J-3637-3 2 Channel Analog Input Module
Contents
1. Module Module in Local Rack E 1 E 2 16 Bit Register Reference Use the following method to reference a 16 bit register as a unit Analog input data update period interrupt control and filter selection registers are typically referenced this way The symbolic name of each register should be as meaningul as possible nnnnn IODEF SYMBOLIC_NAME SLOT s REGISTER r Bit Reference Use the following method to reference individual bits on the module Common clock status and control bits are typically referenced this way The symbolic name of each bit should be as meaningful as possible nnnnn IODEF SYMBOLIC_NAME SLOT s REGISTER r BIT b where nnnnn BASIC statement number This number may range from 1 32767 SYMBOLIC_NAME A symbolic name chosen by the user and ending with un This indicates an integer data type and all references will access register r SYMBOLIC NAMEQ A symbolic name chosen by the user and ending with This indicates a boolean data type and all references will access bit number b in register r SLOT Slot number that the module is plugged into This number may ran2. 3 2 Step 6 Step 7 Step 8 Figure 3 2 Rack Slot Numbers Attach the field terminal connector M N 57C371 to the mating half on the module Make certain that the connector is the proper one for this module Use a screwdriver to secure the connector to the module Note that both the module and the terminal strip connector are equipped with keys These keys should be used to prevent the wrong cable from being connected to a module in the event that the connector needs to be removed for any reason and then reattached later At the time of installation rotate the keys on the module and the connector so that they can be connected together securely It is recommended that for modules so equipped the keys on each successive module in the rack be rotated one position to the right of the keys on the preceeding module If you use this method the keys on a particular connector will be positioned in such a way as to fit together only with a specific module and there will be little chance of the wrong connector being attached to a module Turn on power to the rack Verify the installation by connecting the programming terminal to the system and running the ReSource software Use the I O MONITOR function Set registers 7 and 8 to the value 1 Read register 4 to determine whether bits 8 and 10 are set signifying that the common clock is being driven by another module
3. TOHLNOD 1dNyYy83LNI AlddNS H3MOd ONLLWIOSI d OV WaN SLIM Wan QV3H N3 IH 31A8 gt gt gt AZNVILINI 21901 JOULNOD 4344N8 viva iH31 HHANOO av 113834 8 ssaydqqv u gt sng 4300930 ssayqqv Ssduaav 3dWvs 319VIN B 1 Appendix C Field Connections Function 10 Volts Channel 0 1 Volt Channel 0 common al Note 1 This input may be modified to accept 5 volts by connecting a 22 1K ohm resistor between terminals 1 8 2 or 4 8 5 Note 2 This input may be modified to accept a 20 ma current signal by connecting 51 ohm resistor between terminals 2 amp or 5 4 6 C 1 Appendix D Related Components 57C371 Terminal Strip Cable Assembly This assembly consists of a terminal strip cable and mating connector It is used to connect field signals to the faceplate of the input module D 1 Appendix E Defining Variables in the Configuration Task Local I O Definition This sectio
4. Verify that your interrupt response task contains either a WAIT ON event or CALL SCAN LOOP statement that will be executed Check carefully to determine whether a higher priority task is preventing the interrupt response task from running Make certain that the ordering of your statements agrees with the examples in section 4 4 and that the lowest priority task enables common clock Verify that the hardware is working correctly Systematically swap out the input module and the processor module s If the problem persists take all of the modules except one processor module and the input module out of the backplane If the problem is now corrected one of the other modules in the rack is malfunctioning Re connect the other modules one at a time until the problem reappears If none of these tests reveals the problem replace the backplane Illegal Interrupt Detected Problem All tasks in the chassis are stopped and error code 1F appears on the faceplate of the processor module A hardware interrupt has occurred but no event has been defined Use the following procedure to isolate the problem Step 1 Step 2 Verify that the user application program is correct Verify that your interrupt response task contains an EVENT statement to be executed Check carefully to determine whether a higher priority task is preventing the interrupt response task from running Make sure that the ordering of your statements a
5. Step 2 Step 3 Step 4 5 2 Verify that the input module is in the correct slot and that the I O definitions are correct Refer to figure 3 2 Verify that the slot number being referenced agrees with the slot number defined in the configuration task Verify that the register number is in the range 0 10 Verify that the module can be accessed Connect the programming terminal to the system and run the ReSource Software Use the I O MONITOR to display the eleven registers on the input module If the programmer is able to monitor the inputs the problem lies in the application software proceed to step 3 If the programmer cannot monitor the inputs the problem lies in the hardware proceed to step 4 Verify that the user application program is correct Registers 0 thru 4 of the input module cannot be written to If a BASIC task caused such a bus error the error log will contain the statement number in the task where the error occurred If a control block task caused the error you will need to search the task for any instances in which you wrote to an input Verify that the hardware is working correctly Verify the hardware functionality by systematically swapping out the input module the processor module s and the backplane After each swap if the problem is not corrected replace the original item before swapping out the next item 5 3 5 3 1 5 3 2 Interrupt Problems Problem No interrupts at all
6. Connect the programming terminal to the system and run the ReSource Software Use the I O MONITOR function to display the eleven registers on the input module Verify that the user application program is correct Verify the application program has defined as COMMON any symbolic names associated with the module Verify that an update period has been written to registers 7 and 8 Remember that each count is 0005 seconds 500 useconds This value specifies the frequency with which the analog values will be converted to digital numbers Verify that common clock has been turned on The uppermost LED on the faceplate of the module should be lit If common clock is not present on the backplane the module will not convert the analog inputs to digital values If common clock is originating from this module remember that bit 6 in registers 5 and 6 must be set Verify that the input filters in registers 9 and 10 have been set to the proper values for the signals connected to the module If the filter values are set too low the filters will remove useful signal information If they are set too high the module may convert noise instead of the actual signal Verify that the input is wired to the correct device Verify that all connections at the terminal strip are tight Refer to figure 3 1 for typical field connections and Appendix C for terminal strip connections Make sure that each input channel is wired to the correct field device Co
7. 1 and earlier this is accomplished with IODEF statements in the configuration task See Appendix E for an example In AutoMax Version 3 0 and later you assign symbolic names using the Programming Executive Only one task may act as a receiver for a particular hardware interrupt That task should declare the symbolic names assigned to the interrupt control registers on the input module as COMMON 4 4 1 BASIC Task Example The following is an example of a BASIC task that handles interrupts from channel 0 from the input module 1000 1002 common data declarations 1003 1004 COMMON ANALOG INPUT 0 Data from channel 0 1005 COMMON ISCR_CHANNEL_0 VInterrupt status amp control 0 1010 COMMON CCLK_ENABLE_0 clock enable 0 1015 COMMON CCLK ENABLE 1 0 Common clock enable 1 1020 COMMON UPDATE_TIME_0 Update period for channel 0 1025 COMMON INPUT 0 FILTERS 6 Input filter for channel 0 1100 1150 local data declarations 1175 1200 LOCAL ANALOG_VALUE VAnalog value 2000 2001 setup the conversion parameters 2002 2011 INPUT 0 FILTER 6 2 79 rad sec filter 2900 2950 The following statement connects the name 0 3000 to the interrupt defined in ISCR_CHANNEL_0 The event name 3001 should be as meaningful as possible The watchdog timeout has 3002 been to 120 clock ticks 660 msec 1 tick 3003 equals 0055 seconds If the time between 3004 interrupts exceeds this
8. 3 2 Hardware Event 5 3 5 3 3 Hardware Event Count Limit Exceeded 5 4 5 3 4 Illegal Interrupt Detected enn 5 4 Appendices Appendix A Technical Specifications corista cr daa A 1 Appendix B Block Diagram 52x rr en a en a B 1 Appendix C Field COMM Ct ONS ie C 1 Appendix D Related Components vicios ns ped ieee eren eR ara D 1 Appendix E Defining Variables in the Configuration E 1 List of Figures Figure 2 1 Typical Input Circuit 2 2 Figure 2 2 Module Faceplate 2 3 Figure 3 1 Typical Field Signal Connections 3 1 Figure 3 2 Rack Slot Numbers 3 2 Figure 3 3 Offset and Gain 3 3 Figure 4 1 Analog Input Registers 4 1 Figure 4 2 Current Count Registers 4 1 Figure 4 3 Common Clock Status 4 2 Figure 4 4 Interrupt Control Registers 4 2 Figure 4 5 Analog Update Registers 4 3 Figure 4 6 Input Filter Selection 5 4 3 1 0 INTRODUCTION The products described in this instruction manual are manufactured or distribute
9. An on board DC DC converter provides power to the isolated portion of the circuit The 15 volt outputs from the supply are brought to the connectors on the faceplate of the module A circuit diagram is shown in figure 2 1 Refer to Appendix A for power supply current limitations 2 1 2 2 Figure 2 1 Typical Input Circuit There are 4 LED indicators on the faceplate of the module which reflect the status of the on board 4mhz clock The top LED indicates whether common clock which can be generated from numerous modules is on The next LED indicates whether this module is driving the common clock The bottom two LEDs are used for factory testing purposes only and should be ignored by the user See figure 2 2 Fe ANALOG NPUT 570409 RELIANCE ELECTRICNO Figure 2 2 Module Faceplate 2 3 3 0 3 1 3 2 Installation This section describes how to install and remove the module and its cable assembly Wiring The installation of wiring should conform to all applicable codes To reduce the possibility of electrical noise interfering with the proper operation of the control system exercise care when installing the wiring from the system to the external devices For detailed recommendations refer to IEEE 518 Initial Installation Use the following p
10. LANGUAGE INSTRUCTION MANUAL e 3676 AutoMax CONTROL BLOCK LANGUAGE INSTRUCTION MANUAL e J 3677 AutoMax LADDER LOGIC LANGUAGE INSTRUCTION MANUAL e J 3684 ReSource AutoMax PROGRAMMING EXECUTIVE INSTRUCTION MANUAL VERSION 2 0 e J 3750 ReSource AutoMax PROGRAMMING EXECUTIVE INSTRUCTION MANUAL VERSION 3 0 EEE 518 GUIDE FOR THE INSTALLATION OF ELECTRICAL EQUIPMENT TO MINIMIZE ELECTRICAL NOISE INPUTS TO CONTROLLERS FROM EXTERNAL SOURCES 1 1 2 0 2 1 2 2 MECHANICAL ELECTRICAL DESCRIPTION The following is a description of the faceplate LEDs field termination connectors and electrical characteristics of the field connections Mechanical Description The input module is a printed circuit board assembly that plugs into the backplane of the DCS 5000 AutoMax rack It consists of a printed circuit board a faceplate and a protective enclosure The faceplate contains tabs at the top and bottom to simplify removing the module from the rack Module dimensions are listed in Appendix A The faceplate of the module contains a female connector socket and 4 LED indicators that show the status of the inputs Input signals are brought into the module via a multi conductor cable M N 57C371 see Appendix D One end of this cable attaches to the faceplate connector while the other end of the cable has stake on connectors that attach to a terminal strip for easy field wiring The faceplate connector socket and cable plug are keyed
11. 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 3637 3 November 1992 Copyright 2002 Rockwell Automation Inc All rights reserved Printed in U S A
12. task that handles interrupts from channel 1 of the input module 1000 1001 1003 1004 1005 1010 1015 1020 1025 1200 1300 1400 1401 1402 1403 1500 2000 2001 2002 2010 2011 3000 3001 3002 3003 3004 3005 3006 3007 3008 3009 3010 4000 4001 4002 4003 4004 4005 4010 4020 5000 5001 5002 6000 6001 6002 6003 6004 6005 6006 6007 6008 6010 7000 7001 7002 7010 common data declarations COMMON ANALOG_INPUT_1 from channel 1 COMMON ISCR_CHANNEL_1 Vinterrupt status amp control 1 COMMON CCLK ENABLE 0 clock enable 0 COMMON CCLK ENABLE 19 clock enable 1 COMMON UPDATE TIME 196 Update period for channel 1 COMMON INPUT 1 FILTER 6 VInput filter for channel 1 local data declarations LOCAL LOOP_GAIN Gain of amplifier LOCAL OFFSET Amplifier offset LOCAL NORM_ANALOG_IN lAnalog value set up the conversion parameters 196 100 every 50 milli seconds INPUT_1_FILTER 2 79 rad sec filter The following statement connects the name CHANNEL_1_EVENT to the interrupt defined in ISCR_CHANNEL_1 The event name should be as meaningful as possible The watchdog timeout has been set to 12 clock ticks 66 msec If the time between interrupts exceeds this value a bus error will be indicated on the processor s LED and the system will be stopped For more information refer to the Enhance
13. to prevent the cable from being plugged into the wrong module On the back of the module are two edge connectors that attach to the system backplane Electrical Description The input module contains two analog input channels with software selectable filters These channels are connected through a multiplexer to a successive approximation analog to digital converter As supplied the module can convert 10 volt or 1 volt inputs If you add external resistors the module can convert 5 volt or 4 20 ma current inputs Each channel provides 12 bit conversion plus sign 4095 The module provides 100 overranging in the event that the input signal exceeds the maximum normal input voltage When in the overrange condition the magnitude is doubled 8191 and the accuracy is halved bit 0 is no longer significant The analog to digital converter provides conversion rates as fast as once every 500 microseconds The update period is software programmable in increments of 500 microseconds up to a maximum of 32 7675 seconds Sample and hold circuits maintain constant input values during conversion Each channel contains a low pass filter with user selectable bandwidths to smooth out transients and also provide anti aliasing for signals with high frequency components The filter cutoff frequencies are given in figure 4 6 A single isolated common is provided for both analog input channels Input signals have 600 volt isolation to logic common
14. value a bus error will 3005 indicated on the processor s LED and the system 3006 will be stopped For more information refer to 3007 the Enhanced BASIC Instruction manual J 3675 3008 3010 EVENT NAME CHANNEL 0 EVENT 8 INTERRUPT STATUS ISCR CHANNEL 0 TIMEOUT 120 4000 4001 UPDATE TIME 096 1000 Convert every 5 seconds 4002 The following statements enable common clock on this module 4003 Ifthere is more than one interrupt task in a chassis the 4004 task that enables common clock should always be the lowest 4005 priority task 4006 4010 CCLK ENABLE 0 TRUE Turn on the clock 5000 5001 Place any additional initialization statements here 5002 6000 6001 The next statement synchronizes the task with the external 6002 event via the interrupt Task execution will be suspended 6003 until the interrupt occurs If this task is the highest 6004 priority task waiting to execute at the time of the 6005 interrupt it will become active If it is not the highest 6006 priority task it will remain suspended until all higher 6007 priority tasks have executed at which point it will become 6008 active 6009 6010 WAIT ON CHANNEL 0 EVENT 7000 7001 7002 The next statement performs the interrupt service routine 7003 7010 ANALOG_VALUE ANALOG INPUT 096 8000 GOTO 6010 10000 END 4 7 4 8 4 4 2 Control Block Task Example The following is an example of a control block
15. 1 second 1000 1002 common data declarations 1004 1005 COMMON ANALOG_INPUT_0 VData from channel 0 1010 COMMON CCLK_ENABLE_0 Common clock enable 0 1020 COMMON CCLK_ENABLE_1 Common clock enable 1 1030 COMMON UPDATE_TIME_0 Update period for channel 0 1040 COMMON INPUT_0_FILTER Input filter for channel 0 1400 1450 local data declarations 1475 1500 LOCAL CURRENT_VALUE Current value of analog input 1900 2000 INPUT 0 FILTER 2 79 rad sec crossover frequency 2010 UPDATE_TIME_0 200 1 second conversion 2020 CCLK_ENABLE_0 TRUE Turn on the clock 2030 CCLK_ENABLE_1 TRUE Must turn on both outputs 2500 3000 Place any additional initialization statements here 4000 4001 The rest of the task is run every 1 0 seconds 4002 5000 START EVERY 1 SECONDS 5010 CURRENT VALUE 6 ANALOG INPUT 096 1000 END The symbolic names defined as COMMON reference the inputs defined in the configuration The symbolic name CURRENT VALUE 6 is local to the BASIC task and does not have I O associated with it 4 5 4 6 4 3 2 4 4 Control Block Task Example This example will read an analog input from channel 1 every 55 milliseconds and store the inverted value in the symbol READING The analog value will be digitized every 500 microseconds 1003 common data declarations 1004 1005 COMMON ANALOG_INPUT_1 VData from channel 1 1010 COMMON CCLK_ENABLE_0 VCommon clock enab
16. 2 Channel Analog Input Module M N 57C409 Instruction Manual J 3637 3 ae ELECTRIC ELI The information in this user s manual is subject to change without notice WARNING THIS UNIT AND ITS ASSOCIATED EQUIPMENT MUST BE INSTALLED ADJUSTED AND MAINTAINED BY QUALIFIED PERSONNEL WHO ARE FAMILIAR WITH THE CONSTRUCTION AND OPERATION OF ALL EQUIPMENT IN THE SYSTEM AND THE POTENTIAL HAZARDS INVOLVED FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN BODILY INJURY WARNING UNEXPECTED MACHINE MOVEMENT MAY BE THE RESULT OF INSERTING OR REMOVING THIS MODULE OR ITS CONNECTING CABLES POWER SHOULD BE REMOVED FROM THE MACHINE BEFORE INSERTING OR REMOVING THE MODULE OR ITS CONNECTING CABLES FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN BODILY INJURY CAUTION THIS MODULE CONTAINS STATIC SENSITIVE COMPONENTS CARELESS HANDLING CAN CAUSE SEVERE DAMAGE DO NOT TOUCH THE CONNECTORS ON THE BACK OF THE MODULE WHEN NOT IN USE THE MODULE SHOULD BE STORED IN AN ANTI STATIC BAG THE PLASTIC COVER SHOULD NOT BE REMOVED FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN DAMAGE TO OR DESTRUCTION OF THE EQUIPMENT Multibus is a registered trademark of Intel Corporation AutoMax is a trademark of Reliance Electric Company or its subsidiaries Reliance and ReSource are registered trademarks of Reliance Electric Company or its subsidiaries Table of Contents Introduction 1 1 Mechanical
17. Electrical Description 2 1 2 1 Mechanical Description 2 1 2 2 Electrical Description eere ee eme er eene 2 1 Installation en Rain SR C 3 1 31 ssexiee d Rr rn 3 1 3 2 Initial Installation ic mnm ae 3 1 3 3 Module 3 4 Programming zu s an ae en an 4 1 4 1 Register Organization 4 1 4 2 Configuration 5 are 4 4 4 3 Reading And Writing Data In Application Tasks 4 4 4 3 1 BASIC Task Example 4 5 4 3 2 Control Block Task Example 4 6 4 4 Using Interrupts in Application Tasks 4 6 4 4 1 BASIC Task Example 4 7 4 4 2 Control Block Task Example 4 8 4 5 Restrictions centers recs er nr ee Rae I Nei 4 9 4 5 1 Writing Data to Registers 4 9 4 5 2 Use Remote I O Racks 4 9 4 5 3 Initializing or Updating Filter Registers 4 9 Diagnostics And Troubleshooting 5 1 9 1 Incorrect Data a asus ae ads 5 1 5 2 BUS EMON osse a nen ae 5 2 5 3 Interrupt Problems sosete tects serene ae ann 5 3 531 No aa ea 5 3 5
18. d BASIC Language Instruction Manual J 3675 EVENT NAME CHANNEL_1_EVENT amp INTERRUPT STATUS ISCR CHANNEL _ 1 TIMEOUT 12 The following statements enable common clock on this module If there is more than one interrupt task in a chassis the task that enables common clock should always be the lowest priority task CCLK_ENABLE_0 TRUE Turn on the clock CCLK_ENABLE_1 TRUE Must turn on both outputs Place additional initialization software here The next statement synchronizes the task with the external event via the interrupt Task execution will be suspended until the interrupt occurs If this task is the highest priority waiting to execute at the time of the interrupt it will become active If it is not the highest priority task it will remain suspended until all higher priority tasks have executed at which point it will become active ALL SCAN_LOOP TICKS 9 EVENT CHANNEL_1_EVENT are The next statements perform the interrupt service routine CALL AMPLIFIER INPUT1 ANALOG INPUT 1 amp GAIN1 LOOP_GAIN INPUT2 OFFSET LOOP _GAIN 8 OUTPUT NORM_ANALOG_IN 10000 END 4 5 4 5 1 4 5 2 4 5 3 Restrictions This section describes limitations and restrictions on the use of this module Writing Data to Registers Registers 0 4 are read only and may not be written to by the application software Attempts to write to them will cause a bus error severe system error The followin
19. d by Reliance Electric Company or its subsidiaries This 2 Channel Analog Input Module is used to input analog signals to a local rack in the DCS 5000 AutoMax system The module contains two channels that can be converted as often as once every 500 micro seconds Each channel provides 12 bit conversion plus sign 100 overrange and user programmable filters and conversion rates There is one isolated common for the two input channels Inputs to the module can be either 1 volt 5 volts 10 volts or 4 20 ma The module can be configured to interrupt on every conversion Typically this module is used to read analog voltages from potentiometers tachometers drive control systems and process control systems This manual describes the functions and specifications of the module It also includes a detailed overview of installation and servicing procedures as well as examples of programming methods Related publications that may be of interest e J 2611 DCS 5000 PRODUCT SUMMARY e J 3675 DCS 5000 ENHANCED BASIC LANGUAGE INSTRUCTION MANUAL e J 3676 DCS 5000 CONTROL BLOCK LANGUAGE INSTRUCTION MANUAL e J 3677 DCS 5000 LADDER LOGIC LANGUAGE INSTRUCTION MANUAL e J 3630 ReSource AutoMax PROGRAMMING EXECUTIVE INSTRUCTION MANUAL VERSION 1 0 J 3635 DCS 5000 PROCESSOR MODULE INSTRUCTION MANUAL e J 3649 AutoMax CONFIGURATION TASK MANUAL J 3650 AutoMax PROCESSOR MODULE INSTRUCTION MANUAL e J 3675 AutoMax ENHANCED BASIC
20. each analog channel Channel 0 uses registers 0 2 5 7 and 9 Channel 1 uses registers 1 3 6 8 and 10 Register 4 provides status information on the common clock signal which is shared by both channels Registers 0 and 1 contain the 2 s complement digital value of the analog input The analog to digital converter provides a precision of 12 bits plus sign It also provides 100 overrange capability This means that if the input is maintained within the specified range the digital value will vary 4095 with each of the bits containing significant information If the input exceeds the specified range the digital value will vary 8191 but bit O will no longer be significant These registers are read only Refer to figure 4 1 15 14 13 12 11 10 98 765 43 2 1 0 channel 0 data channel 1 data Figure 4 1 Analog Input Registers Registers 2 and 3 which are also read only contain the time remaining until the next analog to digital conversion Each count is equivalent to 500 microseconds Refer to figure 4 2 15 14 13 12 11 10 9 8 765 43 2 1 0 current count of update period for channel 0 current count of update period for channel 1 Figure 4 2 Current Count Registers 4 1 Register 4 contains the common clock status Bits 8 and 10 indicate that the common clock is being driven by a module in the rack These bits must be set for the module to function correctly Bit 6 indicates that this module is driving the common clock Re
21. er to the rack and all connections Use a screwdriver to loosen the screws holding the connector to the module Remove the connector Loosen the screws that hold the module in the rack Remove the module from the slot in the rack Place the module in the anti static bag it came in being careful not to touch the connectors on the back of the module Place the module in the cardboard shipping container Take the new module out of the anti static bag being careful not to touch the connectors on the back of the module Insert the module into the desired slot in the local rack Use a screwdriver to secure the module into the slot Attach the field terminal connector M N 57C371 to the mating half on the module Make certain that the connector keys are oriented correctly and that the connector is the proper one for this module Use a screwdriver to secure the connector to the module Turn on power to the rack 4 0 4 1 bits register 0 register 1 bits register 2 register 3 PROGRAMMING This section describes how the data is organized in the module and provides examples of how the module is accessed by the application software For more detailed information refer to DCS 5000 Enhanced BASIC Language Instruction Manual J 3600 or AutoMax Enhanced BASIC Language Instruction Manual J 3675 Register Organization The data in the input module is organized as eleven 16 bit registers There is a set of registers for
22. g are examples from programs that write to the module and should therefore be avoided a Referencing the module on the left side of an equal sign in a LET statement in a control block or BASIC task b Referencing an analog input as an output in a control block function Use in Remote I O Racks This module must not be used in a remote rack A processor module must be located in the same rack as this 2 Channel Analog Input module Initializing or Updating Filter Registers A minimum of 5 5 msec is required between programming statements used to initialize or update the filter registers 9 and 10 4 9 5 0 5 1 DIAGNOSTICS AND TROUBLESHOOTING This section explains how to troubleshoot the module and field connections Incorrect Data Problem The data is either always off always on or different than expected The possible causes of this are a module in the wrong slot a programming error or a malfunctioning module It is also possible that the input is either not wired or wired to the wrong device Use the following procedure to isolate the problem Step 1 Step 2 Step 3 Step 4 Verify that the input module is in the correct slot and that the I O definitions are correct Refer to figure 3 2 Verify that the slot number being referenced agrees with the slot number defined in the configuration task Verify that the register number and the bit number are correct Verify that the module can be accessed
23. ge from 0 15 REGISTER Specifies the register that is being referenced This number may range from 0 10 BIT Used with boolean data types only Specifies the bit in the register that is being referenced This number may range from 0 15 Examples of Local I O Definitions The following statement assigns the symbolic name POSITION to register O of the input module located in slot 4 1020 IODEF POSITION SLOT 4 REGISTER 0 The following statement assigns the symbolic name CCLK_ON to bit 8 of register 4 on the input module located in slot 7 2050 IODEF CCLK_ON SLOT 7 REGISTER 4 BIT 8 Sample Configuration Task The following is an example of a configuration task for the input module 1000 1001 1002 1003 analog inputs 1004 1005 IODEF ANALOG_INPUT_0 SLOT 4 REGISTER 0 1006 IODEF ANALOG_INPUT_1 SLOT 4 REGISTER 1 1010 1011 common clock enable 1012 1015 IODEF ENABLE OQ SLOT 4 REGISTER 5 BIT 6 1020 1021 A D update period 1022 1025 IODEF UPDATE TIME 0 510 4 REGISTER 7 1026 IODEF UPDATE TIME 1 510 4 REGISTER 8 1030 1031 input filters 1032 1035 IODEF INPUT_O_FILTER SLOT 4 REGISTER 9 1036 IODEF INPUT_1_FILTER SLOT 4 REGISTER 10 1050 1051 Place any additional configuration statements here 1052 2000 END Sample Configuration Task Defining Interrupts The following is an example of a configuration task for an input module defining
24. gister 4 is read only Refer to figure 4 3 bits 15 14 13 12 11 10 9 Bit 10 Common clock on Bit 8 Common clock on Bit 6 Common clock enabled Figure 4 3 Common Clock Status Register Registers 5 and 6 contain the interrupt control registers Each channel may be programmed to interrupt independently of the other With the exception of bit 6 in each register these registers are controlled by the operating system and must not be written to by the user Refer to figure 4 4 For this module to operate properly the common clock must be present on the backplane The top LED on the module faceplate indicates whether common clock is present Note that the common clock signal can be generated from a number of I O modules including this module 57C409 570421 and 57 411 If this module is to generate the common clock bit 6 in either registers 5 or 6 must be set Refer to figure 4 4 bits 15 14 13 12 11 10 9 sns Bit 15 Interrupt flag Bit 7 Interrupt enabled Bit 6 Common clock enabled N Line ID Bit 2 Interrupt allocated Figure 4 4 Interrupt Control Registers 4 2 Registers 7 and 8 contain the update period for the analog to digital conversion Each count in these registers is equivalent to 500 microseconds The update period may range from 500 microseconds to 32 7675 seconds These two registers must be initialized before the common c
25. grees with the examples in section 4 4 Verify that the hardware is working correctly Systematically swap out the input module and the processor module s If the problem persists take all of the modules except one processor module and the input module out of the backplane If the problem is now corrected one of the other modules in the rack is malfunctioning Re connect the other modules one at a time until the problem reappears If none of these tests reveals the problem replace the backplane Appendix A Technical Specifications Ambient Conditions e Storage temperature 40C 85C e Operating temperature OC 60C e Humidity 5 90 non condensing Maximum Module Power Dissipation e 25 Watts Dimensions e Height 11 75 inches e Width 1 25 inches e Depth 7 375 inches System Power Requirements e 5 volts 3050 ma Isolated Power Supply e 15 volts 25 ma e 15 volts 25 ma e Accuracy 1 e Thermal Drift 01 per degree C Analog Digital Converter e Number of input channels 2 e Repeatability 1 LSB 025 Linearity 082 1 LSB e Thermal drift 015 per degree C e Offset 79 mv 55mv max e Update period 500 micro seconds to 32 767 seconds e Two inputs per isolated common e 600 volt isolation A 1 Appendix B Module Block Diagram T N io 3 o o 5 o o 9 c lt X o Q Gt 49019 NOWWOO
26. in the rack If they are not set then set registers 5 and 6 on this module to the value 64 This will enable common clock on this module Bits 8 and 10 on register 4 should now be set Monitor registers 0 and 1 Verify that they contain numbers proportional to the analog value on their respective channels This confirms that the installation is complete Refer to table 1 for the approximate voltages or currents that should be read Table 1 Step 9 Determine offset and gain compensation This is necessary because manufacturing tolerances on the module can result in small offset and gain differences See figure 3 3 CORRECTED_VALUE COUNTS OFFSET 4 Figure 3 3 Offset and Gain 3 3 3 4 3 3 These can easily be compensated for in software Perform the following steps to determine the compensation values Set the analog input voltage to 0 volts Use the I O MONITOR to read the digital value This is the offset Set the analog input voltage to maximum Use the I O MONITOR to read the digital value Subtract the offset calculated in the previous step from this number The result is the gain Use the following equation in your application program to compensate the data CORRECTED VALUE RAW_DATA OFFSET 4095 GAIN Module Replacement Use the following procedure to replace a module Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Turn off pow
27. interrupts 1000 1001 analog inputs 1002 1005 IODEF ANALOG_INPUT_0 SLOT 4 REGISTER 0 1006 IODEF ANALOG_INPUT_1 SLOT 4 REGISTER 1 1010 1011 interrupt status amp control registers used by the operating sys 1012 1015 IODEF ISCR CHANNEL O96 SLOT 4 REGISTER 5 1016 IODEF ISCR CHANNEL 196 SLOT 4 REGISTER 6 1020 1021 common clock enable 1022 1025 IODEF CCLK_ENABLE_0 SLOT 4 REGISTER 5 BIT 6 1030 1031 A D update periods 1032 1035 IODEF UPDATE TIME 0 SLOT 4 REGISTER 7 1036 IODEF UPDATE TIME 196 SLOT 4 REGISTER 8 1040 1041 input filters 1042 1045 IODEF INPUT_O_FILTER SLOT 4 REGISTER 9 1046 IODEF INPUT_1_FILTER SLOT 4 REGISTER 10 1050 1051 Place any additional configuration statements here 1052 2000 END This sample configuration defines all of the information most commonly used on the module Omit from your program any definitions you do not need to use E 3 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 1 414 212 5200 Fax 1 414 212 5201 Headquarters for Allen Bradley Products Rockwell Software Products and Global Manufacturing Solutions Americas Rockwell Automation 1201 South
28. le 0 1020 COMMON CCLK ENABLE 1 Common clock enable 1 1030 COMMON UPDATE TIME 196 Update period for channel 1 1040 COMMON INPUT 1 FILTER 6 Input filter for channel 1 1400 1450 local data declarations 1475 1500 LOCAL READING Current negative value of input 1600 1900 task initialization 1950 2000 INPUT_1_FILTER 0 11300 rad sec crossover frequency 2010 UPDATE_TIME_1 1 500 microsecond conversion 2020 CCLK_ENABLE_0 TRUE Turn on the clock 2030 CCLK_ENABLE_1 TRUE Must turn on both outputs 4000 4001 Place any additional initialization statements here 4002 4900 The rest of the task is run every 55 milliseconds 4950 5000 CALL SCAN LOOP TICKS 10 5010 CALL INVERTER INPUT ANALOG INPUT 196 8 OUTPUT READING 10000 END The symbolic names defined as COMMON reference the inputs defined in the configuration The symbolic name READING is local to the BASIC task and does not have 1 O associated with it Using Interrupts in Application Tasks Interrupts are used to synchronize software tasks with the analog to digital conversion This input module supports separate interrupts for each A D channel The update period may be specified from 500 microseconds up to a maximum of 32 7675 seconds in increments of 500 microseconds In order to use interrupts on the input module it is necessary to assign symbolic names to the interrupt control registers In AutoMax Version 2
29. lly which eliminates the requirement to write a configuration task for the rack If you are using AutoMax Version 2 1 or earlier refer to Appendix E for example that show how to define variables in the configuration task If you are using AutoMax Version 3 0 or later see the AutoMax Programming Executive J 3750 for information about configuring variables Reading And Writing Data In Application Tasks In order for an input module to be referenced by application software it is first necessary to assign symbolic names to the physical hardware In AutoMax Version 2 1 and earlier this is accomplished by IODEF statements in the configuration task See Appendix E for an example In AutoMax version 3 0 and later you assign symbolic names using the Programming Executive Each application program that references the symbolic names assigned to the input module in configuration must declare those names COMMON The frequency with which tasks or application programs read their inputs and write their outputs depends on the language being used Ladder logic and control block tasks read inputs once at the beginning of each scan and write outputs once at the end of scan BASIC tasks read an input and write an output for each reference throughout the scan 4 3 1 BASIC Task Example This example will read an analog input from channel 0 once every second and store the value in the symbol CURRENT _VALUE The analog value will be digitized every
30. lock is enabled on the backplane Refer to figure 4 5 Refer to figure 4 4 for more information about the common clock bits 15 14 13 12 1110 9 8 7 6 register 7 update period for channel 0 register 8 update period for channel 1 Figure 4 5 Analog Update Registers Registers 9 and 10 contain the input filter being used The purpose of the filter is to remove signal components that are beyond the sampling frequency Note that the module requires a short delay between statements used to initialize these two registers The minimum delay time between initialization of the two registers is 5 5 msec The input filter registers must be initialized after the common clock is turned on Refer to figure 4 6 for the cutoff frequencies available bits 15 14 13 12 11 10 9 Input filter 00 300 rad sec 01 145 rad sec 10 79 rad sec 11 21 rad sec Figure 4 6 Input Filter Selection Registers 4 3 4 2 4 3 4 4 Configuration Before any application programs can be written it is necessary to configure or set the definitions of system wide variables i e those that must be globally accessible to all tasks For DCS 5000 and AutoMax Version 2 1 and earlier you define system wide variables by writing a Configuration task For AutoMax Version 3 0 and later you define system wide variables using the AutoMax Programming Executive After these variables are defined you can generate the configuration file automatica
31. n describes how to configure the output module when it is located in the same rack as the processor module that is referencing it Refer to the figure below Note that this procedure is used only if you are using the AutoMax Programming Executive software version 2 1 or earlier Processor Module 7 6 8 6 ET E SUPPLY POWER ON O PSREADY O SYSTEM READY O BLOWN FUSE NORMAL PROGRAM 8 Te To 9 Te ga Ja Ja Ja 2 Ts Ta Ja Ja o Jo RR Jo o e 8 8 8
32. nnect a voltmeter to the proper points on the terminal strip and confirm that the external device is generating the correct voltage or current Check the cable continuity between the faceplate and the terminal strip 5 1 Step 5 Verify that the hardware is working correctly With a voltmeter connected to the proper points on the terminal strip generate a series of different voltages or currents Verify that registers 0 and 1 contain digital values proportional to the input voltages If the digital values are incorrect perform the following operations e Systematically swap out the input module and the processor module s If the problem persists take all of the modules except one processor module and the input module out of the backplane If the problem is now corrected one of the other modules in the rack is malfunctioning Reconnect the other modules one at a time until the problem reappears If none of these tests reveals the problem replace the backplane 5 2 Bus Error Problem A 31 or 51 through 58 appears on the Processor module s LED This error message indicates that there was a bus error when the system attempted to access the module The possible causes of this error are a missing module a module in the wrong slot or a malfunctioning module It is also possible that the user has attempted to write to the wrong registers on the module Use the following procedure to isolate a bus error Step 1
33. or too many unexpected interrupts signified by error codes being displayed on the faceplate of the Processor module Go through the following steps first before going on to the more specific troubleshooting steps Step 1 Verify that the input module is in the correct slot and that the 1 O definitions are correct Refer to figure 3 2 Verify that the slot number being referenced agrees with the slot number defined in the configuration Verify that the configuration task contains the proper interrupt control definitions Step 2 Verify that the user application program is correct Verify that the application program that uses the symbolic names assigned to the module in the configuration task has defined those names as COMMON Compare your interrupt task with the examples given in sections 4 4 1 and 4 4 2 Make sure that the actions shown in the examples are performed in the same order in your program No Interrupts Problem The program does not execute but no error codes are displayed on the Processor module faceplate If interrupts are never received by the application program and the watchdog timeout parameter in the event definition was disabled the program will never execute The watchdog timer for this module must never be disabled Before you can determine why the program did not execute you must first set the timeout parameter in the event definition Run the program again and proceed to section 5 3 2 Hardware Even
34. rocedure to install the module Step 1 Turn off power to the system All power to the rack as well as all power to the wiring leading to the module should be off Step 2 Mount the terminal strip M N 57C371 on a panel The terminal strip should be mounted to permit easy access to the screw terminals Make certain that the terminal strip is close enough to the rack so that the cable will reach between the terminal strip and the module Step 3 Fasten field wires to the terminal strip Typical field connections are shown in figure 3 1 Refer to Appendix C for the arrangement of terminal board connections Make sure that all field wires are securely fastened Note that for any voltage or current input other than 10 volts or 1 volt an external resistor must be mounted on the terminal strip OPTIONAL 22 1K RESISTOR FOR 5V INPUT VOLTAGE INPUT USER DEVICE COMMON Figure 3 1 Typical Field Signal Connections 3 1 Step 4 Step 5 Typical 16 Slot Rack Take the module out of its shipping container Take it out of the anti static bag being careful not to touch the connectors on the back of the module Insert the module into the desired slot in the rack The module will work only in a rack that contains a processor module Do not attempt to use the module in a remote rack Use a screwdriver to secure the module into the slot Refer to figure 3 2 Typical 10 Slot Rack
35. t Time Out Problem All tasks in the chassis are stopped and error code 12 appears on the faceplate of the processor module The interrupt has either never occurred or is occurring at a slower frequency than the value specified in the timeout parameter in the event definition Use the following procedure to isolate the problem Step 1 Verify that the timeout value is set correctly Check the value specified in the timeout parameter in the event definition The unit is in ticks Each tick is equal to 5 5 msec The timeout value should be at least 2 ticks greater than the interrupt frequency It can reasonably range up to 1 5 times the interrupt frequency Step 2 Verify that the user application program is correct Review the examples in section 4 4 Make certain that common clock has been enabled 5 3 5 4 5 3 3 5 3 4 Step 3 Verify that the hardware is working correctly Systematically swap out the input module the processor module s and the backplane After each swap if the problem is not corrected replace the original item before swapping out the next item Hardware Event Count Limit Exceeded Problem All tasks in the chassis are stopped and error code 1b appears on the faceplate of the processor module A hardware interrupt has occurred but no task is waiting Use the following procedure to isolate the problem Step 1 Step 2 Verify that the user application program is correct
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