AMCI 4402 User manual

MICRO CONTROLS INC.
ADVANCED
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Manual #: 940-04031

ADVANCED MICRO CONTROLS INC.
GENERAL INFORMATION
Important User Information
The products and application data described in this manual are useful in a wide variety of different applica-
tions. Therefore, the user and others responsible for applying these products described herein are responsible
for determining the acceptability for each application. While efforts have been made to provide accurate infor-
mation within this manual, AMCI assumes no responsibility for the application or the completeness of the
information contained herein.
UNDER NO CIRCUMSTANCES WILL ADVANCED MICRO CONTROLS, INC. BE RESPONSIBLE OR
LIABLE FOR ANY DAMAGES OR LOSSES, INCLUDING INDIRECT OR CONSEQUENTIAL DAM-
AGES OR LOSSES, ARISING FROM THE USE OF ANY INFORMATION CONTAINED WITHIN THIS
MANUAL, OR THE USE OF ANY PRODUCTS OR SERVICES REFERENCED HEREIN.
No patent liability is assumed by AMCI, with respect to use of information, circuits, equipment, or software
described in this manual.
The information contained within this manual is subject to change without notice.
This manual is copyright 2023 by Advanced Micro Controls Inc. You may reproduce this manual, in whole or
in part, for your personal use, provided that this copyright notice is included. You may distribute copies of this
complete manual in electronic format provided that they are unaltered from the version posted by Advanced
Micro Controls Inc. on our official website: www.amci.com. You may incorporate portions of this documents
in other literature for your own personal use provided that you include the notice “Portions of this document
copyright 2023 by Advanced Micro Controls Inc.” You may not alter the contents of this document or charge a
fee for reproducing or distributing it.
Standard Warranty
ADVANCED MICRO CONTROLS, INC. warrants that all equipment manufactured by it will be free from
defects, under normal use, in materials and workmanship for a period of [18] months. Within this warranty
period, AMCI shall, at its option, repair or replace, free of charge, any equipment covered by this warranty
which is returned, shipping charges prepaid, within eighteen months from date of invoice, and which upon
examination proves to be defective in material or workmanship and not caused by accident, misuse, neglect,
alteration, improper installation or improper testing.
The provisions of the "STANDARD WARRANTY" are the sole obligations of AMCI and excludes all other
warranties expressed or implied. In no event shall AMCI be liable for incidental or consequential damages or
for delay in performance of this warranty.
Returns Policy
All equipment being returned to AMCI for repair or replacement, regardless of warranty status, must have a
Return Merchandise Authorization number issued by AMCI. Call [phone] with the model number and
serial number (if applicable) along with a description of the problem during regular business hours, Monday
through Friday, 8AM - 5PM Eastern. An "RMA" number will be issued. Equipment must be shipped to AMCI
with transportation charges prepaid. Title and risk of loss or damage remains with the customer until shipment
is received by AMCI.
24 Hour Technical Support Number
24 Hour technical support is available on this product. If you have internet access, start at www.amci.com.
Product documentation and FAQ’s are available on the site that answer most common questions.
If you require additional technical support, call [phone]. Your call will be answered by the factory dur-
ing regular business hours, Monday through Friday, 8AM - 5PM Eastern. During non-business hours an auto-
mated system will ask you to enter the telephone number you can be reached at. Please remember to include
your area code. The system will page an engineer on call. Please have your product model number and a
description of the problem ready before you call.
Waste Electrical and Electronic Equipment (WEEE)
At the end of life, this equipment should be collected separately from any unsorted municipal waste.

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TABLE OF CONTENTS
General Information
Important User Information ..................... 2
Standard Warranty ................................... 2
Returns Policy .......................................... 2
24 Hour Technical Support Number ........ 2
Waste Electrical and Electronic Equipment
(WEEE) .................................................. 2
About this Manual
Audience. ................................................. 5
Applicable Units ...................................... 5
Navigating this Manual ............................ 5
Manual Conventions ................................ 5
Trademarks and Other Legal Stuff .......... 5
Revision Record ....................................... 6
Revision History ............................ 6
Manual Layout ......................................... 6
Reference: 4402 Specifications
Overview .................................................. 7
PWM Outputs ................................ 7
Dithering ........................................ 7
Drivers ........................................... 8
Programming the Module .............. 8
Power Up Defaults ........................ 8
Loss of Communications 
Defaults ....................................... 8
Connector Pinout ..................................... 8
Status LED’s ............................................ 9
Module LED .................................. 9
Network LED ................................ 9
Channel Status LED ...................... 9
Specifications ........................................... 10
PWM Output ............................................ 11
PWM Frequency ............................ 11
Duty Cycle ..................................... 11
Dithering Control ..................................... 11
Dither Frequency ........................... 11
Dither Deviation ............................ 12
Output Duty Cycle Calculation ..... 12
Real Time Control ................................... 13
Power On Behavior .................................. 13
Hardware Installation
Satisfy Environmental and Power 
Requirements ......................................... 15
Module Location ........................... 15
Power Requirements ..................... 15
Safe Handling Guidelines ........................ 15
Prevent Electrostatic Damage ....... 15
Prevent Debris From Entering 
the Module .................................. 15
Remove Power Before Servicing 
in a Hazardous Environment ...... 16
Install the Mounting Base ........................ 16
Installation .................................... 16
Removal ........................................ 16
Install the 4402 Module ........................... 16
Remove Power .............................. 16
Installation .................................... 16
Install the Removable Terminal Block .... 17
Remove Power .............................. 17
Installation .................................... 17
Removal ........................................ 17
Power and Output Wiring ........................ 17
Software Installation
Determine Which Procedure to Use ......... 19
Procedure for CompactLogix 
5370 L1 Local I/O .................................. 19
Procedure for EtherNet/IP Adapters ........ 20
Procedure for DeviceNet Adapters .......... 21
Procedure for ControlNet Adapters ......... 22
RSNetWorx for ControlNet 
Setup (optional) ...................................... 24
Reading Data from the 4402
Buffering Data .......................................... 25
Data Format .............................................. 25
Duty Cycle Words ........................ 25
Status Word ................................... 26
Writing Data to the 4402
Data Format .............................................. 29
Control Bits Description ............... 30
Programming Notes ................................. 31

TABLE OF CONTENTS 4402 User Manual
ADVANCED MICRO CONTROLS INC.
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ABOUT THIS MANUAL
Audience.
This manual explains the installation and operation of AMCI’s 4402. It is written for the engineer responsible
for incorporating the 4402 into a design as well as the individual responsible for its actual installation.
Applicable Units
This manual is applicable to all 4402 and 4402-12 devices at the time of its release.
Navigating this Manual
This manual is designed to be used in both printed and on-line forms. Its on-line form is a PDF document,
which requires Adobe Acrobat Reader version 7.0+ to open it. You are allowed to select and copy sections for
use in other documents and, if you own Adobe Acrobat version 7.0 or later, you are allowed to add notes and
annotations. If you decide to print out this manual, all sections contain an even number of pages which allows
you to easily print out a single chapter on a duplex (two-sided) printer.
Manual Conventions
Three icons are used to highlight important information in the manual:
NOTES highlight important concepts, decisions you must make, or the implications of those
decisions.
CAUTIONS tell you when equipment may be damaged if the procedure is not followed
properly.
WARNINGS tell you when people may be hurt or equipment may be damaged if the pro-
cedure is not followed properly.
The following table shows the text formatting conventions:
Trademarks and Other Legal Stuff
The AMCI logo is a trademark of Advanced Micro Controls Inc. “POINT I/O” is a trademark of Rockwell
Automation. “CIP” is a trademark of Open DeviceNet Vendor Association, Inc. “EtherNet/IP” is a trademark
of ControlNet International, Ltd. under license by Open DeviceNet Vendor Association, Inc. “Adobe” and
“Acrobat” are registered trademarks of Adobe Systems Incorporated.
All other trademarks contained herein are the property of their respective holders.
This product incorporates technology which is licensed from Allen-Bradley Company, LLC. Allen-Bradley
has not technically approved, nor does it warrant or support this product. All warranty and support for this
product and its application is provided solely by Advanced Micro Controls Inc.
Read this chapter to learn how to navigate through this manual and familiarize
yourself with the conventions used in it. The last section of this chapter highlights
the manual’s remaining chapters and their target audience.
Format Description
Normal Font Font used throughout this manual.
Emphasis Font Font used for parameter names and the first time a new term is introduced.
Cross Reference When viewing the PDF version of the manual, clicking on a blue cross refer-
ence jumps you to referenced section of the manual.
HTML Reference When viewing the PDF version of the manual, clicking on a red cross reference
opens your default web browser to the referenced section of the AMCI website
if you have Internet access.

ABOUT THIS MANUAL 4402 User Manual
ADVANCED MICRO CONTROLS INC.
6
Revision Record
This document, 940-04031, is the second release of this manual. It was first released on October 24th, 2023. It
adds clarification notes on default programming and information on the 4402-12.
Revision History
940-04030: 09/17/2015 Initial Release
Manual Layout
You will most likely read this manual for one of two reasons:
If you are curious about the 4402, this manual contains the information you need to determine if it is
the right product for your application. Chapter 1, 4402 Specifications, was written for you. The chapter
contains all of the information you will need to fully specify the 4402 product in your application.
If you need to install and use the 4402, then the rest of the manual is written for you. To simplify instal-
lation and configuration, the rest of the manual is broken down into tasks and references. Using the
4402 requires you to complete four tasks, and the manual is broken down into sections that explain
how to complete each one.
Chapter Title Chapter Description
4402 Specifications Complete specifications of the 4402.
Hardware Installation Task instructions that give you the information and steps needed to
physically install 4402 on your machine.
Software
Installation Task instructions that give you the information and steps needed to
add the 4402 to your host controller.
Reading Data from the
4402 Task instructions that give you the information needed to read data
from the 4402.
Writing Data to the
4402 Task instructions that give you the information needed to write pro- gramming data to the 4402.

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4402 SPECIFICATIONS
Overview
The 4402 is the latest addition to a growing line of AMCI
products for the Bulletin 1734 POINT™ I/O system from
Rockwell Automation. The 4402 offers two channels of Pulse
Width Modulated (PWM) outputs with variable frequency and
duty cycle. The 4402 also offers dithering functionality for use
with proportional control valves and other applications that
must compensate for stiction in the system.
Designed around RA licensed technology, installation of the
4402 is the same as all other POINT I/O modules. The 4402
uses standard eight pin mounting bases, such as the 1734-TB,
that are available from RA.
Power for the module is obtained from the power supply that
powers the POINT I/O drop. Two versions of the 4402 are avail-
able. The 4402 is powered by a 24Vdc supply and offers 24Vdc
outputs. The 4402-12 is powered by a 12Vdc supply and offers
12Vdc outputs.
The 4402 is programmed and controlled with network data
from a host controller. The operating status of the module is
transmitted back to the host controller using six, 16-bit integer
words. Programming the 4402 is accomplished with eight, 
16-bit integer words.
The 4402 can be configured to change the duty cycle of the
outputs as soon as data is received from the host controller.
This allows you to use the host to generate complex wave-
forms, such as S-Curve accelerations between output setpoints,
and send this data to the 4402 in real time. Updates to a single
module can occur as often as every five milliseconds. Worse
case update time for a block of five modules (10 channels) on a
single network drop is fifty milliseconds.
PWM Outputs
Two outputs are available on the 4402. These outputs have independent PWM frequency and duty cycle set-
tings. The PWM frequency settings are programmable over a 1 Hz to 20 kHz range with a resolution of 1 Hz.
Duty cycle settings can range from 0% to 100% when the output frequency for the channel is programmed to
be below 10 kHz. From 10 kHz and above, the duty cycle can be programmed to 0%, 100%, and in the range
of 5% to 95%. In either case, the duty cycle resolution is 0.1%.
Dithering
Dithering is used to overcome problems associated with static friction, which is often referred to as “stiction”.
Static friction can cause errors when the valve is commanded to a new position, but the force generated by the
coil is not great enough to overcome the static friction in the mechanical components. Stiction can also cause
overshoot errors and dampened output oscillations when the static friction is finally overcome.
Dithering overcomes these errors by imposing an AC signal on top of the PWM signal. This AC signal keeps
the valve core in constant motion. The average flow through the valve is unaffected because the average value
of the AC signal is zero. When choosing a dithering frequency, system resonance points must be avoided.
Figure 1 4402 PWM Output Module

4402 SPECIFICATIONS 4402 User Manual
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Overview (continued)
Drivers
Outputs control high current DC drivers that can power many proportional control valves directly. Each out-
put is rated to 1.5 Adc. Total output current for both channels is 2.5 A at 25°C. Both outputs are sourcing out-
puts and drive sinking loads directly.
Programming the Module
The 4402 is typically written to by the host at a defined RPI time. In order to control the flow of programming
data, the 4402 defines a Transmit Bit and an Acknowledge Bit to control a handshaking protocol called a Pro-
gramming Cycle. A Programming Cycle requires a minimum of 4 * (RPI time) seconds to transfer program-
ming data to the 4402.
In order to speed up changes to the PWM Duty Cycle and Dithering Deviation parameters, Real Time
Updates can be enabled. Once enabled, changes to these parameters are accepted immediately, without the
need for a Programming Cycle. The maximum update time for these parameters becomes related to the mod-
ule’s programmed RPI time.
Power Up Defaults
Parameter values are stored in RAM memory. You have the option of programming power up default values
by storing parameter values in flash memory. These values are copied into RAM on power up and used until
new values are written to the module. See the Power On Behavior section on page 13 for a listing of the fac-
tory default settings.
Loss of Communications Defaults
The behavior of the outputs when there is a loss of network communications is programmable. The ouptuts
can be programmed to maintain their current state or use the last values that were programmed into the unit
with a Programming Cycle. This fact is only important if you are using Real Time Updates to control the
PWM Duty Cycle and Dithering Deviation parameters. You have the option of programming safe default val-
ues for the PWM Duty Cycle and Dithering Deviation parameters with a Programming Cycle and then use the
Real Time Update controls to update the parameters while the machine is running. Any loss in communica-
tions while the machine is running will result in the outputs changing to their programmed safe values.
Connector Pinout
Figure 2shows the pin out of the module’s eight pin connector.
A standard Removable Terminal Block (RTM) is used in the
picture.
The DC Power In and DC Power Return pins are con-
nected to the power supply pins of the POINT I/O power
adapter to the left of the module. This supply is used to
power the output drivers and must be capable of supply-
ing the current needed by the loads. The 4402 can source
up to 1.5 Adc per output, 2.5 Adc per module. See
Power and Output Wiring on page 17 for additional
information.
Pins 0 and 1 are electrically connected in the module and
either pin can be used to connect to the load.
Pins 2 and 3 are electrically connected in the module and
either pin can be used to connect to the load.
Pins 6 and 7 are electrically connected in the module and
connected to the POINT I/O power adapter.
If shielded cable is used to wire to the loads, Pin 5 can be
used to connect their shields to chassis ground.
Figure 2 Connector Pin Out
Pin 0
Output 0
Pin 1
Output 0
Pin 2
Output 1
Pin 3
Output 1
Pin 4
DC Power Return
Pin 5
Chassis Ground (Shields)
Pin 6
DC Power In
Pin 7
DC Power In
4402 and 4402-12

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Status LED’s
The module has a total of four status LED’s. Figure 3shows the locations of these LED’s.
Module LED
Network LED
Channel Status LED
State Description
Solid Green Module OK
Blinking Red Programming error
Solid Red Save to Flash memory error
State Description
Off No communications with scanner
Solid Green Active communications with scanner
Blinking Green Point I/O base is not communicating with 
the network.
Solid Red Communications error with scanner
State Description
Off Duty Cycle is equal to its default value
Solid Orange Duty Cycle is not equal to its default value
Blinking Orange Duty Cycle is not equal to its default value
and Dithering is applied.
Figure 3 Status LED Locations
4402
PWM Out
Channel 0
Status
Channel 1
Status

4402 SPECIFICATIONS 4402 User Manual
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10
Specifications
Number of Channels
2. Channels are independent of each other.
Backplane Current Draw
200 mA max.
Maximum of five in a block without the use of an
additional POINT I/O power supply
PWM Frequency Range
1 Hz to 20 kHz. Default of 250 Hz. 
Programmable with 1 Hz resolution.
Duty Cycle Range
Programmable with 0.1% resolution. Factory
default of 10.0% on.
PWM frequency < 10 kHz. 
0.0% to 100.0%
PWM Frequency 10 kHz
0.0%, 5.0 to 95.0%, 100.0%
Dither Frequency
0 Hz to (PWM Frequency / 4) Hz
Programmable with 1 Hz resolution. Program-
ming to 0 Hz disables Dither feature. Default of
0 Hz.
Dither Deviation
0.0% to {Duty Cycle /2}%
Programmable with 0.1% resolution. Program-
ming to 0.0% disables Dither feature. Default of
0.0%
Output Drivers
4402: 24 Vdc Sourcing drivers. 1.5 A max. per 
output.
4402-12: 12 Vdc Sourcing drivers. 1.5 A max. per 
output.
2.5 A max. per module at 25°C
Outputs recieve power from the power supply
attached to the communications adapter or the
±FB pins on the CompactLogix 5370 L1 family
of PLC’s.
Response Time
The greater of 5 milliseconds or 1 output period.
Response time is the time between when the
data is accepted and when it is acted upon. It
does not include network transit time from the
host to the module.
Package Style
Eight pin POINT I/O. 
Compatible with eight pin mounting bases
Ambient Operating Temperature
32°F to 140°F (0°C to 60°C)
Note: Depending on the load and duty cycle, the
4402 can reach an internal temperature of 
170°F (77°C)
Ambient Relative Humidity
5% to 95%, non-condensing
Ambient Storage Temperature
-40°F to +185°F (-40°C to +85°C)

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4402 User Manual 4402 SPECIFICATIONS
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PWM Output
The PWM output is controlled by two parameters.
PWM Frequency
The 4402 has two PWM Frequency parameters, one associated with
each output. The PWM Frequency parameter defines the time period of
the output. It is programmed in hertz, and is programmable from 1 to
20,000 Hz inclusive. This yields a time period between one second and
fifty microseconds.
Duty Cycle
The 4402 has two Duty Cycle parameters, one associated with each
channel. The Duty Cycle parameter defined the time the output is on as
a percentage of the programmed time period. It is programmed as an
integer with a range of 0 to 1,000, which corresponds to a percentage of
0.0 to 100.0%. The output is off when the Duty Cycle is set to 0 and the
output is on all of the time when the Duty Cycle is set to 1000 (100.0%).
When the PWM Frequency parameter is programmed to be less than 10
kHz, the Duty Cycle can be programmed to any value within its 0.0 to
100.0% range.
When the PWM Frequency parameter is programmed to be greater than
or equal to 10 kHz, the Duty Cycle can be programmed to 0.0%, 5.0%
to 95.0%, and 100.0%. This corresponds to integer values of 0, 50 to
950, and 1,000. The Duty Cycle cannot be programmed to be between
0.1% and 4.9% or 95.1% to 99.9% if the PWM Frequency is 10 kHz or
above.
Changes to the Duty Cycle parameter will take a minimum of five milliseconds to occur. When
the programmed PWM Frequency is 200 Hz (1/0.005 sec) or above, the changes will take five
milliseconds to occur. At frequencies below 200 Hz, changes to Duty Cycle will occur at the
beginning of the next time period. This means that the changes to the Duty Cycle will take up to
1/{PWM Frequency} seconds to occur. For example, if the PWM Frequency is set to 10 Hz, then
any change to the Duty Cycle will take between 5 milliseconds and 100 milliseconds to occur.
Dithering Control
Dithering imposes an AC signal within the PWM output. This is accomplished by varying the duty cycle of
the output in a regular fashion. If the PWM signal were to be properly filtered and observed on an oscillo-
scope, the output would appear to be an AC signal riding on the DC value defined by the programmed Duty
Cycle.
Dithering is controlled with two parameters.
Dither Frequency
The 4402 has two Dither Frequency parameters, one associated with each channel. This parameter sets the
frequency of the imposed AC signal. It has a range of 0 Hz to {PWM Frequency}/4. If the Dither Frequency
is set to zero, the dithering functionality is disabled for that channel and the Dither Deviation parameter for
that channel must also equal zero.
Figure 4 PWM Output Examples

4402 SPECIFICATIONS 4402 User Manual
ADVANCED MICRO CONTROLS INC.
12
Dithering Control (continued)
Dither Deviation
The 4402 has two Dither Deviation parameters, one for each channel. Like Duty Cycle, Dither Deviation is
programmed as an integer value that represents a percentage of the programmed time period. The value has a
resolution of 0.1%. Each of these parameters has a range of 0 to {Duty Cycle}/2 and must equal zero if the
Dither Frequency parameter for the channel is set to zero. Additionally, if the channel’s Dither Deviation is
set to zero, the dithering functionality is disabled for that channel.
Output Duty Cycle Calculation
As shown in figure 5below, the Dithering Period is divided into eight segments, which represent the 45°
points of a cycle. The duty cycle at each point is equal to:
Where:
Duty Cycle = Present value of the Duty Cycle parameter for the channel
Dither Deviation = Present value of the Dither Deviation parameter for the channel
= Dither Frequency expressed in radians/second
t = time in seconds
Figure 5 Dithering Output Example
If the Dither Frequency is greater than the PWM Frequency/8, the output will be a triangular wave instead of
a sine wave, but the DC component will remain zero.
The only time dithering will add a DC component to the PWM output is when the programmed Duty Cycle +
the programmed Dither Deviation exceeds 100.0%. For example, if the Duty Cycle is programmed to 80.0%,
the 4402 will accept a Dither Deviation of 40.0%. The combined value of 120% exceeds the maximum
100.0% duty cycle.
If this condition is true, the output is limited at its 100.0% state. The dithering waveform will be distorted, and
the DC component of the PWM output will be lowered.
duty cycle Duty Cycle Dither Deviation+tsin=
+70% Dither Amplitude
–70% Dither Amplitude
Base PWM Value
+100% Dither Amplitude
–100% Dither Amplitude
Duty Cycle = 50.0% Dither Frequency = PWM Frequency/8 Dither Amplitude = 25.0%

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Real Time Control
There are two additional parameters on the 4402. These parameters are called CH0 RT Update Enable and
CH1 RT Update Enable. When real time updates are enabled on a channel, changes in Duty Cycle and Dither
Deviation parameter settings are made as soon as the network data changes. A programming cycle is not
required. This allows changes to the channel outputs with a single network transfer instead of four.
Power On Behavior
The 4402 contains non-volatile Flash memory that stores the settings that will be used on power up.
Table 1shows factory default settings for all of the parameters.
Table 1 Factory Default Settings
With these settings, the 4402 will output at 10% on both channels, with a maximum update time of forty mil-
liseconds (1/250 Hz).
All of these parameters can be programmed through the network data and saved to the Flash memory on the
4402. Once changed, the stored values will be used on power up. Many platforms output data to the module at
regular intervals. In order to prevent inadvertent changes, the 4402 employs a Transmit Bit in the output data
and an Acknowledge Bit in the input data to implement a handshaking mechanism. Programming data is only
accepted on a 01 transition on the Transmit Bit. The module acknowledges the transfer by making a 01
transition on the Acknowledge Bit.
Parameter Setting
Output State on Net Loss Maintain Current Output
CH0 PWM Frequency 250 Hz
CH0 Duty Cycle 10.0% (Integer value of 100)
CH0 Dither Frequency 0 Hz (Disabled state)
CH0 Dither Deviation 0.0% (Disabled state)
CH0 RT Update Enable Disabled
CH1 PWM Frequency 250 Hz
CH1 Duty Cycle 10.0% (Integer value of 100)
CH1 Dither Frequency 0 Hz (Disabled state)
CH1 Dither Deviation 0.0% (Disabled state)
CH1 RT Update Enable Disabled

4402 SPECIFICATIONS 4402 User Manual
ADVANCED MICRO CONTROLS INC.
14
Notes

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REQUIRED TASK
HARDWARE INSTALLATION
1.1 Satisfy Environmental and Power Requirements
1.1.1 Module Location
The 4402 and 4402-12 modules is suitable for use in industrial environments that meet the following criteria:
Only non-conductive pollutants normally exist in the environment, but an occasional temporary con-
ductivity caused by condensation is expected.
Transient voltages are controlled and do not exceed the impulse voltage capability of the product’s
insulation.
Note that these criteria apply to the system as a whole. These criteria are equivalent to the Pollution Degree 2
and Over Voltage Category II designations of the International Electrotechnical Commission (IEC).
Refer to POINT I/O documentation from Rockwell Automation for information on environmental require-
ments for the POINT I/O system as a whole.
Because of their on board microprocessors, the 4402 modules will become warmer than most
POINT I/O modules. Rockwell Automation defined spacing around the POINT I/O system to
allow convection cooling is all that is required. Additional spacing or cooling is not required.
1.1.2 Power Requirements
The 4402 and 4402-12 requires 200 milliamperes at 5 Vdc from the POINT I/O system. Make sure
your system’s power supply has adequate reserve current capacity.
A maximum of five 4402 or 4402-12 modules can be installed in one network base. This limitation is
caused by a small voltage drop across each of the modules. If you attempt to drive more than five mod-
ules, the voltage at the sixth module will be too low for the 4402 or 4402-12 module to operate. It is
possible to add more 4402 or 4402-12 modules to the POINT I/O base by adding a 1734-EP24DC sup-
ply to the system.
1.2 Safe Handling Guidelines
1.2.1 Prevent Electrostatic Damage
Electrostatic discharge can damage a 4402 module if you touch the rear bus connector pins.
Follow these guidelines when handling the module.
1) Touch a grounded object to discharge static potential before handling the module.
2) Work in a static-safe environment whenever possible.
3) Wear an approved wrist-strap grounding device.
4) Do not touch the pins of the bus connector or the I/O connector.
5) Do not disassemble the module
6) Store the module in its anti-static bag and shipping box when it is not in use.
1.2.2 Prevent Debris From Entering the Module
During DIN rail mounting of all devices, be sure that all debris (metal chips, tapping liquid,
etc.) is prevented from falling into the module. Debris may cause damage to the module or
unintended machine operation with possible personal injury. The DIN rail for the modules
should be securely installed and grounded before the modules are mounted on it.
This section is intended for the engineer or technician responsible for physically
installing the 4402 module.

REQUIRED TASK: HARDWARE INSTALLATION 4402 User Manual
ADVANCED MICRO CONTROLS INC.
16
1.2 Safe Handling Guidelines (continued)
1.2.3 Remove Power Before Servicing in a Hazardous Environment
Remove power before removing or installing any modules in a hazardous environment.
1.3 Install the Mounting Base
1.3.1 Installation
1) Verify that the DIN rail locking screw is in the horizontal position. The mounting base will not attach to
the DIN rail if this screw is in the vertical position.
2) Position the mounting base vertically above any currently installed units, such as an adapter, power
supply, or an existing module.
3) Slide the mounting base down allowing the interlocking side pieces to engage the adjacent module or
adapter.
4) Press firmly until the mounting base snaps onto the DIN rail.
5) If this the last mounting base in the block, install the safety end cap to protect the exposed pins.
1.3.2 Removal
1) To remove the mounting base from the DIN rail, first remove the 4402 module and all mounting bases to
the right of the base you wish to remove.
2) Using a small bladed screwdriver, rotate the base locking screw to the vertical position. This releases the
locking mechanism holding the mounting base to DIN rail.
3) Lift the mounting base straight up to remove it from the block.
1.4 Install the 4402 Module
1.4.1 Remove Power
The 4402 and 4402-12 modules are not hot swapable and power must be removed before installing or remov-
ing the module from the Point I/O Base.
1.4.2 Installation
1) Verify that the wiring base is correctly keyed for the 4402 module. If it is not, use a small bladed
screwdriver to rotate the keyswitch on the mounting base until it matches the keying on the 4402 module.
2) Install the 4402 module by inserting it into the mounting base and pressing straight down. The module
will lock into place.
POINT I/O terminal base assemblies are Rockwell Automation products and RA lit-
erature should be considered the authority on installing these products. Steps are
given here as a convenience. If you have any questions, refer to RA documenta-
tion for additional information.
The 4402 installs into the selected wiring base in the same fashion as all other
POINT I/O modules. The 4402 module can be installed in the mounting base before
or after the mounting base is installed on the DIN rail.

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4402 User Manual REQUIRED TASK: HARDWARE INSTALLATION
17
1.5 Install the Removable Terminal Block (as required)
The 1734-TB and 1734-TBS terminal bases require the use of a removable terminal block, part numbers
1734-RTB or 1734-RTBS respectively. The appropriate removable terminal block (RTB) is supplied with the
mounting base assembly that is ordered through RA.
1.5.1 Remove Power
Power should be removed from the system before the RTB is installed or removed. This is to prevent the pos-
sibility of creating an electrical arc when the installation or removal is performed.
1.5.2 Installation
1) Insert the end opposite the handle into the base unit. This end has a curved section that engages with the
wiring base.
2) Rotate the terminal block into the mounting base until it locks itself in place.
3) If a module is installed, snap the RTB handle into place on the module.
1.5.3 Removal
This procedure allows the mounting base to be removed and replaced as necessary without removing any of
the wiring.
1) If need be, pull back on the terminal block handle to disengage it from the module.
2) Pull up on the RTB handle to remove.
1.6 Power and Output Wiring
Figure 1.1 below show that the 4402 obtains its 24 Vdc power from the 24 Vdc supply that is used to power
the POINT I/O drop. The 4402 can source 1.5 A per output, 2.5 A per module @ 25°C. This current load must
be considered when designing the system to assure that the 10 A maximum load on the internal bus is not
exceeded. If this 10 A load limit is exceeded, an additional RA 1734 series power adapter must be added to
the system.
Load 1 is shown attached to the 4402 with a shielded cable. Shielded cables are recommended if the load
draws little current which makes the output susceptible to electrical noise. This decision is based on the elec-
trical environment the system is placed in, and must be made on an individual basis.
Figure 1.1 Power and Output Wiring
Pin 1
Output 0
Load 0
Load 1
Pin 3
Output 1
Pin 4
DC Power Return
Pin 5
Chassis Ground (Shields)
Pin 7
DC Power In
+24Vdc Supply:
+12Vdc Supply:
4402
4402-12
If shielded cable is used to wire the
loads, shields can be attached at the
4402 or at the system ground bus.
1734
Power
Adapter
Pin 0
Output 0
Pin 2
Output 1
Pin 6
DC Power In

REQUIRED TASK: HARDWARE INSTALLATION 4402 User Manual
ADVANCED MICRO CONTROLS INC.
18
Notes

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REQUIRED TASK
SOFTWARE INSTALLATION
2.1 Determine Which Procedure to Use
This task is broken down into different procedures based on the connection between the 4402 and the PLC.
Use the table below to determine the correct procedure to use when adding the 4402 to the software project.
2.2a Procedure for CompactLogix 5370 L1 Local I/O
1) Open RSLogix 5000 and the project in which you want to install the AMCI 4402 module.
2) Right click on I/O Configuration in the Project Tree and select ‘New Module’ in the resulting pop up
window.
3) In the new window that opens, select the following module type from the list that appears.
Type = 1734-MODULE Description = Generic 1734 Module
4) Click the [OK] button. A Module Properties window will appear.
5) Set the following parameters in the Module Properties window. All parameters not listed here are
optional.
Name: A descriptive name for the module. The name must begin with a letter.
Description: Your Choice
Comm Format: Data-INT (The default is Input Data-INT. This must be changed to Data-INT)
Slot: Location of 4402 or 4402-12 module
6) Enter the Connection Parameters from the following table.
Table 2.1 CompactLogix 5370 Connection Parameters
7) Click on Next and select the RPI time. The minimum RPI time for the 4402 is two milliseconds, with five
milliseconds or above recommended.
The 4402 module will now appear in the project tree and three new data tags will have been created,
Local:X.I.Data[Y], Local:X.O.Data[Y] and Local:X.C.Data[Y] where "X" is the slot number and "Y" is the
word number. Module status and duty cycle values for the two channels appear in the Input tags. All com-
mands are sent to the 4402 module through the Output tags. The 4402 does not use the Configuration tags.
Please note that the first two input words, Local:X.I.Data[0] and Local:X.I.Data[1] are not used and will
always equal to zero.
This section is intended for the engineer or technician responsible for adding the
4402 to a software project. The procedure used depends on the interface used to
attach the 4402 to the PLC.
Connection Procedure Page #
CompactLogix 5370 L1 Local I/O 2.2a see below
EtherNet/IP Adapters 2.2b 20
DeviceNet Adapters 2.2c 21
ControlNet Adapters 2.2d 22
RSNetWorx for ControlNet (optional) 2.2e 24
Assembly Instance Size
Input 101 6
Output 102 8
Configuration 103 0

REQUIRED TASK: SOFTWARE INSTALLATION 4402 User Manual
ADVANCED MICRO CONTROLS INC.
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2.2b Procedure for EtherNet/IP Adapters
Being a speciality I/O module, the 4402 uses direct connections to communicate with the pro-
cessor. In this procedure, you will set two RPI times. The RPI time for the adapter controls
how quickly discrete I/O points attached to the adapter are updated. This RPI time is not used
by the 4402 but must still be set. The RPI time of the 4402 controls the rate of updates to the
module.
1) Create or open a new Ladder Logic program.
2) If the processor used in the project has a built-in Ethernet port, it must be configured. If the processor
does not have a built in Ethernet port, a bridge module must be added to the project and it must be
configured before you can continue. Refer to RA documentation if you need help performing this step.
3) Go to Project tree and right click on the configured Ethernet port. Select ‘New Module’ in the resulting
pop up window.
4) In the new window that opens, select the POINT I/O EtherNet/IP adapter used to connect the 4402 to
your processor. The 1734-AENT/A is used in this example.
5) Click the [OK] button. A new Module Properties window will open.
6) Set the following parameters in the Module Properties window.
Name: A descriptive name for the EtherNet/IP adapter. The name must begin with a letter.
Description: Your Choice
Comm Format: Rack Optimization or None
IP Address: The IP address of the EtherNet/IP adapter. For the 1734-AENT/A, the last octet of the
address must match the node number set on the adapter.
Chassis Size: One plus the number of Point I/O modules attached to the 1734-AENT/A.
If adding the 4402 module to an existing system, the Chassis Size parameter must be modified
on the Chassis Size tab of the 1734-AENT/A module. After changing and downloading the
chassis size, go online, select the chassis tab, and click on "Set Chassis Size in Module."
7) If the Comm Format was set to None, click on the [Finish>>] button to accept the configuration. If the
Comm Format above was set to Rack Optimization, click on [Next>] and set the RPI time for the discrete
I/O modules in your system, and then click on [Finish>>] to accept the configuration.
8) Right click on the POINT I/O adapter in the Project tree. Select ‘New Module’ in the resulting pop up
window.
9) In the new window that opens, select the following module type from the list that appears.
Type = 1734-MODULE Description = Generic 1734 Module
10) Click the [OK] button. A Module Properties window will appear.
11) Set the following parameters in the Module Properties window. All parameters not listed here are
optional.
Name: A descriptive name for the 4402 module. The name must begin with a letter.
Description: Your Choice
Comm Format: Data-INT (This parameter must be Data-INT)
Slot: Location of 4402 module. Slot 1 is directly to the right of the adapter.