)
ATTENTION Never install, remove, or wire modules with power
applied to the chassis or devices wired to the
modules.
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2-4 Quick Start for Experienced Users
Make sure system power is off; then insert the analog module into your 1746 chassis. In this
example procedure, local slot 1 is selected.
Card Guide
Top and Bottom Module
Release(s)
5. Wire the module. Reference
Important: Follow these guidelines when wiring the module.
•Use shielded communication cable (Belden 8761) and keep length as short as possible.
•Connect only one end of the cable shield to earth ground.
•Channels are not isolated from each other. All analog commons are connected together
internally.
•The module does not provide power for analog inputs.
•Use a power supply that matches the transmitter (sensor) specifications.
Chapter 3
(Installing and
Wiring Your
Analog Module)
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Quick Start for Experienced Users 2-5
0
1
2
9
10
11
IN 0 +
IN 0
ANL COM
IN 1 +
IN 1
ANL COM
IN 2 +
IN 2
ANL COM
IN 3 +
IN 3
ANL COM
+
analog
source
earth
ground
+
_
analog
source earth
ground
3
4
5
6
7
8
0
1
2
9
10
11
IN 0 +
IN 0
ANL COM
IN 1 +
IN 1
ANL COM
not used
OUT 0
ANL COM
not used
OUT 1
ANL COM
3
4
5
6
7
8
+24V dc
dc COM
OUT 0
ANL COM
ANL COM
OUT 3
ANL COM
OUT 1
OUT 2
ANL COM
Do not jumper
unused outputs.
Jumper unused
inputs.
Jumper unused
inputs.
Do not jumper
unused outputs.
0
1
2
3
4
5
6
7
0
1
earth
ground
+
analog
source
earth
ground
earth
ground
earth
ground
NO4I & NO4V
NIO4I & NIO4V
Analog commons are internally connected
in the module. Channels are not isolated
from each other.
NI4
24V dc power supply if
external power is selected.
Cable length from external
24V dc power supply to analog
module must be less than 10m.
Load
Load
Ext. pwr.
sup.
Load
__
_
_
_
__
_
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2-6 Quick Start for Experienced Users
6. Configure system I/O configuration. Reference
Configure your system I/O configuration for the particular slot the analog module is in. When
assigning an I/O module to a slot location, select the module from the displayed list. If not listed,
select OTHER at the bottom of the list and enter the module’s ID code at the prompt.
Chapter 4
(Module
Operation
and System
Considerations)
Catalog No. Module ID Code
1746-NI4 4401
1746-NIO4I 3201
1746-NIO4V 3202
1746-NO4I 5401
1746-NO4V 5402
7. Check that the module is operating correctly. Reference
Chapter 5
(Testing Your
Module)
ATTENTION Machine motion during system checkout can be
hazardous to personnel. During all checkout
procedures, you must disconnect all devices which,
when energized, might cause machine motion.
Apply power to the fixed or modular system. The analog module LED (red) should be
illuminated, indicating that the module is receiving 24V dc power.
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