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.
4

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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
ADVANCED MICRO CONTROLS INC.
8
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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4402 User Manual 4402 SPECIFICATIONS
9
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
ADVANCED MICRO CONTROLS INC.
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)