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