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J-3671-2 AutoMate Local I/O Head

1. Configuration sci enrr nee ele deem xen a 4 1 Local I O Head with AutoMate 20 4 2 Local I O Head with AutoMate 30 AutoMate 40 or Local I O 4 3 Local I O Head with AutoMate Remote I O Head 4 4 Local I O Head with DCS 5000 AutoMax Remote I O Head Diagnostics and Troubleshooting 5 1 All LEDs on the Faceplate Are Off 5 2 The COM LED IS s adas rb bes ac eer Exe 5 3 RAIL FAULT LEDs On Appendices Appendix A Technical Specifications MIN 61022 L a a ee ea Henn A 1 61 23 u ee ebene nenne ada A 2 Appendix B Local I O Head Mounting Pattern B 1 Figure 2 1 Figure 2 2 List of Figures Local I O Head 120 VAC Local I O Head 24 48 VDC 1 0 1 1 INTRODUCTION The products described in this instruction manual are manufactured or distributed by Reliance Electric Industrial Company The Local I O Head increases the number of RAIL ports available for connecting Rails and Rail compatible devices such as LED and TWS modules to AutoMate and DCS 5000 AutoMax systems One AutoMate Local I O Head allows you to connect up to 64 points of digital I O 16 points of analog I O or a combination of the two to each of the four RAIL ports on the models listed below Note that the v
2. faceplate The power supply provides all of the voltages necessary to power the Head and up to four Digital Rails A power supply is housed in a holder accessible on the faceplate See figure 2 1 and figure 2 2 TO PROCESSOR LOCAL I O PROCESSOR OR REMOTE HEAD AutoMate LOCAL HEAD 61022 FUSE TYPE 250VAC 3AG 4 AMP L1 POWER amp COM 2 RAIL FAULT 0 RAIL FAULT 1 D GND RAIL FAULT 2 RAIL FAULT 3 RAIL CONNECTORS Figure 2 1 Local I O Head 120 VAC The INPUT connector is used for the Local I O Interface cable L1 hot and L2 neutral are input power connections GND is used to connect a ground wire to earth ground 2 1 2 2 TO PROCESSOR LOCAL I O PROCESSOR OR REMOTE HEAD amp on O POWER COM Q com RAIL FAULT 0 7 L RAIL FAULT 1 AutoMate LOCAL HEAD 61023 FUSE TYPE 250VAC AGC 3 AMP RAIL FAULT 2 RAIL FAULT 3 RAIL CONNECTORS Figure 2 2 Local I O Head 24 48 VDC The INPUT connector is used for the Local I O Interface cable and are input power connections GND is used to connect a ground wire to earth ground The six LEDs on the faceplate are identical for bot
3. ReSource AutoMax Programming Executive Instruction Manual Version 3 0 1 1 1 2 1 2 0 45C33 DCS 5000 AutoMax Remote 110 Head Instruction Manual Other instruction manuals applicable to your hardware configuration IEEE 518 GUIDE FOR THE INSTALLATION OF ELECTRICAL EQUIPMENT TO MINIMIZE ELECTRICAL NOISE INPUTS TO CONTROLLERS Related Hardware and Software M N 61C22 or M N 61C23 contains one Local I O Head one 10 Local I O Interface cable MIN 45C8 and two retainer clips for the cable One Local I O Head can connect up to four of the devices listed below in any combination to the AutoMate or DCS 5000 AutoMax system AutoMate Digital Input Output Rail MIN 45C1 16 points digital I O Analog Rail module in AutoMate systems only MIN 61C350 61C351 etc 4 points analog I O per rail 16 total per Local I O Head in the RAIL mode LED module M N 45C631 Thumbwheel Switch module M N 45C630 All of the models listed above come with an I O Rail cable M N 45C5 2 0 MECHANICAL ELECTRICAL DESCRIPTION The Local I O Heads incorporate a custom chip and an internal power supply Model Numbers 61C22 and 61C23 are identical except for the type of power supply contained within the Head Model Number 61C22 has a 120 VAC power supply Model Number 61C23 has a 24 48 VDC power supply The custom chip acts as a communication multiplexer that allows one Rail or Rail compatible device to communicate to each of the four RAIL ports on the
4. of the Local I O Head M N 61 22 or 61 23 will be indicated in register 4 drop status of the MIN 57C416 Remote I O Communications module For earlier versions of the Local I O Head 61C22 or 45C22 the RAIL FAULT LEDs need to be used to diagnose rail faults as described below Step 1 Stop any application tasks that are running and turn off power to the Local I O Head Step2 Tryto clear the condition by disconnecting and then re connecting the I O Rail cable s and the Local Interface cable Make certain the connections are tight Verify that the cables are the correct cables i e M N 45C5 between the Head and the Rails and M N 45C8 between the Head and the host Step 3 Step 4 Turn on power to the Local I O Head and put the application program s into run If any RAIL FAULT LEDs turn on stop application tasks and turn off power to the Local I O Head Troubleshoot the Rail s If the problem is still not corrected replace the Local I O Head 5 3 Appendix A Technical Specifications M N 61C22 Ambient Conditions Storage temperature 20 85 C Operating temperature 0 60 C Humidity 5 9096 non condensing Maximum Power Dissipation 50 Watts with 64 I O installed Dimensions Height 3 5 8 9 cm Width 5 5 14 0 cm Depth 6 7 17 0 cm Weight 2 5 lbs 1 1 kg Electrical Characteristics System power requirements 120 VAC 102 132 VAC acceptable range Cycle loss 3 cycles 60 Hz from lo
5. problem Step 1 Verify that the configuration of the Local I O Head is correct and that no errors have been logged in the error registers Refer to section 4 0 for more information on configuration Refer to J 3120 or J 3150 for more information about error registers in the AutoMate 20 and AutoMate 30 or 40 processors respectively Step 2 Stop any application programs that are running Step3 If a RAIL FAULT LED on the Local I O Head is on troubleshoot the indicated Rail Step4 Examine the processor or Remote I O Head to which the Local I O Head is connected If the LED indicating power is off check the power being supplied to the unit If power is sufficient and the LED is off replace the processor or Remote I O Head Step 5 Verify that the connections on both ends of the Local I O Interface cable are tight Step 6 Turn off power to the Local I O Head and the processor or Remote I O Head Remove the Local I O Interface cable Verify that there are no bent pins on the cable connectors or I O ports Step 7 Replace the Local I O Interface cable If the problem is still not corrected replace the Local I O Head RAIL FAULT LEDs Are On Problem One or all of the RAIL FAULT LEDs are on and outputs from the corresponding Rails are off The possible causes of this problem are a disconnected or malfunctioning I O Rail cable a malfunctioning Rail or a malfunctioning Local I O Head In DCS 5000 AutoMax systems a rail fault
6. will be stored are dependent upon the register assignments of the particular model number If the Local I O Head will be communicating through the DCS 5000 AutoMax Remote I O Head with a DCS 5000 or AutoMax host use the appropriate Executive software to create the configuration that will include the registers points accessed through the Head Use Executive software M N 57C300 57C303 for DCS 5000 Processors and M N 57C304 57C307 M N 57C390 57C393 or M N 57C395 57C397 for AutoMax Processors See below for more specific information on configuring the Head Note that if the Local I O Head will be connected to a rail that contains a M N 45C42 Dual Electronic Input module that rail must be plugged into ports 1 2 or 3 only Local I O Head with AutoMate 20 Four registers are reserved for configuring the Local I O Head for use with an AutoMate 20 These registers and the configuration value to be written for each are listed below in a sample configuration for four Local I O Heads 4 Local I O Heads with AutoMate 20 Configuration Rail or Register Port Type Value Register 2784 o LD 640 2735 1 LHD 6404 4 7 2736 2 LHD 6410 10 13 Up oa Local I O Head with AutoMate 30 AutoMate 40 or Local I O Processor When using the Local I O Head with the AutoMate 30 or 40 or the Local I O Processor only the first register of the four that are needed for the configuration needs to be specified The Executive software automat
7. 7 East Wisconsin Avenue Suite 1400 Milwaukee WI 53202 5302 USA Tel 1 414 212 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 3671 2 March 1992 Copyright 2002 Rockwell Automation Inc All rights reserved Printed in U S A
8. AutoMate Local I O Head MIN 61022 MIN 61023 Instruction Manual J 3671 2 ae lal ELECTRIC ELI The information in this user s manual is subject to change without notice DANGER 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 SEVERE BODILY INJURY OR LOSS OF LIFE WARNING INSERTING OR REMOVING THE LOCAL I O HEAD OR ITS CONNECTING CABLES MAY RESULT IN UNEXPECTED MACHINE MOTION OR LOSS OF CONTROL STOP THE MACHINE OR PROCESS AND DISCONNECT POWER TO THE SYSTEM BEFORE INSERTING OR REMOVING THE HEAD OR ITS CONNECTING CABLES FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN BODILY INJURY AutoMax and ReSource are trademarks of Reliance Electric Company or its subsidiaries Reliance and AutoMate are registered trademarks of Reliance Electric Company or its subsidiaries 1 0 2 0 3 0 4 0 5 0 Table of Contents Introduction au Dre parre e ee tae da e r se 1 1 Additional Information die nre rer me bbe wade ean x 1 2 Related Hardware and Software Mechanical Electrical Description Installation ea 3 4 WING nes d Rr usaq ees ree mere rh ener REIP 3 2 gt Installation
9. arious AutoMate Processor models will support different amounts of total system e AutoMate 20 Processor e AutoMate 30 Processor e AutoMate 40 Processor M N 45C400 or M N 45C409 e AutoMate Local I O Processor MIN 45C200 e AutoMate Remote I O Head M N 45C37 45C38 e DCS 5000 AutoMax Remote I O Head M N 45C33 57C330 The Analog Rail modules e g M N 61C350 61C351 cannot be used with the Local I O Head in this configuration This remainder of this manual describes the functions and specifications of the Local I O Head It also includes an overview of installation and servicing procedures Additional Information You should be familiar with the instruction manuals which describe your system configuration This may include but is not limited to the following e J 3012 AutoMate Digital I O Rail and Modules Instruction Manual e J 3031 AutoMate 30 Processor Hardware Instruction Manual e J 3033 AutoMate Local I O Processor Instruction Manual e J 3037 AutoMate Remote I O Head Instruction Manual e J 3063 AutoMate Programming Executive Instruction Manual J 3120 AutoMate 20 User s Manual e J 3140 AutoMate 40 Logic Processor Instruction Manual e J 3150 AutoMate 30 40 Software Instruction Manual e J 3630 ReSource AutoMax Programming Executive Instruction Manual e J 3649 DCS 5000 AutoMax Configuration Task Instruction Manual e J 3684 ReSource AutoMax Programming Executive Instruction Manual Version 2 0 e J 3750
10. blown replace it following the directions below Otherwise go on to step 4 CAUTION THE FUSE MUST BE REPLACED ONLY BY ANOTHER FUSE OF THE EXACT SAME TYPE AN AGC 4AMP FUSE FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN DAMAGE TO OR DESTRUCTION OF THE EQUIPMENT a Use a screwdriver to release the fuse holder located on the faceplate Pull the fuse holder out of the Local I O Head b Take the old fuse out of the fuse holder and replace with the new fuse c Re insert the fuse holder into the Local I O Head Turn the screwdriver clockwise and press down on the fuse holder at the same time The fuse holder must be flush against the faceplate Step 4 Disconnect the Rail cables from the Head and turn on the power to the Head If the LEDs are lit there is a power supply short in one of the Rails or Rail cables Replace one item Rail or Rail cable at a time until the problem re appears 5 1 5 2 5 2 5 3 The COM LED Is Off Problem The COM LED on the faceplate is off When lit this LED signifies that there is communication between the Local I O Head and the processor or Remote I O Head to which it is connected It should be on if communication is taking place The possible causes of this problem are incorrect configuration a disconnected or malfunctioning Local VO Interface cable a malfunctioning processor or Remote I O Head a rail fault or a malfunctioning Local I O Head Follow the steps below to isolate the
11. d connector labeled INPUT and any Rail connector on the hardware with which the Head will communicate Note that you can substitute the I O Rail cable M N 45C5 for the Local I O Interface cable M N 45 8 in step 5 above You cannot however substitute the Local I O Interface cable for the I O Rail cable If you do so the Rail will not operate Step 6 Verify that power was disconnected from the wires that will be used to provide power to the Head Step 7 For MIN 61C22 connect 120 VAC and ground wiring to the terminals on the Head faceplate as follows impu Terminal cabal x EEE Each screw terminal can accommodate no 12 AWG wires Minimum wire size is 22 AWG or For M N 61C23 connect 24 48 VDC and ground wiring to the terminals on the Head faceplate as follows mp rematar FAB VOC Each screw terminal can accommodate no 12 AWG wires Minimum wire size is 22 AWG Step 8 Check the installation for proper connections safety covers protective devices and means of disconnection Verify that the equipment is ready to apply power 4 0 4 1 4 2 CONFIGURATION Configuration is a method of describing how the system software and the I O are related The process of configuring the Local I O Head is dependent upon the host If the host is an AutoMate use the AutoMate Programming Executive Software M N 45C130 or M N 45C131 to perform the configuration Note that the registers in which the configuration
12. e I O Head This number may range from 1 to 7 Communication port on the DCS 5000 AutoMax Remote Head to which the Local I O Head is connected This number may range from 0 to 3 Register number representing the Local I O head communication port through which the register or bit will be accessed This number may range from 0 to 3 Optional field defining the bit position within the register number This number may range from 0 15 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 This section explains how to troubleshoot the Local I O Head Use the LEDs on the faceplate to determine the state of the Local I O Head If you cannot determine the problem from the instructions below as a guide the unit is not user serviceable 5 1 All LEDs on the Faceplate Are Off Problem All LEDs on the faceplate are off This problem indicates that the Head is not receiving 120VAC power within the specified ranges the fuse has blown or that the Head is malfunctioning Step 1 Using a voltmeter verify that the power source is 120VAC for M N 61C22 or 24 48 VDC for M N 61C23 and that it is functioning correctly Step 2 Stop any application programs that are running and turn off power to the Local I O Head Step 3 Inspect the fuse If the fuse has
13. guration with four Rails connected to the Local I O Head the AutoMate Remote I O Head in drop 6 and the Remote I O Processor master in slot 3 of the master rack MSLT DROP TYPE RSLOT CARD CHO REG CH1 REG CH2 REG CH3 REG 3 6 RHD LHD 0 3 LHD 4 7 LHD 10 13 LHD 14 17 4 4 Local I O Head with DCS 5000 AutoMax Remote I O Head When using the Local I O Head with the DCS 5000 AutoMax Remote IO Head the Local I O Head is configured in the configuration for the rack which contains the DCS 5000 AutoMax Remote master module M N 57C416 If you are using AutoMax Version 2 1 or earlier see below for the format of the statement used in the configuration task If you are using AutoMax Version 3 0 or later the Local I O Head is configured using the AutoMax Programming Executive Note that you cannot mix input and output modules in Rails connected to the Local I O Head when it is connected to a DCS 5000 AutoMax Remote I O Head You also cannot use the Analog Rail modules M N 61C350 61C351 etc in this configuration nnnnn RIODEF name MASTER_SLOT m DROP d SLOT s amp REGISTER r Bit b where nnnnn Configuration task line number This number may range from 1 to 32767 name Symbolic name of register or bit ending with integer for registers or boolean for bits 4 3 4 4 Slot in rack containing DCS 5000 AutoMax master Remote I O module This number may range from 0 to 15 Drop number of DCS 5000 AutoMax Remot
14. h models The LEDs indicate the following POWER COM RAIL FAULT 0 RAIL FAULT 1 RAIL FAULT 2 RAIL FAULT 3 The 5VDC supply for the Rails is within limits There is communication on the Local I O Interface cable The Head and Rail 0 are not communicating An I O reset has shut off Rail outputs The Head and Rail 1 are not communicating An I O reset has shut off Rail outputs The Head and Rail 2 are not communicating An I O reset has shut off Rail outputs The Head and Rail 3 are not communicating An I O reset has shut off Rail outputs 3 0 INSTALLATION This section describes how to install the Local I O Head 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 SERIOUS BODILY INJURY OR LOSS OF LIFE WARNING UNEXPECTED OUTPUT CHANGES MAY RESULT IF A RAIL IS PLUGGED INTO A LOCAL I O HEAD THAT IS COMMUNICATING WITH A PROCESSOR OR REMOTE HEAD 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 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 sys
15. ically assigns the next three contiguous registers for the configuration Note that even if only one port of the Head is being used four contiguous registers are still reserved for the configuration See below for sample configurations 4 1 Sample configuration with four Rails connected to the Local I O Head and the Master 30 or 40 Processor in slot 1 MSLT DROP RSLOT CARD CHO REG CHI REG CH2 REG CH3 REG 1 A M LHD 0 3 LHD 4 7 LHD 10 13 14 17 Sample configuration with four Rails connected to the Local I O Head and the Master Local I O Processor in slot 2 MSLT DROP TYPE RSLOT CARD CHO REG CHI REG CH2 REG CH3 REG 2 LIOP LHD 0 3 LHD 4 7 LHD 10 13 LHD 14 17 Sample configuration with four Rails connected to the Local I O Head the Local I O Processor in remote drop 7 slot 4 and the Master Processor in slot 3 MSLT DROP TYPE RSLOT CARD CHO REG CHI REG CH2 REG CH3 REG 3 7 RRK 4 LIOP LHD 03 LHD 4 7 LHD 10 13 14 17 4 2 4 3 Local VO Head with AutoMate Remote VO Head When using the Local I O Head with the AutoMate Remote I O Head only the first register of the four that are needed for the configuration needs to be specified The Executive software automatically assigns the next three contiguous registers for the configuration Note that even if only one port of the Head is being used four contiguous registers are still reserved for the configuration See below for a sample configuration Sample confi
16. tem and the external devices For detailed recommendations refer to IEEE 518 3 2 Installation Use the following procedure to install each Local I O Head Generally each Head is installed directly above the Rails or Rail compatible devices with which it will be connected leaving at least 2 inches of clearance between the Head and the closest device Multiple Heads should be installed side by side leaving at least 2 inches of clearance in between Heads Step 1 Using the mounting pattern in Appendix B drill four holes of approximately 218 diameter The Head is designed to be mounted vertically using 10 bolts or studs Step 2 Mount the Head using one of the two methods illustrated in Appendix B Step X Attach a retainer clip to the connector at each end of the Local I O Interface cable MIN 45C8 Note that the 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 ensure a tight connection between the cable and faceplate connectors Step 4 Connect a Rail or Rail compatible device to one of the four RAIL ports on the Head using the I O Rail cable M N 45C5 that came with the device Continue with any remaining Rails Instructions on mounting Rails and Rail compatible devices are found in the instruction manuals corresponding to the devices 3 1 3 2 Step 5 Connect the Local I O Interface cable between the Local Hea
17. w line Line frequency 47 5 to 63 Hz Transient voltages maximum of 2 cycles 84 138 VAC Maximum load at 120 VAC 5 Amps Fuse AGC 4Amp 250 V time delay Output power for Rails 5 VDC A 1 A 2 Appendix A Continued M N 61C23 Ambient Conditions e Storage temperature 20 85 C e Operating temperature 0 60 C e Humidity 5 90 non condensing Maximum Power Dissipation e 50 Watts with 64 I O installed Dimensions e Height 3 5 8 9 cm e Width 5 5 14 0 cm e Depth 6 7 17 0 cm e Weight 2 5 105 1 1 kg Electrical Characteristics e System power requirements 24 48 VDC 20 55 VDC acceptable range e Maximum load at 24 VDC 6 Amps e Fuse AGC 3Amp 250 V time delay e Output power for Rails 5 VDC Appendix B Local I O Head Mounting Pattern lt 5 50 gt lt 5 187 gt lt 16 I 50 gt en 3 50 2 47 218 typical Y Appendix B Continued MOUNTING SURFACE LOCAL HEAD NE MOUNTING FLANGE oig DIAMETER BOLT A TYPICAL gt HII STAR WASHER TAPPED HOLE BACK PANEL LOCAL HEAD MOUNTING FLANGE 218 NUT DIAMETER A TYPICAL STAR WASHER AA ANA WELDED STUD B 2 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 77

J-3671-2 AutoMate Local I/O Head

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