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Table of Contents 1.0 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Ć1 1.1 Additional Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Ć1 1.2 Related Hardware and Software . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Ć2 2.0 Mechanical/Electrical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Ć1 2.1 Mechanical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
II Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AĆ1 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BĆ1 Sample AutoMate Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1.1 Ć Analog Rail Module Hardware Configuration . . . . . . . . . . . . . . 1Ć3 Figure 2.1 Figure 2.2 Ć Analog Rail Module Faceplate . . . . . . . . . . . . . . . . . . . . . . . . . . 2Ć2 Ć Typical Input Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Ć4 Figure 3.1 Figure 3.2 Ć Mounting Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Ć2 Ć Typical Recommended Input Shielding Methods . . . . . . . . . . 3Ć5 Figure 4.
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The products described in this instruction manual are manufactured by Reliance Electric Industrial Company. The 4 Input 4Ć20mA Analog Rail module allows you to connect four input 4Ć20mA analog signals to AutoMater,ĂAutoMaxr 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.
JĆ3141 AutoMate 40 CONTROL PROCESSOR INSTRUCTION MANUAL JĆ3150 AutoMate 30/40 SOFTWARE REFERENCE MANUAL JĆ3649 DCS 5000/AutoMax CONFIGURATION TASK INSTRUCTION MANUAL JĆ3630 AutoMax PROGRAMMING EXECUTIVE INSTRUCTION MANUAL JĆ3600 DCS 5000 ENHANCED BASIC LANGUAGE INSTRUCTION MANUAL JĆ3675 AutoMax ENHANCED BASIC LANGUAGE INSTRUCTION MANUAL JĆ3601 DCS 5000 CONTROL BLOCK LANGUAGE INSTRUCTION MANUAL JĆ3676 AutoMax CONTROL BLOCK LANGUAGE INSTRUCTION MANUAL JĆ3602 DCS 5000 CONTROL
6. Two cable retainer clips 7. Four 32mA fuses (installed in the module): part no. 64676Ć44A 8. Four spare 32mA fuses: part no. 64676Ć44A The Analog Rail module can be configured with the hardware (purchased separately) listed in figure 1.1.
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2.0 MECHANICAL/ELECTRICAL DESCRIPTION 2.
Analog Rail 61C345 4 to 20 mA Input Input PWR COM OK OK Local Head Mode Rail Analog Inputs IN CH 0 CH 1 Common IN Common IĆIN CH 2 CH 3 Common IĆIN Common Input Power DCDC+ L2 L1 24 VDC 120 VAC Fuse Type 250V MDQ 24 VDC: Use 0.75A 120 VAC: Use 0.25A GND Figure 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, 12Ćpoint removable plug connector with screwĆtype terminal points. Three successive terminal points are reserved for each channel's connection to external hardware.
+10.000 V to A/D converter IĆIN 32mA ( 250 ) 277.778 IĆCommon Figure 2.2 Ć Typical Input Circuit The Analog Rail module is factory calibrated and requires no offset/gain adjustment. All four analog input 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.
3.
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 is 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.
Step 2. If the power supply you are using is 24 VDC, replace the factoryĆinstalled .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. ReĆinsert the fuse holder into the module. Turn the screwdriver clockwise while pressing down on the fuse holder.
0 1 2 3 IĆIN Common (no label) 4Ć20mA+ input common (shield; no connection)* 1 4 5 6 IĆIN Common (no label) 4Ć20mA+ input common (shield; no connection)* 2 7 8 9 IĆIN Common (no label) 4Ć20mA+ input common (shield; no connection)* 3 10 11 12 IĆIN Common (no label) 4Ć20mA+ input common (shield; no connection)* *This terminal makes no electrical connection to the Analog Rail printed circuit board. Step 10.
Source Channel 0 IĆIn 1 Common 2 + - 3 Source Channel 1 IĆIn 4 Common 5 + - 6 Source Channel 2 IĆIn 7 Common 8 + - 9 Source Channel 3 IĆIn 10 Common 11 + - 12 Figure 3.2 Ć Typical Recommended Input Shielding Methods Step 11. Turn off power to the Reliance device that will be connected to the Analog Rail module. Step 12. Set the Mode" switch on the faceplate of the Analog Rail module to the desired position. Step 13.
Step 16. Verify that the hardware has been installed correctly. 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 input channels by verifying that the input signal in the channel (4Ć20mA) is proportional to an ammeter reading at the terminal points.
Step 12. Attach the original 12Ćpoint and 4Ćpoint 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. Step 13. Set the Mode" switch on the faceplate to the desired position. Step 14. Connect the I/O Rail cable between the Analog Rail connection labeled Input" and any rail connector on the Reliance device that will communicate with the module.
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4.0 PROGRAMMING This section describes how the data 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 because they must be in the specified range of the Analog Rail module (4Ć20 mA). Input signals greater than 20 mA will be clamped at 4095. Signals greater than approximately 22.1 mA will also cause the overĆrange bit (12 decimal; 14 octal) to be set to 1.
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 (APX) software, M/N 45C130 or 45C131. Select CONFIGURE SYSTEM from the main menu to create the configuration.
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 CH0 REGISTER CH1 REGISTER CH2 REGISTER CH3 REGISTER ă1 A/M LHD ăă0Ć3 LHD ăă4Ć7 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 CH0 REGISTER CH1
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 TYP RSLT CARD CH0 REGISTER CH1 REGISTER CH2 REGISTER CH3 REGISTER ă2 A/M LHD ăăă0Ć3 NU NU NU Figure 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 in a remote rack: MSLT DROP TYP RSLT CARD CH0 REGISTER CH1 REGISTER CH2 REGISTER CH3 REGISTER ă2 ă1 RRK ăă2 LIOP LHD ăăă0Ć3 LHD ăăă4Ć7 LHD ăă10Ć13 NU Figure 4.
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 CH0 REGISTER CH1 REGISTER CH2 REGISTER CH3 REGISTER ă1 ă0 RHD LHD ăăă0Ć3 NU NU NU Figure 4.
4.1.2 AutoMate Programming in 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 the 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.
Octal 17 16 15 14 13 12 11 10 7 6 5 4 3 2 1 0 12 bits of converted analog data overĆrange (1=overĆrange) underĆrange (1=underĆrange) not used not used Figure 4.8 Ć Local Head Register Image for Input 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) blocks. The AIN block will set the overĆrange or underĆrange bits if applicable. See section 4.1.
AIN Instruction Block The example below shows an AIN block for an Analog Rail module connected to port 2 of an AutoMate Processor. AIN 12 .01 [ ] EN AIN IOPORT: LHPORT: CHAN: DEST: VALUE: AutoMate 20E with ports 0, 1, 2, and 3 0 1 2 3 IOPORT Ć 2 0 3 2000 EN 13 .01 ( ) ER 76 .00 ( ) Analog Rail with channels 0, 1, 2, and 3 In Rail Mode Chan 0 Chan 1 Chan 2 Chan 3 Processor port to which the Analog Rail is connected (directly or indirectly); value range 0Ć3.
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 overĆrange and underĆrange bits for each channel separately. These bits can also be defined using the RIODEF statement.
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.
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.
5.2 The COM OK" LED is Off Problem: The COM OK" 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.
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). In DCS 5000/AutoMax applications, make certain that the program is not attempting to write to the input channels. Step 2. Stop any application tasks that are running. Turn off power to the Analog Rail module. Step 3. Try to clear the condition by disconnecting and then reconnecting the I/O Rail cable.
Step 5. 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 12Ćpoint connector from the faceplate and set aside. Without disconnecting the wiring, remove the 4Ćpoint connector from the faceplate and set aside.
e) Place the metal enclosure side of the leftĆhand piece on a clean surface. Note the position of the fuses from the drawing below. As shown on the drawing, the top fuse is for channel 0 and the bottom fuse is for channel 3. The fuses are held in place by spring clips and are marked F1, F2, F3 and F4. Remove the blown fuse(s) carefully and discard. Replace the fuse(s) with a new fuse.
" D Storage temperature: -40_C to 85_C -40_F to 185_F D Operating temperature (at the module): 0_C to 60_C 32_F to 140_F D Humidity: 5Ć90% nonĆcondensing D Height: 9.25 inches (23.5 cm) D Width: 2.94 inchesă(7.5 cm) D Depth: 7.75 inches (19.7 cm including plugĆin terminals) D Weight: 4.5 lbs (2.1 kg) D Belden 8761 or equivalent type " ! D 4.
D Operating range:4Ć20 mA D Number of channels: 4 (singleĆended) D Number of commons: 1 (shared among all 4 channels) D Resolution: 12 bits binary D NonĆlinearity: + 1 LSB maximum D Accuracy: +0.
AĆC DĆCAĆC DĆC+ Vcc 12 PNT.
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The following AutoMate program sequences can be used to interface to an AutoMate Processor that does not support the AIN block. Over a period of four scans, the program below inputs four channels from an Analog Rail module in Rail mode. Registers Used 0 Register that is configured to be updated at the end of scan.
If channel 2 was read in, put the data in register 42. 0.17 [ăă] Ă45.02 (ăă) EN MOVM EN LENGTH: 1 SRC: 0 SCR2: K0011ă1111ă1111ă1111 DEST: 42 0.16 [Ă/Ă] If channel 3 was read in, put the data in register 43. 0.17 [ăă] Ă45.03 (ăă) EN MOVM EN LENGTH: 1 SRC: 0 SCR2: K0011ă1111ă1111ă1111 DEST: 43 0.16 [Ăăă] At the End of the Scan Select the channel to read in at end of scan. CĆ2 Ă44 .00 [ăă] ă0 .16 (ăă) Ă44 .01 [ăă] ă0 .
Increment counter 0, 1, 2, 3 and then back to 0. EN ADD LENGTH: 1 SRC: 44 SCR 2: K1 DEST: 44 EN 45.10 (ăă) EN ADD LENGTH: 1 SRC: 44 SCR 2: K3 DEST: 44 EN 45.
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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 Publication J-3689-2 - April 1993 Copyright © 2002 Rockwell Automation, Inc. All rights reserved. Printed in U.S.A.
