Rockwell Automation AB Quality Allen-Bradley SLC 500 User manual

SLC500FastAnalog
I/O Module
Catalog Numbers 1746-FIO4I and
1746-FIO4V
User Manual

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://literature.rockwellautomation.com) 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, when necessary, we use notes to make you aware
of safety considerations.
Rockwell Automation, Allen-Bradley, TechConnect, RSLogix500, SLC, SLC 500, and SLC 5/02 are trademarks of Rockwell
Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
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, and recognize
the consequence
SHOCK HAZARD Labels may be on or inside the equipment, for example, a drive or
motor, to alert people that dangerous voltage may be present.
BURN HAZARD Labels may be on or inside the equipment, for example, a drive or
motor, to alert people that surfaces may reach dangerous
temperatures.

3Publication 1746-UM009B-EN-P - September 2007
Table of Contents
Preface
About This Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . 5
Additional Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Chapter 1
Quick Start
Required Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . 7
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Chapter 2
Install and Wire the Modules
Determine the Module’s Power Requirements . . . . . . . . . . . 11
Determine Compatibility with Other I/O Modules. . . . . . . . . 12
Configure Input Channels . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Select the I/O Rack Slot. . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Install the Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Considerations When Wiring . . . . . . . . . . . . . . . . . . . . . . . . 16
Minimize Electrical Noise Interference . . . . . . . . . . . . . . . . . 18
Wire the Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Minimize Ground Loops . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Label the Terminal Block. . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Chapter 3
Access Files to Configure I/O
Click and Drag Configuration . . . . . . . . . . . . . . . . . . . . . . . 23
Read IO Config Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Chapter 4
Processor and Module
Considerations
Processor Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Module Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Chapter 5
Write Ladder Logic
Retentive and Non-retentive Programming . . . . . . . . . . . . . . 39
Detect an Out-of-range Input. . . . . . . . . . . . . . . . . . . . . . . . 41
Overview of Scaling Inputs and Outputs . . . . . . . . . . . . . . . 42
Scale an Analog Input and Detect an Out-of-range Condition 44
Scale an Analog Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Scale Offsets When >32,767 or <32,768. . . . . . . . . . . . . . . . 49
Range-check an Analog Input and Scale It for an Output . . . 52
PID Control with Analog I/O Scaling . . . . . . . . . . . . . . . . . . 56

Publication 1746-UM009B-EN-P - September 2007
4Table of Contents
Chapter 6
Calibrate the Module
Calibration Tradeoffs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Calibrate an Analog Input Channel . . . . . . . . . . . . . . . . . . . 62
Chapter 7
Test Module Operation
Test the SLC 500 System . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Test the Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Chapter 8
Maintenance and Safety
Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Safety Considerations When Troubleshooting. . . . . . . . . . . . 76
Appendix A
Module Specifications
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Appendix B
2’s-complement Binary Numbers
Use 2’s-complement Binary Numbers. . . . . . . . . . . . . . . . . . 83
Appendix C
Module Input and Output Circuits
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Index

5Publication 1746-UM009B-EN-P - September 2007
Preface
About This Publication
Read this preface to familiarize yourself with the rest of the manual.
This preface covers the following topics:
•Who should use this manual
•The purpose of this manual
•Terms and abbreviations
•Conventions used in this manual
•Allen-Bradley support
This manual is a reference guide for the 1746-NR4 RTD/Resistance
Input Module. The manual:
•gives you an overview of system operation.
•explains the procedures you need to install and wire the module
at the customer site.
•provides ladder programming examples.
•provides an application example of how this input module can
be used to control a process.
Who Should Use This
Manual
Use this manual if you are responsible for designing, installing,
programming, or troubleshooting control systems that use
Allen-Bradley small logic controllers.
You should have a basic understanding of SLC 500 products. You
should understand programmable controllers and be able to interpret
the ladder logic instructions required to control your application. If
you do not, contact your local Allen-Bradley representative for
information on available training courses before using this product.

Publication 1746-UM009B-EN-P - September 2007
6Preface
Additional Resources
The following documents contain information that may be helpful to
you as you use Allen-Bradley SLC products.
You can view or download publications at
http://literature.rockwellautomation.com. To order paper copies of
technical documentation, contact your local Rockwell Automation
distributor or sales representative.
Conventions
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.
Resource Description
SLC 500 Systems Selection Guide, publication 1747-SG001 An overview of the SLC 500 family of products
SLC 500 Module Hardware Style User Manual, publication
1747-UM011
A description on how to install and use your modular SLC 500
programmable controller
Installation & Operation Manual for Fixed Hardware Style
Programmable Controllers, publication 1747-6.21
A description on how to install and use your fixed SLC 500
programmable controller
SLC 500 Instruction Set Reference Manual, publication
1747-RM001
A reference manual that contains status file data, instruction set,
and troubleshooting information about the software
SLC 500 4-Channel Analog I/O Modules User’s Manual, publication
1746-UM005
A resource manual and user’s guide containing information about
the analog modules used in your SLC 500 system.
Industrial Automation Wiring and Grounding Guidelines, publication
1770-4.1
In-depth information on grounding and wiring Allen-Bradley
programmable controllers
Application Considerations for Solid-State Controls. publication
SGI-1.1
A description of important differences between solid-state
programmable controller products and hard-wired
electromechanical devices
National Electrical Code, published by the National Fire Protection
Association of Boston, MA
An article on wire sizes and types for grounding electrical
equipment

7Publication 1746-UM009B-EN-P - September 2007
Chapter 1
Quick Start
This chapter presents an overview of installation and start-up
procedures to help you get the module working quickly.
It refers to full procedures in corresponding chapters of this manual or
in other SLC documentation that may be helpful if you are unfamiliar
with programming techniques or system installation.
We recommend that you use this chapter in either of two ways.
•Use as a fast installation and start-up guide for the experienced
users.
•Use as an overview for using the entire manual for the first-time
user.
Required Tools and
Equipment
Have the following tools and equipment ready.
•Medium flat-head screwdriver
•Medium Phillips-head screwdriver
•Wire strippers
•Utility knife
•Hot-air blower
•Shrink wrap
•Belden 8761 cable or equivalent
•Analog I/O devices for your application
•I/O modules (1746-FIO4I and/or 1746-FIO4V)
•Programming software
IMPORTANT If you have any questions about the abbreviated procedures
presented in this chapter, always read the referenced chapters
and other recommended documentation before trying to apply
the information.

Publication 1746-UM009B-EN-P - September 2007
8Quick Start
Procedures
Follow these steps to get your module running in your SLC system.
1. Plan the inclusion of analog I/O modules in your SLC system.
If a new system, specify the type of processor, number of I/O
racks, I/O modules, and power supply. If adding to an existing
system:
•assign modules to slot locations in the I/O rack.
•verify that the power supply for the I/O rack can handle the
increased load.
See SLC 500 Systems Selection Guide, publication 1747-SG001,
for more information.
2. Configure module input channels for current or voltage
operation.
Locate the 2-switch assembly on the module’s circuit board, and
set each channel as follows.
3. Connect I/O devices with cables.
Refer to Install and Wire the Modules on page 11.
IMPORTANT •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 loop power for analog inputs.
•Use a power supply that matches the transmitter (sensor)
specifications.
12
N
O
Current (ON)
Voltage (OFF)
Switch 1 = Channel 0
Switch 2 = Channel 1

Publication 1746-UM009B-EN-P - September 2007
Quick Start 9
4. Configure the system I/O and module ID.
With the software, configure the processor, I/O racks, slots, and
I/O modules.
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.
ID code for 1746-FIO4I is 3224
ID code for 1746-FIO4V is 3218
5. Understand A/D & D/A converter resolution on input and
output words.
The module’s I/O channel converters limit bit usage to less than
a full 16-bit word.
The input channel converter resolution is 12 bits, where the
highest four bits are always zero.
The output channel converter resolution is 14 bits, where the
lowest two bits are never used.
For Differential Inputs
For Single-ended Input
with 3-wire Transmitter
Analog
Sensor
+
–
Earth
Ground
Important:Jumper
unused inputs.
Load
Earth
Ground
Important: Do not
jumper unused outputs.
Power
Supply
+
–
Transmitter
SignalSupply
GND
3
4
5
Module
IN +
IN –
ANL COM
Module
0
1
2
IN 0 +
IN 0 –
ANL COM
3
4
5
IN 1 +
IN 1 –
ANL COM
6
7
8
Not Used
OUT 0
ANL COM
9
10
11
Not Used
OUT 1
ANL COM

Publication 1746-UM009B-EN-P - September 2007
10 Quick Start
The lowest two bits have no effect on the output value.
Refer to Processor and Module Considerations on page 29 for
more information.
6. Write ladder logic to process the module’s analog data.
We provide several programming examples that include the
following:
•Clear the output when changing mode or cycling power
•Detect an out-of-range input
•Scale analog outputs
•Scale offsets
•Scale and range-check analog inputs and outputs
•PID control with analog I/O scaling
Study these examples to understand how to program the
module.
Refer to Write Ladder Logic on page 39.
7. (Optional) Write ladder logic to maintain calibrated inputs.
We show you how to write ladder logic that provides a
calibrated input reference during runtime, and lets you
periodically calibrate module inputs. We suggest that you modify
the logic examples to suit your application and add them to your
application program.
Refer to Calibrate the Module on page 61 for more information.
SLC 500 Processor
Data Files
X
(variable input data)msb
Channel 0 Output Word
Channel 1 Output Word
Channel 0 Input Word
Channel 1 Input Word
Input Image
(2 words)
Output Image
(2 words)
Address
I:1.0
I:1.1
Address
O:1.0
O:1.1
lsb
variable output data)msb lsb
X
0000
Bit 15 Bit 11 Bit 0
Bit 15 Bit 2 Bit 0
X = not used

11 Publication 1746-UM009B-EN-P - September 2007
Chapter 2
Install and Wire the Modules
This chapter describes procedures to install fast analog I/O modules in
an SLC 500 system. The procedures include the following tasks.
•determine the module’s power requirements
•determine compatibility with other I/O modules
•configure input channels
•select the I/O rack slot
•install the module
•consider when wiring
–using system wiring guidelines
–grounding the cable
–determining cable length
•minimize electrical noise interference
•wire the module
•minimize ground loops
•label the terminal block
Determine the Module’s
Power Requirements
Analog modules require power from the 5V dc and 24V dc backplane
power supplies of the SLC 500 system. This table shows the backplane
power requirements for fast analog I/O modules.
Use this table to compute the module’s portion of total load on the
modular system power supply.
For more information, refer to SLC 500 Systems Selection Guide,
publication 1747-SG001.
Current Load
Catalog Number Current at 5V dc Current at 24V dc
1746-FIO4I 55 mA 150 mA
1746-FIO4V 55 mA 120 mA

Publication 1746-UM009B-EN-P - September 2007
12 Install and Wire the Modules
Determine Compatibility
with Other I/O Modules
Use the I/O Compatibility chart when using the expansion rack of a
fixed controller (1747-L20, 1747-L30, and 1747-L40). The chart
determines compatibility of other I/O modules with fast analog
modules. Compatibility is solely based on current drawn from the
backplane.
For more information, refer to the SLC 500 Fixed Hardware Style
Installation and Operation Manual, publication 1747-6.21.
I/O Compatibility
1746-FIO4I 1746-FIO4V 1746 Module
FIO4I
FIO4V
•(1) •IA4, IA8, IA16
•• IB8, IB16
•• IB32
•• IG16
•• IM4, IM8, IM16
•• IN16
•• IO4
•IO8
IO12
•• ITB16, ITV16
•• IV8, IV16, IV32
NIO4I, NIO4V
∇(2) ∇NO4I, NO4V
NI4
•• NR4
•• NT4
•• OA8
OA16
•• OB8
OB16, OB32
•OBP16
•• OG16
•• OV8
•OV16
OV32

Publication 1746-UM009B-EN-P - September 2007
Install and Wire the Modules 13
Configure Input Channels
Your fast analog I/O modules have a two-switch assembly to
configure the input channels for either current or voltage operation.
The switches are on the module’s circuit board. Switch orientation is
shown on the nameplate of the module.
Switch Orientation
Switches labeled 1 and 2 control the input mode of channels 0 and 1
respectively.
Channels 0 and 1 Input Mode
•OW4
OW8, OW16
OX8
•BASIC
BASn
DCM
HS
•KE
KEn
(1) The •symbol indicates an allowable combination of 1746 I/O modules.
(2) The ∇symbol indicates an auxiliary 24V dc power supply may be needed.
I/O Compatibility
1746-FIO4I 1746-FIO4V 1746 Module
ON – Configures channel for current input
OFF – Configures channel for voltage input
12
N
O
Current (ON)
Switch 1 = Channel 0
Switch 2 = Channel 1
Voltage (OFF)

Publication 1746-UM009B-EN-P - September 2007
14 Install and Wire the Modules
Select the I/O Rack Slot
Two factors determine where you should locate the module in the
I/O rack: ambient temperature and electrical noise. Consider the
following conditions when selecting an I/O rack slot for the module.
Position the module:
•in a slot away from ac or high voltage dc modules.
•away from the rack power supply if installed in a modular system.
•in the I/O rack lowest in the enclosure for a cooler ambient.
Install the Module
When installing the module in an I/O rack, you do not need to remove
the terminal block from the module. However, if the terminal block is
removed, use the write-on label located on the side of the terminal
block to identify the module location and type. To remove the terminal
block, grasp it on the top and bottom and pull outward and down.
Follow these steps when installing or removing the module.
1. Verify that input configuration switches 1 and 2 are set correctly.
2. Align the module’s circuit board with the rack’s card guide.
See Installing the Module on page 15.
3. Slide the module in until top and bottom retaining clips are
secured.
ATTENTION Never install, remove, or wire modules with power applied to
the I/O rack. Rid yourself of electrostatic charge before
handling the module. Electrostatic discharge can degrade
module performance or destroy analog circuitry.
IMPORTANT Do not tamper with the module’s factory-sealed potentiometer.
It does not require any adjustments.
ATTENTION Take care to avoid connecting a voltage source to a channel
configured for current input. This could result in improper
module operation or damage to the module.

Publication 1746-UM009B-EN-P - September 2007
Install and Wire the Modules 15
4. To remove the module, press the retaining clips at the top and
bottom of the module and slide the module out.
Installing the Module
Card Guide
Self-locking tabs secure the
module in the I/O rack.

Publication 1746-UM009B-EN-P - September 2007
16 Install and Wire the Modules
Considerations When
Wiring
This section provides guidelines on wiring the system, grounding the
cables, determining cable length.
System Wiring Guidelines
Use the following guidelines in planning the system wiring to the
module.
•Analog common terminals (ANL COM) are electrically
interconnected inside the module, but not internally connected
to earth.
•Voltages on IN+ and IN– terminals must be within 0…20V with
respect to ANL COM to ensure proper input channel operation.
This is true for current and voltage input channel operation.
•Voltage outputs (OUT 0 and OUT 1) of the 1746-FIO4V module
are referenced to ANL COM. Load resistance (R1) for a voltage
output channel must be equal to or greater than 1 KΩ.
•Current output channels (OUT 0 and OUT 1) of the 1746-FIO4I
module source current that returns to ANL COM. Load resistance
(R1) for a current output channel must be within 0…500 Ω.
•Input connections for single-ended or differential input are the
same.
ATTENTION Before wiring the module, disconnect SLC system power, I/O
rack power, and module power.

Publication 1746-UM009B-EN-P - September 2007
Install and Wire the Modules 17
Ground the Cable
Signal cable such as Belden cable #8761 (or equivalent) has two signal
wires (black and clear), one drain wire, and a foil shield. The drain
wire and foil shield must be grounded at only one end of the cable,
not at both ends.
Typical Signal Cable
Determine Cable Length
When you determine the length of cable required to connect an I/O
device, remember to include additional length to route the drain wire
and foil shield to earth ground. Route your cable long enough to
avoid areas of high radiated electrical noise, but short enough to avoid
signal attenuation.
IMPORTANT Ground the cable shield at one end having a good earth-ground
connection, such as at an I/O chassis mounting bolt or nearest
ground bus in the I/O enclosure. Make this connection as short
as possible. Do not ground the cable at the module’s terminal
block.
Insulation
Shrink Wrap
Clear Wire Drain Wire
Black Wire
Foil Shield

Publication 1746-UM009B-EN-P - September 2007
18 Install and Wire the Modules
Minimize Electrical Noise
Interference
Because high-speed analog signals are particularly vulnerable to
electrical noise, take precautions when routing your signal cables. To
help reduce the effects of electrical noise on analog signals, we
recommend that you do the following:
•Install the SLC 500 system in a NEMA rated enclosure.
•Make sure that the SLC 500 system is properly grounded.
•Use Belden cable #8761 (or equivalent) for signal wiring.
•Ground the cable properly.
•Route signal cables away from other wiring or in grounded
conduit.
•Group these modules away from ac or high-voltage dc modules.
We recommend re-checking system operation after installing new
machinery or other sources of electrical noise near the system.
For additional information on this subject, refer to Industrial
Automation Wiring and Grounding Guidelines, publication 1770-4.1.
Wire the Module
Follow this procedure when wiring your modules.
1. Strip about 7.6 cm (3 in.) of casing to expose the wires at each
end of the cable.
2. Twist the drain wire and foil shield together and bend them
away from the cable at the grounded end of the cable.
ATTENTION Before wiring a module, disconnect power from the SLC 500
system and from any other source to the module.
Black Wire
Casing Clear Wire
Shrink Wrap
Grounded End
Ungrounded End
Black Wire
Clear Wire
Shrink Wrap
Casing
Twisted Foil Shield and Drain Wire

Publication 1746-UM009B-EN-P - September 2007
Install and Wire the Modules 19
3. Apply shrink wrap where wires leave the casing with the hot-air
blower.
4. Cut off the drain wire and foil shield at the other end of the
cable.
5. Apply shrink wrap to the junction where wires leave the casing.
6. Trim the signal wires to 5 cm (2 in.) lengths. Strip about
4.76 mm (3/16 in.) of insulation away to expose the copper
strands for your connections.
7. Decide where you will connect the cable to earth ground, and
ground it.
Refer to Ground the Cable on page 17.
8. Connect signal wires (black and clear) to the terminal block and
to the input or output device.
Wiring Diagram for Module, Sensor, and Load (showing differential inputs)
Important: Channels are not isolated from each other.
All analog commons are connected together internally.
Important: Jumper
unused inputs.
Important: Do not
jumper unused outputs.
Load
Analog
Sensor
Earth
Ground
Earth
Ground
+
–
0
1
2
IN 0 +
IN 0 –
ANL COM
3
4
5
IN 1 +
IN 1 –
ANL COM
6
7
8
not used
OUT 0
ANL COM
9
10
11
not used
OUT 1
ANL COM

Publication 1746-UM009B-EN-P - September 2007
20 Install and Wire the Modules
Wiring Schematic for Single-ended Current-loop Analog Input Connections
9. Repeat steps 1…6 for each channel. For each unused input
channel, jumper together the plus (+), minus (–), and common
(ANL COM) terminals. For each unused output channel, do not
connect terminals.
Minimize Ground Loops
To keep the ground-loop currents of input circuits to a minimum, we
recommend that you:
•use the same power supply to power both input channels of a
module.
•otherwise, tie together the grounds of separate power supplies.
See Wiring Schematic for Single-ended Current-loop Analog Input
Connections for more information.
IMPORTANT Single-ended inputs are less immune to noise than are
differential inputs.
Important: The module does not provide loop power for analog inputs.
Use a power supply that matches the transmitter specifications.
Power
Supply
+
–
Power
Supply
+
–
Power
Supply
+
–
2-wire Transmitter
3-wire Transmitter
4-wire Transmitter
Transmitter
SignalSupply
GND
Transmitter
SignalSupply
+
–
Transmitter
+
–
+–Module
IN +
IN –
ANL COM
Module
IN +
IN –
ANL COM
Module
IN +
IN –
ANL COM