Reliance electric 57C409 User manual

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 
 

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WARNING
THIS UNIT AND ITS ASSOCIATED EQUIPMENT MUST BE INSTALLED,
ADJUSTED AND MAINTAINED BY QUALIFIED PERSONNEL WHO ARE
FAMILIAR WITH THE CONSTRUCTION AND OPERATION OF ALL EQUIPMENT
IN THE SYSTEM AND THE POTENTIAL HAZARDS INVOLVED. FAILURE TO
OBSERVE THESE PRECAUTIONS COULD RESULT IN BODILY INJURY.
WARNING
UNEXPECTED MACHINE MOVEMENT MAY BE THE RESULT OF INSERTING OR
REMOVING THIS MODULE OR ITS CONNECTING CABLES. POWER SHOULD BE
REMOVED FROM THE MACHINE BEFORE INSERTING OR REMOVING THE
MODULE OR ITS CONNECTING CABLES. FAILURE TO OBSERVE THESE
PRECAUTIONS COULD RESULT IN BODILY INJURY.
CAUTION
THIS MODULE CONTAINS STATICĆSENSITIVE COMPONENTS. CARELESS
HANDLING CAN CAUSE SEVERE DAMAGE.
DO NOT TOUCH THE CONNECTORS ON THE BACK OF THE MODULE. WHEN
NOT IN USE, THE MODULE SHOULD BE STORED IN AN ANTIĆSTATIC BAG.
THE PLASTIC COVER SHOULD NOT BE REMOVED. FAILURE TO OBSERVE
THIS PRECAUTION COULD RESULT IN DAMAGE TO OR DESTRUCTION OF
THE EQUIPMENT.

I
Table of Contents
1.0 Int oduction 1Ć1...............................................
2.0 Mechanical/Elect ical Desc iption 2Ć1...........................
2.1 Mechanical Description 2Ć1...................................
2.2 Electrical Description 2Ć1.....................................
3.0 Installation 3Ć1................................................
3.1 Wiring 3Ć1..................................................
3.2 Initial Installation 3Ć1.........................................
3.3 Module Replacement 3Ć4.....................................
4.0 P og amming 4Ć1..............................................
4.1 Register Organization 4Ć1....................................
4.2 Configuration 4Ć4...........................................
4.3 Reading And Writing Data In Application Tasks 4Ć4..............
4.3.1 BASIC Task Example 4Ć5...............................
4.3.2 Control Block Task Example 4Ć6.........................
4.4 Using Interrupts in Application Tasks 4Ć6.......................
4.4.1 BASIC Task Example 4Ć7...............................
4.4.2 Control Block Task Example 4Ć8.........................
4.5 Restrictions 4Ć9.............................................
4.5.1 Writing Data to Registers 4Ć9............................
4.5.2 Use in Remote I/O Racks 4Ć9...........................
4.5.3 Initializing or Updating Filter Registers 4Ć9................
5.0 Diagnostics And T oubleshooting 5Ć1...........................
5.1 Incorrect Data 5Ć1...........................................
5.2 Bus Error 5Ć2...............................................
5.3 Interrupt Pro lems 5Ć3.......................................
5.3.1 No Interrupts 5Ć3......................................
5.3.2 Hardware Event TimeĆOut 5Ć3...........................
5.3.3 Hardware Event Count Limit Exceeded 5Ć4...............
5.3.4 Illegal Interrupt Detected 5Ć4............................

II

 
Technical Specification AĆ1......................................
 
Module Block Diagram BĆ1......................................
 
Field Connection CĆ1...........................................
 
Related Component DĆ1........................................
 
Defining Variable in the Configuration Ta k EĆ1....................

III
  
Figure 2.1 Ć Typical I put Circuit 2Ć2...................................
Figure 2.2 Ć Module Faceplate 2Ć3.....................................
Figure 3.1 Ć Typical Field Sig al Co ectio s 3Ć1........................
Figure 3.2 Ć Rack Slot Numbers 3Ć2...................................
Figure 3.3 Ć Offset a d Gai 3Ć3.......................................
Figure 4.1 Ć A alog I put Registers 4Ć1................................
Figure 4.2 Ć Curre t Cou t Registers 4Ć1...............................
Figure 4.3 Ć Commo Clock Status Register 4Ć2.........................
Figure 4.4 Ć I terrupt Co trol Registers 4Ć2.............................
Figure 4.5 Ć A alog Update Registers 4Ć3..............................
Figure 4.6 Ć I put Filter Selectio Registers 4Ć3..........................

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1Ć1
 
The products described in this instruction manual are manufactured
or distributed by Reliance Electric Company or its subsidiaries.
This 2 Channel Analog Input Module is used to input analog signals
to a local rack in the DCS 5000/AutoMax system. The module
contains two channels that can be converted as often as once every
500 microĆseconds. Each channel provides 12 bit conversion plus
sign, 100% overrange, and userĆprogrammable filters and conversion
rates.
There is one isolated common for the two input channels. Inputs to
the module can be either +1 volt +5 volts, +10 volts or 4Ć20 ma. The
module can be configured to interrupt on every conversion.
Typically, this module is used to read analog voltages from
potentiometers, tachometers, drive control systems, and process
control systems.
This manual describes the functions and specifications of the
module. It also includes a detailed overview of installation and
servicing procedures, as well as examples of programming methods.
Related publications that may be of interest:
JĆ2611 DCS 5000 PR DUCT SUMMARY
JĆ3675 DCS 5000 ENHANCED BASIC LANGUAGE
INSTRUCTI N MANUAL
JĆ3676 DCS 5000 C NTR L BL CK LANGUAGE
INSTRUCTI N MANUAL
JĆ3677 DCS 5000 LADDER L GIC LANGUAGE
INSTRUCTI N MANUAL
JĆ3630 ReSource AutoMax PR GRAMMING
EXECUTIVE INSTRUCTI N MANUAL VERSI N 1.0
JĆ3635 DCS 5000 PR CESS R M DULE INSTRUCTI N
MANUAL
JĆ3649 AutoMax C NFIGURATI N TASK MANUAL
JĆ3650 AutoMax PR CESS R M DULE INSTRUCTI N
MANUAL
JĆ3675 AutoMax ENHANCED BASIC LANGUAGE
INSTRUCTI N MANUAL
JĆ3676 AutoMax C NTR L BL CK LANGUAGE
INSTRUCTI N MANUAL
JĆ3677 AutoMax LADDER L GIC LANGUAGE
INSTRUCTI N MANUAL
JĆ3684 ReSource AutoMax PR GRAMMING
EXECUTIVE INSTRUCTI N MANUAL VERSI N 2.0
JĆ3750 ReSource AutoMax PR GRAMMING
EXECUTIVE INSTRUCTI N MANUAL VERSI N 3.0
IEEE 518 GUIDE F R THE INSTALLATI N F ELECTRICAL
EQUIPMENT T MINIMIZE ELECTRICAL N ISE
INPUTS T C NTR LLERS FR M EXTERNAL
S URCES

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2Ć1
2.0 MECHANICAL/ELECTRICAL
DESCRIPTION
The following is a description of the faceplate LEDs, field termination
connectors, and electrical characteristics of the field connections.
2.1 Mechanical Descrip ion
The input module is a printed circuit board assembly that plugs into
the backplane of the DCS 5000/AutoMax rack. It consists of a printed
circuit board, a faceplate, and a protective enclosure. The faceplate
contains tabs at the top and bottom to simplify removing the module
from the rack. Module dimensions are listed in Appendix A.
The faceplate of the module contains a female connector socket and
4 LED indicators that show the status of the inputs. Input signals are
brought into the module via a multiĆconductor cable (M/N 57C371;
see Appendix D). One end of this cable attaches to the faceplate
connector, while the other end of the cable has stakeĆon connectors
that attach to a terminal strip for easy field wiring. The faceplate
connector socket and cable plug are keyed to prevent the cable from
being plugged into the wrong module.
On the back of the module are two edge connectors that attach to
the system backplane.
2.2 Elec rical Descrip ion
The input module contains two analog input channels with
softwareĆselectable filters. These channels are connected through a
multiplexer to a successive approximation analog to digital converter.
As supplied, the module can convert +10 volt or +1 volt inputs. If
you add external resistors, the module can convert +5 volt or 4Ć20
ma current inputs.
Each channel provides 12 bit conversion plus sign (+4095). The
module provides 100% overranging in the event that the input signal
exceeds the maximum normal input voltage. hen in the overrange
condition, the magnitude is doubled (+8191) and the accuracy is
halved (bit 0 is no longer significant).
The analog to digital converter provides conversion rates as fast as
once every 500 microseconds. The update period is software
programmable in increments of 500 microseconds, up to a maximum
of 32.7675 seconds. Sample and hold circuits maintain constant
input values during conversion.
Each channel contains a low pass filter with userĆselectable
bandwidths to smooth out transients and also provide antiĆaliasing
for signals with high frequency components. The filter cutoff
frequencies are given in figure 4.6.
A single isolated common is provided for both analog input channels.
Input signals have 600 volt isolation to logic common. An onĆboard
DCĆDC converter provides power to the isolated portion of the circuit.
The +15 volt outputs from the supply are brought to the connectors
on the faceplate of the module. A circuit diagram is shown in figure
2.1. Refer to Appendix A for power supply current limitations.

2Ć2
+
-
O/A
1
2
3
Figure 2.1 Ć Typical Input Circuit
There are 4 LED indicators on the faceplate of the odule which
reflect the status of the onĆboard 4 hz clock. The top LED indicates
whether co on clock, which can be generated fro nu erous
odules, is on. The next LED indicates whether this odule is driving
the co on clock. The botto two LEDs are used for factory testing
purposes only and should be ignored by the user. See figure 2.2.

2Ć3
ANALOG
INPUT
57C409
B
C
DE
F
G
1
2
36
7
8
1
2
3
4
5
6
7
8
9
1
0
P3
Fi ure 2.2 Ć Module Faceplate

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3Ć1
 
This section describes how to install and remove the module and its
cable assembly.
 
The installation of wiring should conform to all applicable codes.
To reduce the possibility of electrical noise interfering with the proper
operation of the control system, exercise care when installing the
wiring from the system to the external devices. For detailed
recommendations refer to IEEE 518.
  
se the following procedure to install the module:
Step 1. Turn off power to the system. All power to the rack as well
as all power to the wiring leading to the module should be
off.
Step 2. Mount the terminal strip (M/N 57C371) on a panel. The
terminal strip should be mounted to permit easy access to
the screw terminals. Make certain that the terminal strip is
close enough to the rack so that the cable will reach
between the terminal strip and the module.
Step 3. Fasten field wires to the terminal strip. Typical field
connections are shown in figure 3.1.
Refer to Appendix C for the arrangement of terminal board
connections. Make sure that all field wires are securely
fastened. Note that for any voltage or current input other
than +10 volts or + 1 volt, an external resistor must be
mounted on the terminal strip.
1
2
3
SER
DEVICE
COMMON
VOLTAGE INP T
OPTIONAL
22.1K RESISTOR
FOR +5V INP T
Figure 3.1 Ć Typical Field Signal Connections

3Ć2
Step 4. T ke the module out of its shipping cont iner. T ke it out of
the ntiĆst tic b g, being c reful not to touch the
connectors on the b ck of the module.
Step 5. Insert the module into the desired slot in the r ck. The
module will work only in r ck th t cont ins processor
module. Do not ttempt to use the module in remote
r ck. Use screwdriver to secure the module into the slot.
Refer to figure 3.2.
P/S 0123456789101112131415
10
Typic l 10 Slot R ck
16
Typic l 16 Slot R ck
Figure 3.2 Ć R ck Slot Numbers
Step 6. Att ch the field termin l connector (M/N 57C371) to the
m ting h lf on the module. M ke cert in th t the
connector is the proper one for this module. Use
screwdriver to secure the connector to the module.
Note th t both the module nd the termin l strip connector
re equipped with keys." These keys should be used to
prevent the wrong c ble from being connected to
module in the event th t the connector needs to be
removed for ny re son nd then re tt ched l ter.
At the time of inst ll tion, rot te the keys on the module
nd the connector so th t they c n be connected together
securely. It is recommended th t, for modules so
equipped, the keys on e ch successive module in the
r ck be rot ted one position to the right of the keys on the
preceeding module.
If you use this method, the keys on p rticul r connector
will be positioned in such w y s to fit together only with
specific module, nd there will be little ch nce of the
wrong connector being tt ched to module.
Step 7. Turn on power to the r ck.
Step 8. Verify the inst ll tion by connecting the progr mming
termin l to the system nd running the ReSource
softw re. Use the I/O MONITOR function.
Set registers 7 nd 8 to the v lue 1.

3Ć3
Read register 4 to determine whether bits 8 and 10 are set,
signifying that the common clock is being driven by
another module in the rack. If they are not set, then set
registers 5 and 6 on this module to the value 64. his will
enable common clock on this module. Bits 8 and 10 on
register 4 should now be set.
Monitor registers 0 and 1. Verify that they contain numbers
proportional to the analog value on their respective
channels. his confirms that the installation is complete.
Refer to table 1 for the approximate voltages or currents
that should be read.
able 1
 + +  
ă4095 +1.0V +10.0V 20 ma
ăă819 +ă.2V +2.0V ă4 ma
ăăă0 0.0V 0.0V ă0 ma
-4095 -1.0V -10.0V ă -
Step 9. Determine offset and gain compensation. his is
necessary because manufacturing tolerances on the
module can result in small offset and gain differences (See
figure 3.3).
VOL S0
4095
10
COUN S
CORREC ED_VALUE%
OFFSE
RAW_DA A%
Figure 3.3 Ć Offset and Gain

3Ć4
These can easily be compensated for in software. erform
the following steps to determine the compensation values:
Set the analog input voltage to 0 volts. Use the I/O
MONITOR to read the digital value. This is the offset.
Set the analog input voltage to maximum. Use the I/O
MONITOR to read the digital value. Subtract the offset
calculated in the previous step from this number. The
result is the gain.
Use the following equation in your application program to
compensate the data:
CORRECTED VALUE%=(RAW DATA% Ć OFFSET%) * 4095/GAIN%
  
Use the following procedure to replace a module:
Step 1. Turn off power to the rack and all connections.
Step 2. Use a screwdriver to loosen the screws holding the
connector to the module. Remove the connector.
Step 3. Loosen the screws that hold the module in the rack.
Remove the module from the slot in the rack.
Step 4. lace the module in the antiĆstatic bag it came in, being
careful not to touch the connectors on the back of the
module. lace the module in the cardboard shipping
container.
Step 5. Take the new module out of the antiĆstatic bag, being
careful not to touch the connectors on the back of the
module.
Step 6. Insert the module into the desired slot in the local rack.
Use a screwdriver to secure the module into the slot.
Step 7. Attach the field terminal connector (M/N 57C371) to the
mating half on the module. Make certain that the
connector keys are oriented correctly and that the
connector is the proper one for this module. Use a
screwdriver to secure the connector to the module.
Step 8. Turn on power to the rack.

4Ć1
4.0 PROGRAMMING
This section describes how the d t is org nized in the module nd
provides ex mples of how the module is ccessed by the pplic tion
softw re. For more det iled inform tion, refer to DCS 5000 Enh nced
BASIC L ngu ge Instruction M nu l (JĆ3600) or AutoM x Enh nced
BASIC L ngu ge Instruction M nu l (JĆ3675).
4.1 Register Organization
The d t in the input module is org nized s eleven 16 bit registers.
There is set of registers for e ch n log ch nnel. Ch nnel 0 uses
registers 0,2,5,7, nd 9. Ch nnel 1 uses registers 1,3,6,8, nd 10.
Register 4 provides st tus inform tion on the common clock sign l
which is sh red by both ch nnels.
Registers 0 nd 1 cont in the 2's complement digit l v lue of the
n log input. The n log to digit l converter provides precision of
12 bits plus sign. It lso provides 100% overr nge c p bility. This
me ns th t if the input is m int ined within the specified r nge, the
digit l v lue will v ry +4095, with e ch of the bits cont ining
signific nt inform tion. If the input exceeds the specified r nge, the
digit l v lue will v ry +8191, but bit 0 will no longer be signific nt.
These registers re re d only. Refer to figure 4.1.
15 Ă14 Ă 13Ă 12 Ă11 Ă 10 Ă 9 Ă 8 Ă 7 Ă 6 Ă 5 Ă 4Ă 3Ă 2Ă 1 Ă 0
register 0
register 1
sign
sign
ch nnel 0 d t
ch nnel 1 d t
bits
Figure 4.1 Ć An log Input Registers
Registers 2 nd 3, which re lso re d only, cont in the time
rem ining until the next n log to digit l conversion. E ch count is
equiv lent to 500 microseconds. Refer to figure 4.2.
register 2
register 3
current count of upd te period for ch nnel 0
current count of upd te period for ch nnel 1
15Ă 14ă 13 Ă12Ă11Ă 10Ă 9 Ă8 Ă7Ă 6Ă 5Ă 4Ă 3Ă 2Ă 1 Ă0bits
Figure 4.2 Ć Current Count Registers

4Ć2
Register 4 cont ins the common clock st tus. Bits 8 nd 10 indic te
th t the common clock is being driven by module in the r ck.
These bits must be set for the module to function correctly. Bit 6
indic tes th t this module is driving the common clock. Register 4 is
re d only. Refer to figure 4.3.
bits
register 4 rr
Bit 10 Ć Common clock on
Bit ă8 Ć Common clock on
Bit ă6 Ć Common clock en bled
----- - -r ------
1514131211109876543 210
Figure 4.3 Ć Common Clock St tus Register
Registers 5 nd 6 cont in the interrupt control registers. E ch
ch nnel m y be progr mmed to interrupt independently of the other.
With the exception of bit 6 in e ch register, these registers re
controlled by the oper ting system nd must not be written to by the
user. Refer to figure 4.4.
For this module to oper te properly, the common clock must be
present on the b ckpl ne. The top LED on the module f cepl te
indic tes whether common clock is present. Note th t the common
clock sign l c n be gener ted from number of I/O modules,
including this module (57C409), 57C421, nd 57C411. If this module
is to gener te the common clock, bit 6 in either registers 5 or 6 must
be set. Refer to figure 4.4.
rw rwrwrw rw
register 5
Bit 15 Ć Interrupt fl g
Bit ă7 Ć Interrupt en bled
Bit ă6 Ć Common clock en bled
Bit ă2 Ć + Interrupt lloc ted
---- --
rw
rw -
---- ---
rw rw - --
---
rw rw rw
register 6
Interrupt Line ID
bits 1514131211109876543 210
Figure 4.4 Ć Interrupt Control Registers

4Ć3
Re isters 7 and 8 contain the update period for the analo to di ital
conversion. Each count in these re isters is equivalent to 500
microseconds. The update period may ran e from 500 microseconds
to 32.7675 seconds. These two re isters must be initialized before
the common clock is enabled on the backplane. Refer to fi ure 4.5.
Refer to fi ure 4.4 for more information about the common clock.
re ister 7
re ister 8
update period for channel 0
update period for channel 1
bits 1514131211109876543 210
Fi ure 4.5 Ć Analo Update Re isters
Re isters 9 and 10 contain the input filter bein used. The purpose of
the filter is to remove si nal components that are beyond the
samplin frequency. Note that the module requires a short delay
between statements used to initialize these two re isters. The
minimum delay time between initialization of the two re isters is 5.5
msec. The input filter re isters must be initialized after the common
clock is turned on. Refer to fi ure 4.6 for the cutoff frequencies
available.
re ister 10
channel 1
00 = 300 rad/sec
01 = 145 rad/sec
10 = ă79 rad/sec
11 = ă21 rad/sec
rw rw
re ister 9
channel 0 ---- ---
---- ---
---
---
rw rw----
----
+ Input filter
bits 1514131211109876543210
Fi ure 4.6 Ć Input Filter Selection Re isters

4Ć4
4.2 Configuration
Before any application programs can be written, it is necessary to
configure, or set, the efinitions of systemĆwi e variables, i.e. those
that must be globally accessible to all tasks.
For DCS 5000 an AutoMax Version 2.1 an earlier, you efine
systemĆwi e variables by writing a Configuration task. For AutoMax
Version 3.0 an later, you efine systemĆwi e variables using the
AutoMax Programming Executive. After these variables are efine ,
you can generate the configuration file automatically, which
eliminates the requirement to write a configuration task for the rack. If
you are using AutoMax Version 2.1 or earlier, refer to Appen ix E for
example that show how to efine variables in the configuration task. If
you are using AutoMax Version 3.0 or later, see the AutoMax
Programming Executive (JĆ3750) for information about configuring
variables.
4.3 Reading And Writing Data In Application
Tasks
In or er for an input mo ule to be reference by application
software, it is first necessary to assign symbolic names to the
physical har ware. In AutoMax Version 2.1 an earlier, this is
accomplishe by IODEF statements in the configuration task. See
Appen ix E for an example. In AutoMax version 3.0 an later, you
assign symbolic names using the Programming Executive.
Each application program that references the symbolic names
assigne to the input mo ule in configuration must eclare those
names COMMON.
The frequency with which tasks, or application programs, rea their
inputs an write their outputs epen s on the language being use .
La er logic an control block tasks rea inputs once at the
beginning of each scan an write outputs once at the en of scan.
BASIC tasks rea an input an write an output for each reference
throughout the scan.