Allen-Bradley SLC 500 1746-FIO4I Bedienungsanleitung

ALLEN-BRADLEY

SLC 500Fast Analog I/O Modules

(Catalog Numbers 1746–FIO4I and FIO4V)

User Manual

AB Parts

Because of the variety of uses for the products described in this publication,

those responsible for the application and use of this control equipment must

satisfy themselves that all necessary steps have been taken to assure that each

application and use meets all performance and safety requirements, including

any applicable laws, regulations, codes, and standards.

The illustrations, charts, sample programs, and layout examples shown in

this guide are intended solely for purposes of example. Since there are

many variables and requirements associated with any particular installation,

Allen-Bradley does not assume responsibility or liability (to include

intellectual property liability) for actual use based upon the examples shown

in this publication.

Allen-Bradley publication SGI-1.1, Safety Guidelines For The Application,

Installation and Maintenance of Solid State Control (available at your local

Allen-Bradley office) describes some important differences between solid-

state equipment and electromechanical devices which should be taken into

consideration when applying products such as those described in this

publication.

Reproduction of the contents of this copyrighted publication, in whole or in

part, without written permission of Allen-Bradley Company, Inc. is prohibited.

Throughout this manual we make notes to alert you to possible injury to people

or damage to equipment under specific circumstances.

ATTENTION: Identifies information about practices or

circumstances that can lead to personal injury or death, property

damage or economic loss.

Attention helps you:

- Identify a hazard

- Avoid the hazard

- Recognize the consequences

Important: Identifies information that is critical for successful application and

understanding of the product.

SLC, SLC 5/01, SLC 5/02, SLC 5/03, SLC 5/04, SLC 100, SLC 500, and DTAM are trademarks of Allen–Bradley Company, Inc.

Important User Information

Using This Manual

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Using This Manual

Read this preface to familiarize yourself with the rest of this manual.

It provides information concerning the:

contents of this manual

intended audience

concept of analog control

common terminology

definition of terms

related publications

This manual helps you install the following fast analog I/O modules

and integrate them into your SLC 500system.

Catalog Number 1746–FIO4I Fast Analog I/O Module

Catalog Number 1746–FIO4V Fast Analog I/O Module

The following table identifies the chapters, titles and contents.

Chapter Title Describes

1Quick Start Abbreviated procedures for the advanced

technician, or otherwise used as an overview

2Installing Modules How to install and wire the module

3Processor and Module

Considerations Monitoring I/O data, addressing I/O image words,

signal resolution and conversion in I/O channels

4Create or Open a File

and Configure the

Software Procedures to create new files or return to existing

files to configure software or write ladder logic

5Programming Examples How to program analog modules

6Calibrating the Module How to write ladder logic to maintain a calibrated

input reference and to calibrate the module

8Maintenance, Safety,

and Troubleshooting Preventive maintenance suggestions,

safety considerations, and troubleshooting

7Testing Your Module How to test analog modules during initial installation

AModule Specifications Detailed technical specifications

B2’s-complement Binary

Numbers Explanation of how to use this number system

CModule I/O Circuits Internal wiring of the module’s I/Ocircuits

Using

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Contents of this Manual

AB Parts

Using

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We assume that you have a working knowledge of the SLC 500 family of

processors and related products. If you do not, obtain the proper training

from your local sales or distributor office.

Analog control of a process refers to continuous control, where the signal

amplitude varies with time. With digital control, the signal amplitude

jumps between zero and a maximum value (on/off) with time. The

following example shows a conceptual analog control application.

In this conceptual example, molding material is forced into the mold cavity

at controlled pressure. The purpose of the control system is to control the

pressure in the mold cavity according to a pressure algorithm programmed

into the processor. The pressure algorithm controls filling the mold cavity

rapidly and attaining the desired density of material in the mold cavity.

The analog I/O module converts the analog signal from the pressure sensor

(process variable) to a digital signal for transfer to the processor. The

module also converts the digital signal from the processor to an analog

signal (control variable) to control the pressure in the mold cavity by

adjusting pressure or flow through the valve. The pressure algorithm is a

ladder program stored in processor memory.

Pressure

Sensor

SLC 500

Processor

Analog Input

Analog Output

Valve Analog I/O

Module

inflow

Mold Cavity

Standard analog I/O modules respond to changes in analog signals measured

in seconds. Fast analog I/O modules respond to changes in analog signals

measured in milliseconds. What you gain in faster response, you loose in

susceptibility to electrical noise. Fast analog modules respond faster

because they have little input filtering. Therefore, we recommend that when

using fast analog I/O modules, you take precautions to minimize electrical

noise interference. We cover how to do this in chapter 2.

Intended Audience

Concept of Analog Control

Fast Analog Response

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For a complete glossary, refer to the Allen-Bradley Industrial Automation

Glossary, publication AG-7.1.

A/D Conversion

Generation of a digital value whose magnitude is proportional to the

instantaneous magnitude of an analog signal.

Common Mode Rejection

The ability of a differential analog input to cancel a common-mode signal,

expressed in dB.

Common Mode Voltage

A voltage that appears in common at both input terminals of a differential

analog input with respect to ground.

Common Mode Voltage Range

The largest voltage difference (positive or negative) allowed at either input

terminal of a differential analog input with respect to ground.

D/A Conversion

Generation of an analog signal whose instantaneous magnitude is

proportional to the magnitude of a digital value.

Differential Voltage, Maximum

The largest voltage difference allowed between the negative terminal and

positive terminal during normal differential operation.

Full Scale

The maximum voltage or current over which normal operation is measured.

Gain

Ratio of output signal to input signal magnitudes. The “gain” of an analog

input or output is the scale factor which provides the nominal conversion

relationship. Typically, this is the slope of the line when analog voltage or

current is plotted versus the corresponding digital codes. (see Gain Error.)

Gain Error

Gain error is the deviation of the scale factor or slope of the line from the

ideal or nominal value. Gain error is expressed in percent of input or output.

Gain Error = Change in slope

(exaggerated)

Actual Transfer Function

Nominal Transfer

Function

Glossary

AB Parts

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Gain Error Drift

The effect of temperature on gain error is expressed by gain error drift.

As temperature varies from +25°C, the possible gain error increases.

The gain error drift is specified in percent of input or output value /°C.

I/O Rack

An assembly that typically holds the processor, power supply, and I/O

modules that plug into slots. In a modular system, it is a 4-, 7-, 10- or

13–slot I/O rack. In a fixed system, it is a 2–slot expansion I/O rack.

Least Significant Bit (LSB)

The digit (or bit) in a binary word that carries the smallest value or weight.

The right-most bit in a 16-bit 2’s-complement binary code. For the FIO4I

and FIO4V modules, the LSB is defined by I/O channel converters as:

for outputs, the 3rd rightmost bit, bit 02

for inputs, the right-most bit, bit 00

Linearity Error

For an ideal A/D or D/A conversion, a graph of the digital values plotted

against the corresponding analog values should form a straight line. Linearity

error is any deviation from a straight line expressed in percent of full scale.

Linearity Error = Variation from straight line

(exaggerated)

Actual Transfer Function Linear Transfer Function

Offset

The steady-state deviation of a controlled variable from a fixed setpoint.

Offset Error

For A/D conversion, the digital value generated by a zero analog signal.

For D/A conversion, the digital value that generates a zero analog signal.

Offset Error

(exaggerated)

Nominal

Transfer Function Actual

Transfer Function

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Offset Error Drift

The change in offset error due to the change in temperature.

As temperature varies from +25°C, the possible offset error increases.

The offset error drift is specified in LSB /°C of full scale.

Overall Accuracy

For outputs, the worst case deviation of the output voltage or current from

the ideal over the full output range. For inputs, the worst case deviation of

the digital representation of the input signal from the ideal over the full

input range. It is expressed in percent of full scale.

Gain error, offset error, and linearity error all contribute to input and output

channel accuracy.

Resolution

The nominal voltage or current increment that equals the smallest change,

step or level, detected or represented by the analog channel. For A/D or

D/A conversion, may be expressed as the number of bits in the digital

value that corresponds to a full-scale analog value.

Safe State

The state to which analog outputs must be set when the processor is not in

RUN mode. The user must ensure that this is a safe state for the application.

Step Response Time

The time required for the digital representation of the analog input to reach

95% of the expected final value.

Update Time

For analog inputs, the time between updates to the memory of the analog

module of the digital value representing the analog input signal.

For analog outputs, the time from when the digital code is received at the

module to when the analog output signal corresponds to that digital value.

You may want to refer to these manuals while working with analog modules:

SLC 500 System Overview, Publication 1747-2.30

Getting Started Guide for APS, Publication 1747-6.3

Industrial Automation Wiring & Grounding Guidelines, Pub 1770-4.1

Advanced Programming Software User Manual, Publication 1747-6.4

Advanced Programming Software Reference, Publication 1747-6.11

Installation and Operation Manual for Fixed or Modular Hardware

Programmable Controllers, Publication 1747-6.2 or 1747-NI002

Safety Guidelines for the Application, Installation, and Maintenance

of Solid State Controls, Publication SGI–1.1

Related Publications

AB Parts

Table of Contents

Chapter 1

Required Tools and Equipment 1–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Procedures 1–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 2

Determining the Module’s Power Requirements 2–1. . . . . . . . . . . . . . . .

Determining Compatibility with Other I/O Modules 2–2. . . . . . . . . . . . . .

Configuring Input Channels 2–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selecting the I/O Rack Slot 2–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the Module 2–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Considerations When Wiring 2–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Wiring Guidelines 2–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Grounding the Cable 2–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Determining Cable Length 2–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Minimizing Electrical Noise Interference 2–6. . . . . . . . . . . . . . . . . . . . . .

Wiring the Module 2–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Minimizing Ground Loops 2–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Labeling the Terminal Block 2–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 3

Create a New File 3–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Configure I/O 3–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Return to an Existing File 3–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 4

Processor Considerations 4–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Processor Update of Analog I/O Data 4–1. . . . . . . . . . . . . . . . . . . . . . .

Monitoring Analog I/O Data 4–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Addressing I/O Image Words 4–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Module Considerations 4–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Data Resolution of the Module’s I/O Channel Converters 4–3. . . . . . .

Converting Analog Input Data 4–4. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compute the Analog Input Signal Level 4–4. . . . . . . . . . . . . . . . . . . . .

Converting Analog Output Data 4–4. . . . . . . . . . . . . . . . . . . . . . . . . . .

Compute the Analog Output 4–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Input Channel Filtering 4–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Time Delay for A/D Conversion 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . .

Response to Slot Disable 4–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safe State for Outputs 4–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Module I/D Code 4–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quick Start

Installing and Wiring

Modules

Accessing Files

to Configure I/O

Processor and Module

Considerations

Table of Contents

Chapter 5

Retentive and Non-retentive Programming 5–1. . . . . . . . . . . . . . . . . . . . .

Retain an Analog Output 5–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Non-retentive Analog Output 5–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clear the Output for Changing Mode or Cycling Power 5–2. . . . . . . .

Detect an Out-of-range Input 5–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overview of Scaling Inputs and Outputs 5–4. . . . . . . . . . . . . . . . . . . . . . .

Scale an Analog Input and Detect an Out-of-range Condition 5–5. . . . . .

Input Scaling 5–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Calculating the Linear Relationship 5–5. . . . . . . . . . . . . . . . . . . . . . . .

Calculating the Out-of-range Limits 5–6. . . . . . . . . . . . . . . . . . . . . . .

Ladder Logic 5–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Scale an Analog Output 5–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Calculating the Linear Relationship 5–8. . . . . . . . . . . . . . . . . . . . . . . .

Ladder Logic 5–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Scale Offsets When > 32,768 or < –32,768 5–10. . . . . . . . . . . . . . . . . . . . .

Ladder Logic 5–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Range-check an Analog Input and Scale It For an Output 5-12. . . . . . . . . .

Calculating the Linear Relationship 5–12. . . . . . . . . . . . . . . . . . . . . . . .

Ladder Logic 5–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PID Control with Analog I/O Scaling 5-16. . . . . . . . . . . . . . . . . . . . . . . . .

Ladder Logic 5–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 6

Calibration Tradeoffs 6–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Calibrating an Analog Input Channel 6–1. . . . . . . . . . . . . . . . . . . . . . . . . .

Example Calibration Program 6–2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Calibration Procedure 6–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 7

Testing the SLC 500 System 7–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Testing the Module 7–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Inspect Module Switches and Wiring 7–1. . . . . . . . . . . . . . . . . . . .

2. Disconnect Analog Process Control Devices 7–2. . . . . . . . . . . . . . .

3. Power Up the I/O Rack 7–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Test Analog Inputs 7–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Test Analog Outputs 7–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 8

Preventive Maintenance 8–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Considerations When Troubleshooting 8–1. . . . . . . . . . . . . . . . . . .

Writing Ladder Logic

Calibrating the Module

Testing Module Operation

Maintenance and Safety

AB Parts

Table of Contents

iii

Appendix A

General Description A–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications A–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Specifications A–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Input Specifications A–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Voltage input Specifications A–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Current-loop Input Specifications A–3. . . . . . . . . . . . . . . . . . . . . . . . . .

Current Output Specifications for FIO4I A–3. . . . . . . . . . . . . . . . . . . .

Voltage Output Specifications for FIO4V A–4. . . . . . . . . . . . . . . . . . . .

Appendix B

Using 2’s-complement Binary Numbers B–1. . . . . . . . . . . . . . . . . . . . . . .

Positive Decimal Values B–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Negative Decimal Values B–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix C

Input and Output Circuits C–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Index I–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 Installing the Module 2–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 Typical Signal Cable 2–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 Cable Preparation 2–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4 Wiring Diagram for Module, Sensor, and Load 2–7. . . . . . . . . . . . . .

2.5 Wiring Schematic for Single-ended Current-loop Analog Inputs 2–8.

2.6 Terminal Block 2–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 Processor I/O Image Words Used by the Module 4–2. . . . . . . . . . . . .

4.2 Bit Usage of the Module’s I/O Channel Converters 4–3. . . . . . . . . . .

4.3 Percent of Signal Passed 4–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 Input Channel Frequency Response 4–6. . . . . . . . . . . . . . . . . . . . . . .

4.5 Response Time of A/D Converter 4–7. . . . . . . . . . . . . . . . . . . . . . . . .

C.1 Module Input and Output Circuits C–1. . . . . . . . . . . . . . . . . . . . . . . .

Module Specifications

2’s-complement

Binary Numbers

Module Input and Output

Circuits

Index

List of Figures

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