J-3673-3 2-In/2-Out 4-20 mA Analog Rail Module
Contents
1. Technical Specifications Ambient Conditions Storage temperature 40 C to 85 C 40 F to 185 F Operating temperature at the module 0 C to 60 C 32 F to 140 F e Humidity 5 90 non condensing Dimensions e Height 9 25 inches 23 5 cm Width 2 94 inches 7 5 cm Depth 7 75 inches 19 7 cm including plug in terminals e Weight 4 5 lbs 2 1 kg Recommended Cable for Analog Signal Wiring Belden 8761 or equivalent type Maximum Power Dissipation 4 5 Watts Communication Power Requirements e 5V 250 mA supplied by host through I O Rail cable Analog Circuit Power Supply use either 120 VAC or 24 VDC supply 120 supply 92 132V acceptable range 15 20 Maximum current 150mA 24VDC supply 20 32V acceptable range 4 3396 1696 Maximum current 350mA Maximum Source KVA e 10 Fuse Types and Rating e MDQ 250 VAC 25A for 120 VAC power e 250 VAC 75A for 24 VDC power e GDB 250 VAC 032A for analog signal inputs A 1 A 2 Appendix A Continued Input Channels Operating range 4 20mA Number of channels 2 single ended Number of commons 1 shared among all 4 channels Resolution 12 bits binary Non linearity 1 LSB maximum Accuracy 0 33 of full scale at 25 C maximum Thermal drift 50 ppm degrees C Type of converter Successive approximation Speed of conversion 13 usec Impedance 278 Ohms plus 32mA fuse re2. section of the module faceplate is securely attached to its mating half Step 3 Verify that the signal wiring on the module faceplate is correct See step 9 in section 3 2 for more information Verify that the wiring is tight and functioning properly Step 4 Step 5 Turn on power to the module and to the external hardware Use the Executive software to read the value on the input channel Use an ammeter to read the input signals at the terminal point and compare the two If both read zero verify that the external hardware is operating correctly If the external hardware is operating correctly the 32mA fuse for the input channel may be blown Replace the 32mA fuse s that has blown following the directions below a Stop any application tasks that are running b Turn off power to the external hardware connected to the module Turn off power 120 VAC or 24 VDC to the module c Without disconnecting the wiring remove the 12 point connector from the faceplate and set aside Without disconnecting the wiring remove the 4 point connector from the faceplate and set aside d Before disassembling the module note that it consists of two major pieces the metal enclosure and the printed circuit board which is screwed to the left side of the enclosure if facing the front of the module After the screws are removed the two pieces can be seperated in a manner similar to that of opening a book Simply pull the left side of
3. Figure 4 12 AOUT Instruction Block 4 2 Analog Rail Module in DCS 5000 AutoMax Systems This section describes how the Analog Rail is used with DCS 5000 AutoMax systems 4 2 1 Configuring the Analog Rail Module with a DCS 5000 AutoMax Remote I O Head The Analog Rail module is used in the Local Head mode when the host is a DCS 5000 AutoMax Remote I O Head For AutoMax Version 3 0 and later the Analog Rail module is configured using the AutoMax Programming Executive Refer to instruction manual J 3750 for more information For DCS 5000 or AutoMax Version 2 1 or earlier the module is defined in the configuration task for the master rack using the DCS 5000 or AutoMax Programming Executive software See instruction manual J 3649 for more information on the configuration task 4 10 4 2 2 4 2 3 For DCS 5000 or AutoMax Version 2 1 or earlier use the RIODEF statement to define each channel on the Analog Rail module as a separate register Note that in addition to defining each channel as a register you can also define the over range and under range bits for each channel separately These bits can also be defined using the RIODEF statement Use the following format for the RIODEF statement nnnnn RIODEF name MASTER_SLOT m DROP d SLOT s REGISTER r BIT b where nnnnn Configuration task line number range 1 32767 name Symbolic name of channel ending with integer for registers booleans for bits Slot in rack con
4. WISI sna viva JOHINO9 aalv os y 93151999 5 k 334A 39VIIOA sna viva SIVN9IS TOHLNOO 3151939 ABLINOHIO TOHLNOI 9311081 STVNDIS 5 Auvaunoa o 99A GQ31NOLLVOINDIWWOO TOHLNOI NIVIA ABLINOHIO 1SOH 30V443LNI LSOH VIHIS ABLINDHIO 13534 HOLI3SNNOI 1SOH 1 HOLIMS HO 1v901 B 1 The following AutoMate program sequences can be used to interface to an AutoMate Processor that does not support the AIN or AOUT blocks Over a period of four scans the program below maps registers 40 through 43 to the four channels of an Analog Rail module in Rail mode Registers Used 0 40 41 42 43 44 45 Register that is configured to be updated at the end of scan Value to output to channel 0 Value to output to channel 1 Value as input to channel 2 Value as input to channel 3 Counter to select channel to operate this scan Coils Beginning of the Scan If channel
5. a aden ae 3 1 3l WINO e Gd tally idee veo eh we haba 3 1 3 2 Initial Installation serias coa ria 3 2 3 3 Module 2 55 22 5990959 3 6 Programming 4 1 4 1 Analog Rail Module in AutoMate Systems 4 1 4 1 1 Configuring the AutoMate Processor for Use with the Analog Rail Module 4 2 4 1 2 AutoMate Programming in Rail Mode 4 7 4 1 3 AutoMate Programming Local Head Mode 4 8 4 1 4 Analog In AIN and Analog Out AOUT Instruction Blocks na ann 4 9 4 2 Analog Rail Module in DCS 5000 AutoMax Systems 4 10 4 2 1 Configuring the Analog Rail Module with a DCS 5000 AutoMax Remote I O Head 4 10 4 2 2 Configuring the Analog Rail Module with a Power Module Interface Processor 4 11 4 2 3 DCS 5000 AutoMax 4 11 Diagnostics and Troubleshooting 5 1 5 1 Both LEDs on the Faceplate are Off 5 1 5 2 The COM OK LED is 5 3 5 9 Incorrect Data main Re sa maa ari abia akan ROS 5 3 5 4 Constant Under Range 5 4 Appendices Appendix A Technical Specifications 2 0 22 s8i0eisoit LR ese bad LER Appendix B Block Diagram cc cance ae nee
6. 24 VDC you need to replace the factory installed 25A fuse in the new module with the 75A fuse that came in the shipping box with the module Use a screwdriver to release the fuse holder located on the Analog Rail module faceplate Pull the fuse holder out of the module Remove the 25A fuse from the fuse holder and replace it with the 75A fuse Re insert the fuse holder into the module Turn the screwdriver clockwise while pressing down on the fuse holder at the same time The fuse holder must be flush against the faceplate Remove the two plug connectors from the faceplate of the new module by pulling them firmly away from the faceplate Place the new module over the pattern drilled and attach it securely to the panel with 10 or M5 studs or bolts Attach the original 12 point and 4 point connectors with wiring to the faceplate of the module Use the stud marked GND ground on the bottom right flange of the module to connect a ground wire Set the Mode switch on the faceplate to the desired position Connect the I O Rail cable between the Analog Rail connection labeled Input and the I O port Turn on power to the Reliance device connected to the Analog Rail module Recall that the Mode switch is read each time the Reliance device connected to the module is powered up If applicable re connect the cable between the Local I O Head or the DCS 5000 Remote I O Head and the host Turn on power to the Analog Rai
7. 3675 J 3601 J 3676 J 3602 J 3677 J 3671 J 3750 J2 3045 S 3006 S 3008 AutoMate 20 USER S MANUAL AutoMate 40 CONTROL PROCESSOR INSTRUCTION MANUAL AutoMate 30 40 SOFTWARE REFERENCE MANUAL DCS 5000 AutoMax CONFIGURATION TASK INSTRUCTION MANUAL AutoMax PROGRAMMING EXECUTIVE INSTRUCTION MANUAL DCS 5000 ENHANCED BASIC LANGUAGE INSTRUCTION MANUAL AutoMax ENHANCED BASIC LANGUAGE INSTRUCTION MANUAL DCS 5000 CONTROL BLOCK LANGUAGE INSTRUCTION MANUAL AutoMax CONTROL BLOCK LANGUAGE INSTRUCTION MANUAL DCS 5000 CONTROL BLOCK LANGUAGE INSTRUCTION MANUAL AutoMax LADDER LOGIC LANGUAGE INSTRUCTION MANUAL AutoMate LOCAL I O HEAD INSTRUCTION MANUAL ReSource AutoMax PROGRAMMING EXECUTIVE INSTRUCTION MANUAL VERSION 3 0 AutoMax PROGRAMMING EXECUTIVE VERSION 3 3 D C DRIVE CONFIGURATION AND PROGRAMMING INSTRUCTION MANUAL POWER MODULE INTERFACE RACK INSTRUCTION MANUAL Your personal computer and DOS operating system manual s IEEE 518 GUIDE FOR THE INSTALLATION OF ELECTRICAL EQUIPMENT TO MINIMIZE ELECTRICAL NOISE INPUTS TO CONTROLLERS 1 2 Related Hardware and Software DCS 5000 AutoMax Remote I O Head The 2 In 2 Out 4 20mA Analog Rail module M N 61C351 contains the following 1 One 2 In 2 Out 4 20mA Analog Rail module 2 One I O Rail cable M N 45C5 Two plug connectors 12 point connector part no 419434 2R 4 point connector part no 419434 1R One 25A fuse installed in the module pa
8. an analog to digital converter and a dual digital to analog converter for two output channels The module is housed in a protective metal enclosure designed for panel mounting See figure 2 1 2 1 AutoMate Analog Rail 610351 4 to 20 mA IN OUT Input PWR COM OK OK OO Mode Rail Analog I O OUT Common OUT Common I IN Common 10 I IN 11 Common Fuse Type 250V MDQ ed Q Figure 2 1 Analog Module Faceplate 2 2 2 2 The faceplate of the module contains three electrical connectors labeled Input Analog I O and Input Power reading top to bottom The top connector is used for connection to the I O port A cable M N 45C5 is provided for this purpose The second connector labeled Analog I O is a numbered 12 point removable plug connector with screw type terminal points Three successive terminal points are reserved for each channel s connection to external hardware The top 6 points are reserved for the two output channels channel 0 and channel 1 and the bottom 6 are reserved for the two input channels channel 2 and channel 3 The Analog 1 0 terminals are designed for 14 22 AWG wire The third connector on the faceplate also a removable plug connector with screw type terminal points is used for input power The terminal points are labeled The top two points are used if the power source is 24 VDC The bottom two points are used if the power sou
9. as CHANNEL_2 is either over range or under range 10000 RANGE_ERROR CHANNEL 2 AND 3000H The value in the channel defined as CHANNEL 2 is over range 11000 OVER_ERROR CHANNEL 2 AND 1000H The value in the channel defined as CHANNEL 2 is under range 12000 UNDER_ERROR CHANNEL 2 AND 2000H 5 0 DIAGNOSTICS AND TROUBLESHOOTING DANGER THE REMAINING STEPS ARE MADE WITH POWER ON EXERCISE EXTREME CAUTION BECAUSE HAZARDOUS VOLTAGE EXISTS FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE WARNING ONLY QUALIFIED ELECTRICAL PERSONNEL FAMILIAR WITH THE CONSTRUCTION AND OPERATION OF THIS EQUIPMENT AND THE HAZARDS INVOLVED SHOULD INSTALL ADJUST OPERATE AND OR SERVICE THIS EQUIPMENT READ AND UNDERSTAND THIS MANUAL IN ITS ENTIRETY BEFORE PROCEEDING FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN BODILY INJURY WARNING INSERTING OR REMOVING THIS PRODUCT OR ITS CONNECTING CABLES MAY RESULT IN UNEXPECTED MACHINE MOTION POWER TO THE MACHINE SHOULD BE TURNED OFF BEFORE INSERTING OR REMOVING THE PRODUCT OR ITS CONNECTING CABLES FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN BODILY INJURY This section explains how to troubleshoot the Analog Rail module If you cannot correct the problem using the instructions below the unit is not user serviceable 5 1 Both LEDs on the Faceplate are Off Problem The PWR LEDs on the faceplate are off This problem can ind
10. block for an Analog Rail module connected to port 2 of an AutoMate Processor AIN 12 EN AIN LHPORT CHAN DEST VALUE AutoMate 20E Analog Rail with with ports channels 0 1 2 and 3 0 1 2 and 3 In Rail Mode Processor port to which the Analog Rail is connected directly or indirectly value range 0 3 LHPORT Local I O Head port to which the Analog Rail is connected value range 0 3 If a Local I O Head is not used the value is 0 CHAN Channels on the Analog Rail module to read value range 2 or 3 DEST Register number where the value of the channel is stored Figure 4 11 AIN Instruction Block 4 9 AOUT Instruction Block The example below shows an AOUT block for an Analog Rail module connected to port 2 of a Local I O Head which in turn is connected to port 3 of an AutoMate Processor Data from register 2000 is used in this example AOUT 12 01 AutoMate 20 Local Head Analog Rail with with ports with ports channels 0 1 2 and 3 0 1 2 0 1 2 and In Rail Mode SRC Register number from which the data to output will be taken IOPORT Processor port to which the Analog Rail is connected directly or indirectly value range 0 3 LHPORT Local I O Head port to which the Analog Rail is connected value range 0 3 If a Local I O Head is not used the value is 0 CHAN Channel on the Analog Rail module to write value range 0 or 1
11. 2 In 2 Out 4 20 mA Analog Rail Module M N 61C351 Instruction Manual J 3673 3 ae ELECTRIC The information this user s manual is subject to change without notice WARNING ONLY QUALIFIED ELECTRICAL PERSONNEL WHO ARE FAMILIAR WITH THE CONSTRUCTION AND OPERATION OF THIS EQUIPMENT AND THE HAZARDS INVOLVED SHOULD INSTALL ADJUST OPERATE AND OR SERVICE THIS EQUIPMENT READ AND UNDERSTAND THIS MANUAL IN ITS ENTIRETY BEFORE PROCEEDING FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE BODILY INJURY WARNING INSERTING OR REMOVING THIS PRODUCT OR ITS CONNECTING CABLES MAY RESULT IN UNEXPECTED MACHINE MOTION POWER TO THE MACHINE SHOULD BE TURNED OFF BEFORE INSERTING OR REMOVING THE PRODUCT OR ITS CONNECTING CABLES FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN BODILY INJURY AutoMax AutoMate and Reliance are registered trademarks of Reliance Electric Company or its subsidiaries Belden is a registered trademark of Belden Inc 1 0 2 0 3 0 4 0 5 0 Table of Contents Introduction scssi crise san nenn RO aa CR C 1 1 1 1 Additional Information ns 1 1 1 2 Related Hardware and Software 1 2 Mechanical Electrical Description 2 1 2 1 Mechanical Description 2 1 22 Electrical Description seti cess er es 2 3 Installation aie sie wis tise areca a
12. 2 was selected at the end of last scan read the data that has now come back into register 42 The channel select bits are cleared but the under range and over range bits are left for later testing EN MOVM LENGTH 1 SRC 0 MASK 0011 1111 1111 1111 DEST 42 If channel 3 was selected at the end of last scan read the data that has now come back into register 43 The channel select bits are cleared but the under range and over range bits are left for later testing EN MOVM LENGTH 1 SRC 0 MASK 0011 1111 1111 1111 DEST 43 C 1 Continued At the End of the Scan If counter 0 MOVE register 40 to register O for output EN MOVE LENGTH 1 SRC 40 DEST 0 If counter 1 MOVE register 41 to register O for output EN MOVE LENGTH 1 SRC 41 DEST 0 Move counter to two most significant bits of output register to select which channel to update C 2 Continued Increment counter 0 1 2 and then back to 0 and so on LENGTH SRC SCR 2 DEST EN CMP SRC 44 SCR 2 MODE A gt B EN MOVK LENGTH 1 VALUE 0 DEST 44 For additional information 1 Allen Bradley Drive Mayfield Heights Ohio 44124 USA Tel 800 241 2886 or 440 646 3599 http www reliance com automax www rockwellautomation com Corporate Headquarters Rockwell Automation 777 East Wisconsin Avenue Suite 1400 Milwaukee WI 53202 5302 USA Tel 1
13. 414 212 5200 Fax 1 414 212 5201 Headquarters for Allen Bradley Products Rockwell Software Products and Global Manufacturing Solutions Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation SA NV Vorstlaan Boulevard du Souverain 36 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation 27 F Citicorp Centre 18 Whitfield Road Causeway Bay Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Headquarters for Dodge and Reliance Electric Products Americas Rockwell Automation 6040 Ponders Court Greenville SC 29615 4617 USA Tel 1 864 297 4800 Fax 1 864 281 2433 Europe Middle East Africa Rockwell Automation Br hlstra e 22 D 74834 Elztal Dallau Germany Tel 49 6261 9410 Fax 49 6261 17741 Asia Pacific Rockwell Automation 55 Newton Road 11 01 02 Revenue House Singapore 307987 Tel 65 6356 9077 Fax 65 6356 9011 Publication J 3673 3 April 1993 Copyright 2002 Rockwell Automation Inc All rights reserved Printed in U S A
14. Appendix C Sample AutoMate List of Figures Figure 1 1 Analog Rail Module Hardware Configuration Figure 2 1 Analog Rail Module Faceplate Figure 2 2 Typical Output Figure 2 3 Typical Input Circuit ri Figure 3 1 Mounting Dimensions Figure 3 2 Typical Recommended Input and Output Shielding Methods er nenne Figure 4 1 Input Signal Conversion Figure 4 2 Configuration for Analog Rail Module with AutoMate 20 00005 9990 ia neri Figure 4 3 Sample Configurations for Analog Rail Module Connected Directly to AutoMate 30 40 Figure 4 4 Sample Configuration for Analog Rail Module Connected to AutoMate 30 or 40 Through Local I O Head Figure 4 5 Sample Configuration for Analog Rail Module with AutoMate Local I O Processor Figure 4 6 Sample Configuration for Analog Rail Module with AutoMate Remote I O Head Figure 4 7 Rail Mode Register Image for Input Channels Figure 4 8 Rail Mode Register Image for Output Channels Figure 4 9 Local Head Mode Register Image for Input Channels Figure 4 10 Local Head Mode Register Image for Output Channels Figure 4 11 AIN Instruction B
15. ER 2 A M LHD 0 3 NU NU NU n d Figure 4 4 Sample Configuration for Analog Rail Module Connected to AutoMate 30 or 40 Through Local I O Head 4 4 Analog Rail Module with AutoMate Local I O Processor Local Head Mode Only The following sample configuration shows three Analog Rail modules connected to a Local I O Processor a remote rack MSLT DROP RSLT CARD CHO REGISTER REGISTER CH2 REGISTER CH3 REGISTER 2 1 RRK 2 LIOP LHD 0 3 LHD 4 7 LHD 10 13 NU Figure 4 5 Sample Configuration for Analog Rail Module with AutoMate Local I O Processor 4 5 Analog Rail Module with AutoMate Remote I O Head Local Head Mode Only The following sample configuration shows one Analog Rail module connected to an AutoMate Remote I O Head MSLT DROP TYP RSLT CARD CHO REGISTER REGISTER CH2 REGISTER CH3 REGISTER 1 NU NU 0 RHD LHD 0 3 NU Figure 4 6 Sample Configuration for Analog Rail Module with AutoMate Remote I O Head 4 6 4 1 2 AutoMate Programming Rail Mode In Rail mode the Analog Rail module is imaged in one I O register of the processor Data from one of the four channels will occupy the register as a function of the channel select bits The active channel is updated at the end of each scan For input channels the two channel select bits in the register must be set to the appropriate input channel number After the I O update the register contains the data in the format shown in figure 4 7 Fo
16. TED OUTPUT CHANGES MAY RESULT IF AN ANALOG RAIL IS PLUGGED INTO A LOCAL HEAD THAT IS COMMUNICATING WITH PROCESSOR ANY HARDWARE CONFIGURATION CHANGES MUST BE MADE ONLY WITH THE LOCAL I O INTERFACE CABLE M N 45C8 DISCONNECTED FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN BODILY INJURY CAUTION THE ANALOG RAIL MODULE IS DESIGNED TO BE POWERED BY EITHER 24 VDC OR 120 VAC CONNECT THE PROPER POWER SOURCE TO THE MODULE FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN DAMAGE TO OR DESTRUCTION OF THE EQUIPMENT 3 1 Wiring To reduce the possibility of electrical noise interfering with the proper operation of the control system exercise care when installing the wiring between the module and the external hardware Use shielded twisted pair for all wiring between the Analog Rail module and the external hardware Belden 8761 or an equivalent cable type is recommended For detailed recommendations refer to IEEE 518 3 1 3 2 Initial Installation Use the following procedure to install the Analog Rail module Step 1 Using the mounting dimensions shown in figure 3 1 prepare the necessary mounting provisions on the panel The module designed to be mounted vertically using four 10 or M5 bolts or studs Multiple modules should be mounted side by side The flange width of two modules side by side is sufficient to dissipate the heat produced by the modules The modules can also be mounted one above the other but since t
17. ains two output channels that can output 4 20mA analog signals proportional to an input value of 0 to 4095 A user supplied power supply in series with the external hardware is required for the output channels Note that at a digital output 4096 the output rolls over to zero again Negative output values cannot be accommodated The A D and D A conversions are triggered by the actual I O update sequences The conversion rate is therefore dependent upon the scan time of the application task See figure 2 2 for a typical output circuit See figure 2 3 for a typical input circuit 2 3 104 167 Figure 2 2 Typical Output Circuit 10 000 V 0 to A D converter 277 778 Q Figure 2 3 Typical Input Circuit The Analog Rail module is factory calibrated and requires no offset gain adjustment All four analog I O channels are referenced to the same common This common is isolated from both the external power supply and the I O port connection The module incorporates extensive diagnostics In Rail mode check bits are monitored for accuracy on every transfer of data between the processor and the module In Local Head mode parity bits are monitored for accuracy on every transfer of data A Rail fault LED on the processor Remote Head or Local Head will be illuminated if the check bits or parity bits are wrong and all transmission will stop after retries where n is a value determined by the host s software a
18. are cannot respond to outputs from the Analog Rail module For input channels use the Executive software to read the value on the input channels Use an ammeter to read the input signal and compare the two If the signal is being converted correctly there is a problem with the external hardware or wiring For output channels use the Executive software to write a value between 0 and 4095 to each channel Use an ammeter to verify that the signal on the terminal points is proportional to the value If the signal is being converted correctly there is a problem with the external hardware or wiring Troubleshoot the external hardware the wiring and the host Constant Under Range Problem the under range bit 12 decimal on an input channel register is constantly set to 1 Assuming that the power supply for the external hardware connected to the input channel is providing an input signal within the specified limits 4 20mA the possible causes of this problem are a loose connector on the analog I O section of the faceplate loose or malfunctioning wiring incorrect reversed input signal wiring on the module faceplate or a blown input channel fuse 32mA fuse Follow the steps below to isolate the problem Step 1 Stop any application tasks that are running Turn off power to the external hardware connected to the module Turn off input power 120 VAC or 24 VDC to the module Step 2 Verify that the 12 point connector on the analog
19. during the scan if AIN and AOUT blocks are used 4 1 4 1 1 Configuring the AutoMate Processor for Use with the Analog Rail Module Configuration is the process of describing in software how the hardware and software in the system are related The Analog Rail module is configured using the AutoMate Programming Executive software 45C130 or 45 131 Select CONFIGURE SYSTEM from the main menu to create the configuration Note that the Analog Rail module can also be configured using the AutoMate Programming System APS software M N 450134 45C141 45 142 or 45C143 Refer to instruction manual J2 3041 for additional information The Analog Rail module is configured depending upon the mode in which it is being used See figures 4 2 4 3 4 4 4 5 and 4 6 for how to configure the Analog Rail for use with AutoMate processors The sample configurations are shown as they appear on the APX screen Unless otherwise noted all references to the AutoMate 20 30 and 40 will also apply to the 20E 30E and the 40E respectively Analog Rail Module with AutoMate 20 Local Head Mode or Rail Mode AutoMate 20 registers reserved for port configuration 2734 Port 0 of AutoMate 20 2735 Port 1 of AutoMate 20 2736 Port 2 of AutoMate 20 2737 Port 3 of AutoMate 20 Local Head Mode Enter the value 64 for the register representing the port to which the Analog Rail module is connected where XX is a value from 00 14 The XX value rep
20. el Terminal Number 120 neutral L2 N 3 120 VAC hot L1 4 Step 6 Use the stud marked GND ground on the bottom right flange of the module to connect a ground wire DANGER THE USER IS RESPONSIBLE FOR CONFORMING WITH THE NATIONAL ELECTRICAL CODE AND ALL OTHER APPLICABLE LOCAL CODES WIRING PRACTICES GROUNDING DISCONNECTS AND OVER CURRENT PROTECTION ARE OF PARTICULAR IMPORTANCE FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE Step 7 Turn off all power to any external hardware that will provide input signals to the module or be powered by the module Step 8 Attach a retainer clip to the connector at each end of the Rail cable M N 45C5 Note that faceplate connectors have slots that correspond to the part of the retainer clip that protrudes away from the cable connector The retainer clip is used to assure a tight connection between the cable and faceplate connectors Step 9 Using 14 22AWG wire connect external hardware to the Analog I O plug connector on the faceplate as shown below Strip off approximately 5 16 insulation from the wires 3 3 3 4 Channel Terminal Terminal Number Label OUT 4 20 output Common common no label shield no connection OUT 4 20mA output Common common no label shield no connection I IN 4 20 input Common common no label shield no connection I IN 4 20 input C
21. his hardware configuration does not allow the most efficient heat dissipation the minimum clearance between the module chassis 3 See figure 3 1 DER mid Depth 7 75 Diameter of mounting holes 7 32 ma i e Figure 3 1 Mounting Dimensions 3 2 Step 2 Ifthe power supply you are using is 24 VDC replace the factory installed 25A fuse with the 75A fuse that came in the shipping box with the module Use a screwdriver to release the fuse holder located on the Analog Rail module faceplate Pull the fuse holder out of the module Take the 25A fuse out of the fuse holder and replace it with the 75A fuse Re insert the fuse holder into the module Turn the screwdriver clockwise while pressing down on the fuse holder The fuse holder must be flush against the faceplate Step 3 Mount the Analog Rail on the panel and attach it securely to the wall with 10 M5 studs or bolts Step 4 certain that no voltage is present on the wires that will be used to provide 120 VAC or 24 VDC power to the Analog Rail module Use either a 120 VAC or 24 VDC power supply but not both Step 5 Using 14 AWG wire connect input power to the screw terminals on the Input Power plug connector on the faceplate as shown below Strip off approximately 5 16 of insulation from the wires 24 VDC Power Signal Terminal Label Terminal Number 24 VDC 1 24 VDC 2 120 VAC Power Signal Terminal Lab
22. icate that the unit is not receiving the 5V from the processor or Local or Remote Head the 120 VAC or 24 VDC from the external power supply or both within the specified ranges This problem can also indicate that the external power supply fuse 75A or 25A has blown or that the module is malfunctioning Step 1 Stop any application programs or tasks that are running Use a voltmeter to measure the input power 120 VAC or 24 VDC to the module Verify that the power source is providing 120 VAC or 24 VDC whichever is appropriate DANGER VOLTAGE IS PRESENT ON THE PLUG CONNECTOR TERMINALS DISCONNECT THE POWER AT THE SOURCE BEFORE TOUCHING THE PLUG CONNECTOR TERMINALS FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE 5 1 DANGER DO NOT TOUCH THE CONNECTORS ON THE FACEPLATE IF THERE IS POWER ON THE WIRES ATTACHED TO THE PLUG CONNECTOR SCREW TERMINALS ALWAYS TURN OFF POWER BEFORE HANDLING A CONNECTOR THAT IS WIRED FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE Step 2 off power to the module Verify that the input power connector is connected securely to the faceplate Verify that the I O Rail cable connections are tight at both ends Step 3 Turn on power to the module If LEDs are still off try replacing the I O Rail cable Check that the pins on the input connector are not bent Step 4 Ifthe LEDs are still off turn off power to
23. in Rail mode when it is connected to one I O port of a Local I O Head which in turn is connected to one I O port of an AutoMate processor The Analog Rail module will occupy one register of the host in Rail mode The Rail mode is used to expand the I O address space available through the front I O port of the processor by multiplexing each group of four analog points through one register Note that the Analog Rail module cannot be used with the Local I O Head in DCS 5000 AutoMax systems The Analog Rail module operates in Rail mode when it is connected to one I O port of the Power Module Interface PMI Processor B M 60000 which is in turn connected to a Universal Drive Controller UDC module M N 57552 which resides in an AutoMax rack The remainder of this manual describes the functions and specifications of the module It also includes a detailed overview of installation and troubleshooting procedures as well as examples of configuration and programming Additional Information You must become familiar with the instruction manuals which describe your system configuration This may include but is not limited to the following e J 3031 AutoMate 30 PROCESSOR HARDWARE INSTRUCTION MANUAL e J 3033 AutoMate LOCAL I O PROCESSOR INSTRUCTION MANUAL e J 3037 AutoMate REMOTE HEAD INSTRUCTION MANUAL e J 3063 AutoMate PROGRAMMING EXECUTIVE INSTRUCTION MANUAL 1 1 1 2 43120 J 3141 J 3150 J 3649 J 3630 J 3600 J
24. is organized in the module and provides examples of how the module is accessed by application programs When creating application programs the programmer must estimate the magnitude of input signals and output data because both must be in the specified range of the Analog Rail module 4 20mA Input signals greater than 20mA will be clamped at 4095 Signals greater than approximately 22 6mA will also cause the over range bit 12 decimal 14 octal to be set to 1 Input signals less than 4mA are clamped at zero 0 Signals less than approximately 2 5mA will also cause the under range bit 13 decimal 15 octal to be set to 1 See figure 4 1 gt 22 6 over range 4 lt 2 5 under range Figure 4 1 Input Signal Conversion Recall that at a digital output 4096 the output rolls over to zero again The programmer must include limits in the application software to ensure that the data sent to output channels is always in the specified range allowable range 0 to 4095 Analog Rail Module in AutoMate Systems This section describes how the Analog Rail is used with AutoMate systems Local Head mode allows all four channels on the module to be updated at the end of the scan normal I O update rate in this configuration or during the scan using AIN and AOUT blocks see section 4 1 4 Rail mode allows only one channel to be updated at the end of the scan normal I O update rate in this configuration or all four channels to be updated
25. l module Input Power connections Turn on power to the external hardware connected to the Analog Rail module Verify that the hardware has been installed correctly Before testing insure that the external hardware cannot respond to output signals from the Analog Rail module WARNING BE CAREFUL WHEN WRITING TO THE OUTPUTS TO INSURE THAT NO UNEXPECTED MACHINE MOTION WILL RESULT FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN BODILY INJURY OR DAMAGE TO EQUIPMENT For AutoMate systems use the APX Point Monitor function to test the module You can test the Analog Rail module output channels by writing a value between O and 4095 to those channels and with an ammeter verifying that the output on the terminal points 4 20mA is proportional To test input channels verify that the input signal in the channel 4 20mA is proportional to an ammeter reading at the terminal points 3 7 3 8 For DCS 5000 or Distributed Power D C Drive systems use the DCS 5000 or AutoMax Programming Executive software I O Monitor function respectively Test output channels by writing a value between 0 and 4095 to those channels and using an ammeter to verify that the signal on the terminal points 4 20mA is proportional To test input channels verify that the input signal in the channel 4 20mA is proportional to an ammeter reading at the terminal points 4 0 PROGRAMMING 4 1 This section describes how the data
26. lock Figure 4 12 Instruction Figure 5 1 Disassembling the Module to Replace the 32mA Fuse Figure 5 2 Replacing the 32mA Fuse 1 0 1 1 INTRODUCTION The products described in this instruction manual are manufactured by Reliance Electric Industrial Company The 2 In 2 Out 4 20mA Analog Rail module allows you to connect two input and two output 4 20mA analog signals to AutoMate AutoMax and DCS 5000 systems Typically the Analog Rail module is used with potentiometers valve actuators pressure or flow transducers and meters in both drive control systems and process control systems The Analog Rail module is hardware configurable by means of a faceplate switch to emulate one of two types of devices AutoMate Rails or AutoMate Local Heads In some hardware configurations the type of interface device available for the Analog Rail module will determine the mode of operation that can be selected see figure 1 1 The Analog Rail module operates in Local Head mode when it is connected directly to one of the processor s four I O ports in AutoMate systems to an AutoMate Local I O Processor or to one of the four I O ports of the DCS 5000 AutoMax Remote Head in DCS 5000 AutoMax systems The Analog Rail data will take up four registers in the host when operating in Local Head mode The module operates
27. locks The AIN block will set the over range or under range bits if applicable See section 4 1 4 for more information about the AIN and AOUT blocks Note that the AIN and AOUT blocks are supported by the AutoMate 20E M N 45 224 and 45 225 but not the AutoMate 20 M N 45 20 45C21 45C220 45C221 by Version 3 0 4 8 For processors that do not support the AIN AOUT blocks you can use the MOVE block to move data in and out of the registers assigned Over range and under range bits should be used as inputs to error coils The I O update will occur automatically at the end of each scan See Appendix C for a sample AutoMate program that writes to and reads from the Analog Rail module without using AIN and AOUT blocks 4 1 4 Analog In AIN and Analog Out AOUT Instruction Blocks The AIN and AOUT blocks are used respectively to read inputs from and write outputs to the Analog Rail module AIN and AOUT blocks are supported for the 20E processor The AIN and AOUT blocks make it possible to update the channels on the Analog Rail module during the scan instead of at the end of the scan the standard AutoMate I O update The blocks also make it possible to update all four channels during the scan in Rail mode a hardware configuration which would otherwise allow only one channel on the module to be updated The format of the two blocks is shown in figures 4 11 and 4 12 AIN Instruction Block The example below shows an AIN
28. oMax or Distributed Power D C Drive systems use the DCS 5000 or AutoMax Programming Executive software I O Monitor function respectively Test output channels by writing a value between 0 and 4095 to those channels and using an ammeter to verify that the signal on the terminal points 4 20mA is proportional To test input channels verify that the input signal in the channel 4 20mA is proportional to a ammeter reading at the terminal points 3 3 Module Replacement Use the following procedure to replace the module Step 1 Stop any application programs that are running Step 2 off power to the external hardware connected to the input and output channels on the faceplate of the module Step 3 off power to the Analog Rail module 120 VAC or 24 VDC Step 4 off power to the Reliance device connected to the Analog Rail module Step 5 Disconnect the I O Rail cable from the Analog Rail module Step 6 Without disconnecting the wiring remove the 12 point terminal from the faceplate and set aside Step 7 Without disconnecting the wiring remove the 4 point terminal from the faceplate and set aside Disconnect the ground wire from the bottom of the right hand flange Step 8 Loosen the screws that hold the Analog Rail module to the panel and remove the module 3 6 Step 9 Step 10 Step 11 Step 12 Step 13 Step 14 Step 15 Step 16 Step 17 If the power supply you are using is
29. ommon common no label shield no connection 7 2 3 4 5 6 7 8 9 This terminal makes electrical connection to the Analog Rail printed circuit board Step 10 Step 11 For each of the two output channels connect a shield wire from the external hardware to the third terminal terminals 3 and 6 respectively The shield wire at the external hardware end of the cable should be connected to the source reference point See figure 3 2 For each of the two input channels connect a shield wire from the external hardware to the third terminal terminals 9 and 12 respectively The shield wire at the external hardware end of the cable should be connected to the source reference point See figure 3 2 Channel 0 Channel 1 Channel 2 Channel 3 Common I In Source Source Source Figure 3 2 Typical Recommended Input and Output Shielding Methods Step 12 Step 13 Step 14 Step 15 Step 16 Turn off power to the Reliance device that will be connected to the Analog Rail module Set the Mode switch on the faceplate of the Analog Rail module to the desired position Connect the I O Rail cable between the Analog Rail connection labeled Input and an I O port on the Reliance device that will communicate with the module Turn on power to the Reliance device that will communicate with the Analog Rail module Recall that the Mode switch is read each time the Reliance de
30. r output channels the data in the register must be in the format shown in figure 4 8 prior to the update 6 15 1413 z 5 4 af 2 MSBLSB CH 12 bits of converted analog data 0 CHO over range 1 over range 1 CH1 under range 1 under range 0 CH2 1 CH3 channel being read LSB channel being read MSB Figure 4 7 Rail Mode Register Image for Input Channels 1 7 6 5 4 9121 1 ol MSBLSB CH 12 bits of analog output data 0 0 CHO not used 1 CH1 not used 0 1 0 CH2 4 1 CH3 channel being modified LSB channel being modified MSB Figure 4 8 Rail Mode Register Image for Output Channels The Analog Rail module data may also be accessed in the middle of the scan as opposed to the end of the scan which is the normal mode of operation for digital rail I O using the appropriate number of Analog In AIN and Analog Out AOUT blocks The AIN block will check whether the over range or under range bits have been set by the module and the error coil will be energized if applicable The AOUT block will set the channel select bits appropriately See section 4 1 4 for more information about the AIN and AOUT blocks Note that the AIN and AOUT blocks are supported by the AutoMate 20E M N 45C224 and 45C225 but not the AutoMate 20 M N 45C20 45 21 45C220 45 221 by Version 3 0 4 7 For processors that do not support the AOUT blocks yo
31. rce is 120 VAC The Input Power terminals are designed to use 14 AWG wire A terminal stud for connecting a grounding conductor is provided on the bottom of the right hand mounting flange The module faceplate also contains two LEDs a mode switch and a fuse holder and fuse LED labeled PWR indicates that the port the external power source and the internally generated voltages necessary for operation of the module are present The COM OK LED indicates whether all four channels are successfully communicating with the host The switch labeled Mode is used to select between Local Head and Rail mode Note that the position of the switch is read only once at the time power is turned on to the Reliance device that is connected to the Analog Rail module The mode will remain fixed as long as this device is powered up As shipped from the factory the fuse holder on the bottom of the faceplate contains a 25A fuse for 120 VAC input power If input power will be 24 VDC you need to replace the fuse with the 75A fuse included along with the Analog Rail module Electrical Description The Analog Rail module contains two analog input channels that convert 4 20mA analog input signals to proportional values between 0 and 4095 equal to 12 bits of digital data Input channels are protected with 32mA user replaceable fuse Input signals are filtered through a second order low pass filter The module also cont
32. re sents the first register in a set of four contiguous registers that will be used to store data for the port Rail Mode Enter the value 16XX for the register representing the port to which the Analog Rail module is connected where XX is a value from 00 17 The XX value repre sents the register that will be used to multiplex data through the I O port Values are in octal notation Figure 4 2 Configuration for Analog Rail Module with AutoMate 20 4 2 Analog Rail Module Connected Directly to AutoMate 30 or 40 Local Head Mode or Rail Mode The following sample configuration shows two Analog Rail modules connected directly to an AutoMate 30 or 40 Processor in Local Head mode MSLT DROP TYP RSLT CARD CHO REGISTER REGISTER CH2 REGISTER CH3 REGISTER 1 A M LHD 0 3 LHD 4 7 NU NU The following sample configuration shows two Analog Rail modules connected directly to an AutoMate 30 or 40 Processor in Rail Mode MSLT DROP TYP RSLT CARD CHO REGISTER REGISTER CH2 REGISTER CH3 REGISTER 1 A M RAIL 0 RAIL 1 NU NU I Figure 4 3 Sample Configurations for Analog Rail Module Connected Directly to AutoMate 30 or 40 4 3 Analog Rail Module Connected to AutoMate 30 or 40 Through a Local I O Head Rail Mode Only The following sample configuration shows two Analog Rail modules connected to an AutoMate 30 or 40 through a Local I O Head MSLT DROP RSLT CARD CHO REGISTER REGISTER CH2 REGISTER CH3 REGIST
33. rt no 64676 23J One 75A fuse required for operation on 24 VDC part no 64676 23Q 6 Two cable retainer clips 7 Two 32mA fuses installed in the module part no 64676 44A 8 Two spare 32mA fuses part no 64676 44A The Analog Rail module can be configured with the hardware purchased separately listed in figure 1 1 Host Model Operating Mode M N 57C330 Local Head M N 45C20 45 21 AutoMate 20 20E 45 220 45 221 Local Head Rail 450224 450225 M N 45C301 45C305 AutoMate 30 30E 450307 Local Head or Rail AutoMate 40 40E M N 450410 450411 Local Head or Rail AutoMate Local M N 45C200B Processor and later versions Local Head AutoMate Remote I O Head 45C37 45C38 Local Head Power Module B M 60000 Rail Interface Processor Direct connection to the Processors Local Head mode or connection through an AutoMate Local I O Head 45 22 61C22 61 22 or 61C23 Rail mode Note that it is also permissible to configure the Analog Rail module for Rail mode even if it is connected directly to an AutoMate 20 30 or 40 Processor Figure 1 1 Analog Rail Module Hardware Configuration 1 3 2 0 2 1 MECHANICAL ELECTRICAL DESCRIPTION The following sections describe the mechanical and electrical characteristics of the Analog Rail module Mechanical Description The Analog Rail module is a self contained electronic module containing two input channels multiplexed to
34. sistance an additional 200 400 Ohms Input filter 2nd order 160 Hz low pass Input over current protection 32mA fuse per input channel Isolation of analog section from host and input power 2500V RMS Output Channels Operating range 4 20mA short circuit protected Number of channels 2 single ended Number of commons 1 shared among all 4 channels Output range of external power supply channels 5 32 VDC Resolution 12 bits binary Non linearity 1 LSB maximum Accuracy 0 33 of full scale at 25 C maximum Thermal drift 50 ppm degrees C Gain error 4 LSB maximum Type of converter 2 independent DACs on a monolithic IC Speed of conversion Scan Dependent Output settling time 200 usec maximum Load resistance range 0 1450 Ohms Isolation of analog section from host and input power 2500V RMS Block Diagram _4 DOTVNV 110 vuoz v Ei ot s LN 1903130 39NV8 GALVIOSI 110 ot U3LU3ANOI J3UA
35. taining DCS 5000 AutoMax master remote module range 0 15 Drop number of DCS 5000 AutoMax Remote I O Head range 1 7 Communication port on the DCS 5000 AutoMax Remote Head to which the Analog Rail module is connected range 0 3 Register number range 0 3 m d o 1 1 Optional field defining the bit position within the register number range 0 15 Configuring the Analog Rail Module with a Power Module Interface Processor Host The Analog Rail module is used in the Rail mode when the host is a Power Module Interface PMI Processor Beginning with AutoMax Version 3 3 the Analog Rail module is configured using the AutoMax Programming Executive Refer to instruction manual J2 3045 for more information DCS 5000 AutoMax Programming When programming the Analog Rail module it is recommended that you monitor the state of the over range and under range bits for the input channels You can check the status of the appropriate bits directly if they were defined in the configuration You can also use the BASIC expression AND with the variable name assigned to the input channel to mask off the 12 bits of analog data and read the values in the over range and under range bits Any non zero result means that the value is out of range See the following three statements for examples of how to detect values out of range Use the hexadecimal values shown to mask off the analog data The value in the channel defined
36. the module including the faceplate to the left away from the remainder of the metal enclosure See below for the screws that need to be removed If some of the screws are inaccessible remove the entire module from the cabinet before proceeding 5 5 3 screws Module Faceplate 3 screws screws on the righ 3 screws on bottom Figure 5 1 Disassembling the Module to Replace the 32mA Fuse e Place the metal enclosure side of the left hand piece on a clean surface Note the position of the fuses from the drawing in figure 5 2 As shown on the drawing the top fuse labeled F1 is for channel 2 and the bottom fuse labeled F2 is for channel 3 The fuses are held in place by spring clips Remove the blown fuse s carefully and discard Replace the fuse s with a new fuse 5 6 12 point Connector Mating Half Module Faceplate 4 point Connector Mating Half Printed Circuit Board Facing Up Channel 2 2mA Fi Channel 3 Sama puses Transformer Figure 5 2 Replacing the 32mA Fuse f Using the reserved screws re attach the printed circuit board assembly to the metal enclosure making certain that the lip on the metal enclosure is covered by the printed circuit board assembly If the module is re assembled incorrectly the screw holes will not line up properly Re attach the two connectors to the faceplate of the module Turn on power to the module Turn on power to the external hardware 5 7
37. the module and replace the power supply fuse on the front panel following the directions below CAUTION MAKE CERTAIN THAT THE ANALOG RAIL MODULE CONTAINS THE PROPER FUSE FOR THE POWER SUPPLY BEING USED USE A 25 A FUSE FOR 120 VAC POWER AND 75 FUSE FOR 24 VDC POWER FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN DAMAGE TO OR DESTRUCTION OF THE EQUIPMENT a Use screwdriver to release the fuse holder located on the Analog Rail module faceplate Pull the fuse holder out of the module b Take the old fuse out of the fuse holder and replace it with the new fuse Use a 25A fuse for 120 VAC power and 75A fuse for 24 VDC power See Appendix A for the fuse type and rating c Re insert the fuse holder into the module Turn the screwdriver clockwise while pressing down on the fuse holder The fuse holder must be flush against the faceplate Step 5 on power to the module If both LEDs still do not light replace the module 5 2 5 2 The OK LED is Problem The LED on the faceplate is off This LED signifies whether there is communication between the Analog Rail and the host The LED should be on if communication is taking place The possible causes of this problem are incorrect configuration a disconnected or malfunctioning I O Rail cable a malfunctioning host or a malfunctioning Analog Rail module After verifying that the configuration of the Analog Rail is correct follo
38. u can use the MOVE block to move data in and out of the registers assigned and to determine the channel select bits Over range and under range bits should be used as inputs to error coils The I O update will occur automatically at the end of each scan See Appendix C for a sample AutoMate program that writes to and reads from the Analog Rail module without using AIN and AOUT blocks 4 1 3 AutoMate Programming in Local Head Mode In Local Head mode the module is imaged in four I O registers of the processor Data from all four channels is always available and will be updated at the end of each scan For input channels it is not necessary to select the channel After the I O update the register contains the data in the format shown in figure 4 9 For output channels the data in the register must be in the format shown in figure 4 10 prior to the I O update 7 6 5 4 sf 2 1 ol 12 bits of converted analog data over range 1 over range under range 1 under range not used not used Figure 4 9 Local Head Mode Register Image for Input Channels 7 6 5 4 sf 2 12 bits of analog output data not used not used not used not used Figure 4 10 Local Head Mode Register Image for Output Channels The Analog Rail module data may also be accessed in the middle of the scan as opposed to the end of the scan using the appropriate number of Analog In AIN and Analog Out AOUT b
39. verage n 4 for AutoMax AutoMate n 2 In the event of a rail fault all outputs will be set to 0 The COM Ok LED on the module will go off If any power required by the module i e the 5 Volts from the I O port required for communication the external power supply or the power required by the Analog I O section is not within specified limits all outputs will be set to 0 and the PWR Ok LED will go off 2 4 3 0 INSTALLATION This section describes how to install replace the Analog Rail module Note that analog signals are sensitive to variations in temperature The Analog Rail module is designed to perform optimally at room temperature approximately 25 C In all cases the ambient temperature of the installation must be maintained in the range specified in Appendix A to ensure the highest possible accuracy DANGER THE USER IS RESPONSIBLE FOR CONFORMING WITH THE NATIONAL ELECTRICAL CODE AND ALL OTHER APPLICABLE LOCAL CODES WIRING PRACTICES GROUNDING DISCONNECTS AND OVER CURRENT PROTECTION ARE OF PARTICULAR IMPORTANCE FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE DANGER DO NOT TOUCH THE CONNECTORS ON THE FACEPLATE IF THERE IS POWER ON THE WIRES ATTACHED TO THE PLUG CONNECTOR SCREW TERMINALS ALWAYS TURN OFF POWER BEFORE HANDLING A CONNECTOR THAT IS WIRED FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE WARNING UNEXPEC
40. vice connected to the module is powered up The Analog Rail installation is now ready for testing Inspect all work to assure that the installation has been performed properly Turn on power to the Input Power wiring Turn on power to the external hardware Recall that external hardware being powered by the output of the Analog Rail module must be in series with an external power supply See figure 3 2 See Appendix A for the power supply specifications 3 5 Step 17 Verify that the hardware has been installed correctly Before testing insure that the external hardware will not respond to output signals from the Analog Rail module WARNING BE CAREFUL WHEN WRITING TO THE OUTPUTS TO INSURE THAT NO UNEXPECTED MACHINE MOTION WILL RESULT FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN BODILY INJURY OR DAMAGE TO EQUIPMENT For AutoMate systems you must configure the AutoMate processor using the AutoMate Programming Executive APX before testing See section 4 0 for more information After configuring the module use the APX Point Monitor function to test the module You can test the Analog Rail module output channels by writing a value between 0 and 4095 to those channels and with an ammeter verifying that the output on the terminal points 4 20mA is proportional To test input channels verify that the input signal in the channel 4 20mA is proportional to an ammeter reading at the terminal points For DCS 5000 Aut
41. w the steps below to isolate the problem Step 1 Stop any application tasks or programs that are running and turn off power to the Analog Rail module DANGER VOLTAGE IS PRESENT ON THE PLUG CONNECTOR TERMINALS DISCONNECT THE POWER AT THE SOURCE BEFORE TOUCHING THE PLUG CONNECTOR TERMINALS FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE DANGER DO NOT TOUCH THE CONNECTORS ON THE FACEPLATE IF THERE IS POWER ON THE WIRES ATTACHED TO THE PLUG CONNECTOR SCREW TERMINALS ALWAYS TURN OFF POWER BEFORE HANDLING A CONNECTOR THAT IS WIRED FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE Step 2 Verify that the connections on both ends of the I O Rail cable are tight Check that the pins on the input connector are not bent Step 3 Turn on power to the module The OK LED should be illuminated if communication is taking place If the LED still does not illuminate turn off power to the module and replace the I O Rail cable Step 4 If applicable try to reset the condition by disconnecting and then re connecting the cable between the host and the Local I O Head the AutoMate Remote I O Head or the DCS 5000 AutoMax Remote I O Head Troubleshoot the host if necessary If the problem is still not corrected replace the Analog Rail module 5 3 Incorrect Data Problem The data signal being read or written is always on always off or different than e
42. xpected The possible causes of this problem are incorrect configuration a programming error a disconnected or malfunctioning I O Rail cable disconnected or malfunctioning wiring to the external hardware malfunctioning external hardware or a malfunctioning Analog Rail module After verifying that the configuration of the module is correct follow the steps below to isolate the problem Step 1 Verify that the application program s is correct Check to see that the program is referencing the correct registers AutoMate or symbolic names DCS 5000 AutoMax 5 3 5 4 5 4 Step 2 Step 3 Step 4 Step 5 Step 6 In DCS 5000 AutoMax applications make certain that the program is not attempting to write to the input channels Verify that the data being output is within the specified limits Stop any application tasks that are running Turn off power to the Analog Rail module Try to clear the condition by disconnecting and then reconnecting the I O Rail cable Make certain the connections are tight If applicable check the connections between the host and the Local I O Head the AutoMate Remote I O Head or the DCS 5000 AutoMax Remote l O Head Check that the pins on the input connector are not bent Turn off power to the external hardware Verify that the wiring to the external hardware tight and functioning correctly Turn on power to the external hardware Before testing make certain that the external hardw
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