Rockwell Automation 1771-IXHR User Manual

High Resolution Thermocouple/Millivolt Input Module Cat. No. 1771-IXHR

User Manual

Important User Information

Because of the variety of uses for this product and because of the differences between solid state products and electromechanical products, those responsible for applying and using this product must satisfy themselves as to the acceptability of each application and use of this product. For more information, refer to publication SGI–1.1 (Safety Guidelines For The Application, Installation and Maintenance of Solid State Control).

The illustrations, charts, and layout examples shown in this manual are intended solely to illustrate the text of this manual. Because of the many variables and requirements associated with any particular installation, Allen–Bradley Company cannot assume responsibility or liability for actual use based upon the illustrative uses and applications.

No patent liability is assumed by Allen–Bradley Company with respect to use of information, circuits, equipment or software described in this text.

Reproduction of the contents of this manual, in whole or in part, without written permission of the Allen–Bradley Company is prohibited.

Throughout this manual we make notes to alert you to possible injury to people or damage to equipment under specific circumstances.

WARNING: Tells readers where people may be hurt if procedures are not followed properly.

CAUTION: Tells readers where machinery may be damaged or economic loss can occur if procedures are not followed properly.

Warnings and Cautions:

- Identify a possible trouble spot.

- Tell what causes the trouble.

- Give the result of improper action.

- Tell the reader how to avoid trouble.

Important: We recommend you frequently backup your application programs on appropriate storage medium to avoid possible data loss.



1991 Allen-Bradley Company

PLC is a registered trademark of Allen-Bradley Company

, Inc.

Important User Information 1. . . . . . . . . . . . . . . . . . . . . . . .

Using This Manual 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Purpose Audience 11 Vocabulary 11 Manual Organization 11 Warnings and Cautions 12 Related Products 12 Product Related

of Manual

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Compatibility Publications

11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overview of the High Resolution Thermocouple/Millivolt

Input Module

Chapter Module Description 21 Features How Analog Modules Communicate with Programmable Controllers 22

Accuracy 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Getting Started 23 Chapter Summary 23

Objectives

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of the Input Module

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21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the High Resolution Thermocouple/Millivolt

Input Module

31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter Before Y Electrostatic Damage 31 Power Requirements 31 Module Module Keying 32 Connecting Wiring 33 Grounding Installing Interpreting the Indicator Lights 36 Chapter Summary 37

Objectives

ou Install Y

Location in the I/O Chassis

the Input Modules

the Input Module

our Input Module 31. . . . . . . . . . . . . . . . . . . . . .

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31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32. . . . . . . . . . . . . . . . . . . . . . .

34. . . . . . . . . . . . . . . . . . . . . . . . . . .

36. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contentsii

Module

Chapter Block Transfer Programming 41 PLC-2 PLC-3 Program Example 42 PLC-5 Program Example 44 Module Scan Time 45 Chapter Summary 45

Programming

Objectives

Applications

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41. . . . . . . . . . . . . . . . . . . . . . . . . . . .

41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Module Configuration 51. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter Configuring the Module 51 Input Type 52 Zoom Feature 52 Temperature Scale 52 Real T Channel Alarms 53 Calibration 53 Configuration Block for a Block Transfer Write 54 Bit/Word Descriptions 56 Chapter Summary 58

Objectives

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ime Sampling

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51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Module Status and Input Data 61. . . . . . . . . . . . . . . . . . . . . .

Chapter Reading Data from the Module 61 Bit/Word Descriptions 62 Chapter Summary 63

Objectives

61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Module Calibration 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter Tools and Equipment 71 Calibrating your Input Module 71 About Auto-calibration 71 Performing Auto-calibration 72 Performing Chapter Summary 79

Objective

Manual Calibration

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71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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75. . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents iii

Troubleshooting 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter Diagnostics Reported by the Module 81 Troubleshooting Status Reported by the Module 82 Chapter Summary 84

Objective

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with the Indicators

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81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82. . . . . . . . . . . . . . . . . . . . . . .

Specifications A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High Resolution Thermocouple/Millivolt Input Module Accuracy A-2. . . Lead Resistance Compensation A-3 Filtering A-3

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Programming Examples B1. . . . . . . . . . . . . . . . . . . . . . . . . . .

Sample Programs for the Input Module B1. . . . . . . . . . . . . . . . . . . .

PLC-3 Family Processors B1 PLC-5 Family Processors B2

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Thermocouple Restrictions

(Extracted from NBS Monograph 125 (IPTS-68)) C1. . . . .

General C1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using This Manual

Chapter

Purpose of Manual

Audience

Vocabulary

Manual Organization

This manual shows you how to use your High Resolution Thermocouple/Millivolt input module with an Allen–Bradley programmable controller. It helps you install, program, calibrate, and troubleshoot your module.

You must be able to program and operate an Allen–Bradley programmable controller (PLC) to make efficient use of your input module. In particular, you must know how to program block transfer instructions.

We assume that you know how to do this in this manual. If you do not, refer to the appropriate PLC programming and operations manual before you attempt to program this module.

In this manual, we refer to:

The individual input module as the “input module” or the ”IXHR” The Programmable Controller, as the “controller.”

This manual is divided into eight chapters. The following chart shows each chapter with its corresponding title and a brief overview of the topics covered in that chapter.

Chapter Title Topics Covered

2 Overview of the Input Module Description of the module, including general and hardware

features

3 Installing the Input Module Module power requirements, keying, chassis location

Wiring of field wiring arm

4 Module Programming How to program your programmable controller for this module

Sample programs

5 Module Configuration Hardware and software configuration

Module write block format

6 Module Status and Input Data Reading data from your module

Module read block format

7 Module Calibration How to calibrate your module

8 Troubleshooting Diagnostics reported by the module

11

Chapter 1

Using This Manual

Chapter Topics CoveredTitle

Appendix A Specifications Your module's specifications

Appendix B Programming Examples

Appendix C Thermocouple Characteristics Extractions from NBS Monograph 125 (IPTS-68)

Warnings and Cautions

Related Products

This manual contains warnings and cautions.

WARNING: A warning indicates where you may be injured if you use your equipment improperly.

CAUTION: Cautions indicate where equipment may be damaged from misuse.

You should read and understand cautions and warnings before performing the procedures they precede.

You can install your input module in any system that uses Allen–Bradley PLC–3 and PLC–5 programmable controllers with block transfer capability and the 1771 I/O structure.

Contact your nearest Allen–Bradley office for more information about your programmable controllers.

Product Compatibility

12

These input modules can be used with any 1771 I/O chassis. Communication between the analog module and the processor is bidirectional. The processor block–transfers output data through the output image table to the module and block–transfers input data from the module through the input image table. The module also requires an area in the data table to store the read block and write block data. I/O image table use is an important factor in module placement and addressing selection. The module’s data table use is listed in the following table.

Chapter 1

Using This Manual

Table 1.A Compatibility

and Use of Data T

Catalog Number

Input Output Read Write Image Image Block Block Bits Bits Words Words

1771-IXHR 8 8 12/13 27/28 Yes Yes Yes A

= Compatible with 1771-A1, A2, A4 chassis. B = Compatible with 1771-A1B, A2B, A3B, A4B chassis. Y

es = Compatible without restriction No = Restricted to complementary module placement

able

Use of Data T

able

Compatibility

Addressing Chassis 1/2 -slot 1-slot 2-slot

Series

and B

You can place your input module in any I/O module slot of the I/O chassis. You can put:

two input modules in the same module group

an input and an output module in the same module group.

Do not put the module in the same module group as a discrete high density module unless you are using 1 or 1/2 slot addressing. Avoid placing this module close to AC modules or high voltage DC modules.

Related Publications

For a list of publications with information on Allen–Bradley programmable controller products, consult our publication index SD499.

13

Chapter

Overview of the High Resolution Thermocouple/Millivolt Input Module

Chapter 2

Chapter Objectives

Module Description

This chapter gives you information on:

features of the input module

how an input module communicates with programmable controllers

The High Resolution Thermocouple/Millivolt input module is an intelligent block transfer module that interfaces analog input signals with any Allen–Bradley programmable controllers that have block transfer capability.

Note: Use with PLC–2 family programmable controllers is not recommended. The 1771–IXHR module is only available with 2’s complementary binary as its only data type. The PLC–2 family does not use 2’s complementary binary.

Block transfer programming moves input data words from the module’s memory to a designated area in the processor data table in a single scan. It also moves configuration words from the processor data table to module memory.

The input module is a single slot module which does not require an external power supply. After scanning the analog inputs, the input data is converted to a specified data type in a digital format to be transferred to the processor’s data table on request. The block transfer mode is disabled until this input scan is complete. Consequently, the minimum interval between block transfer reads is the same as the total input update time for each analog input module (25ms).

Features of the Input Module

The 1771–IXHR module senses up to 8 differential analog inputs and converts them to values compatible with Allen–Bradley programmable controllers.

This module’s features include:

8 input channels configurable for thermocouple input ranges or millivolt

input ranges: Types B, E, J, K, T, R and S thermocouples and + two types of inputs allowed: 4 of one input type and 4 of another cold junction compensation scaling to selected temperature range in oC or oF temperature resolution of 0.1oC or 0.1oF, millivolt resolution to 1 microvolt user selectable high and low temperature alarms all features selectable through programming

100 millivolts

21

Chapter 2

Overview of the High Resolution Thermocouple/Millivolt Input Module

self–diagnostics and status reporting at power–up detection of open circuit if thermocouple fails automatic offset and gain calibration for each channel software calibration of all channels, eliminating potentiometers programmable filters for each group of 4 inputs X10 magnification (zoom) for millivolt mode

How Analog Modules Communicate with Programmable Controllers

The processor transfers data to and from the module using BTW (block transfer write) and BTR (block transfer read) instructions in your ladder diagram program. These instructions let the processor obtain input values and status from the module, and let you establish the module’s mode of operation (Figure 2.1).

1. The processor transfers your configuration data and calibration values to

the module using a block transfer write instruction.

2. External devices generate analog signals that are transmitted to the

module.

Figure 2.1 Communication

BTW

Between Processor and Module

Memory

User Program

To Output Devices

22

High Resolution

Thermocouple/Millivolt

Input Module

1771-IXHR

3. The module converts analog signals into binary format, and stores these

BTR

PC Processor

(PLC-5/40 Shown)

12933-I

values until the processor requests their transfer.

Chapter 2

Overview of the High Resolution Thermocouple/Millivolt Input Module

4. When instructed by your ladder program, the processor performs a read

block transfer of the values and stores them in a data table.

5. The processor and module determine that the transfer was made without

error, and that input values are within specified range.

6. Your ladder program can use and/or move the data (if valid) before it is

written over by the transfer of new data in a subsequent transfer.

7. Your ladder program should allow write block transfers to the module only

when enabled by the operator at power–up.

Accuracy

Getting Started

The accuracy of the input module is described in Appendix A.

Your input module package contains the following items. Please check that each part is included and correct before proceeding.

High Resolution Thermocouple/Millivolt Input Module (Cat. No. 1771–IXHR)

User’s Manual

Chapter Summary

Input Module Field Wiring Arm User's Manual

1771-IXHR Cat.

In this chapter you read about the functional aspects of the input module and how the module communicates with programmable controllers.

No. 1771-WI

1771-6.5.80

10526-I

23

Chapter

Installing the High Resolution Thermocouple/Millivolt Input Module

Chapter Objectives

Before You Install Your Input Module

Electrostatic Damage

This chapter gives you information on:

calculating the chassis power requirement choosing the module’s location in the I/O chassis keying a chassis slot for your module wiring the input module’s field wiring arm installing the input module

Before installing your input module in the I/O chassis you must:

Action required: Refer to:

Calculate the power requirements of all modules in each chassis. Power Requirements

Determine where to place the module in the I/O chassis. Module Location in the I/O Chassis

Key the backplane connector in the I/O chassis. Module Keying

Make connections to the wiring arm. Connecting Wiring and Grounding

Electrostatic discharge can damage semiconductor devices inside this module if you touch backplane connector pins. Guard against electrostatic damage by observing the following warning:

Power Requirements

CAUTION: Electrostatic discharge can degrade performance or cause permanent damage. Handle the module as stated below.

Wear an approved wrist strap grounding device when handling the module. Touch

Handle

Keep the module in its static–shield bag when not in use, or during shipment.

Your module receives its power through the 1771 I/O chassis backplane from the chassis power supply. The maximum current drawn by the thermocouple/millivolt input module from this supply is 750mA (3.75 Watts).

a grounded object to rid yourself of electrostatic char

the module.

the module from the front, away from the backplane connector

touch backplane connector pins.

ge before handling

. Do not

31

Chapter 3

Installing the High Resolution Thermocouple/Millivolt Input Module

Add this value to the requirements of all other modules in the I/O chassis to prevent overloading the chassis backplane and/or backplane power supply.

Module Location in the I/O Chassis

Module Keying

Place your module in any slot of the I/O chassis except for the extreme left slot. This slot is reserved for processors or adapter modules.

Group your modules to minimize adverse affects from radiated electrical noise and heat. We recommend the following.

Group analog and low voltage DC modules away from AC modules or high

voltage DC modules to minimize electrical noise interference. Do not place this module in the same I/O group with a discrete high–density

I/O module when using 2–slot addressing. This module uses a byte in both

the input and output image tables for block transfer.

After determining the module’s location in the I/O chassis, connect the wiring arm to the pivot bar at the module’s location.

Use the plastic keying bands, shipped with each I/O chassis, for keying the I/O slot to accept only this type of module.

The input modules are slotted in two places on the rear edge of the circuit board. The position of the keying bands on the backplane connector must correspond to these slots to allow insertion of the module. You can key any connector in an I/O chassis to receive these modules except for the leftmost connector reserved for adapter or processor modules. Place keying bands between the following numbers labeled on the backplane connector (Figure 3.1):

32

Between 20 and 22 Between 24 and 26

You can change the position of these bands if subsequent system design and rewiring makes insertion of a different type of module necessary. Use needlenose pliers to insert or remove keying bands.

Figure 3.1

Positions

Keying

Chapter 3

Installing the High Resolution Thermocouple/Millivolt Input Module

2 4 6 8 10 12 14 16 18 20 22

Keying

Bands

Upper Connector

CAUTION: The High Resolution Thermocouple/Millivolt Input Module uses the same keying slots as the 1771–IXE Thermocouple/Millivolt Input Module. If you are replacing a 1771–IXE with a 1771–IXHR, the ladder program must be modified to accept the new block transfer format.

24 26 28 30 32 34 36

14288

Connecting Wiring

Connect your I/O devices to the 1771–WI field wiring arm shipped with the module (see Figure 3.2). Attach the field wiring arm to the pivot bar at the bottom of the I/O chassis. The field wiring arm pivots upward and connects with the module so you can install or remove the module without disconnecting the wires.

Connect inputs in successive order starting with channel 1: positive leads to even–numbered terminals, negative leads to odd–numbered terminals of the wiring arm. Make connections to channel 1 at wiring arm terminals 18 (+) and 17(–). Follow the connection label on the side of the module for connecting the remaining inputs (Figure 3.2).

33

Chapter 3

Installing the High Resolution Thermocouple/Millivolt Input Module

Figure 3.2 Connection

Terminal

Identification

Diagram for the 1771-IXHR Inputs

Terminal Function

18 Input 1 (+ lead) 17 Input 1 (- lead)

16 Input 2 (+ lead) 15 Input 2 (- lead) 14 Input 3 (+ lead)

13 Input 3 (- lead) 12 Input 4 (+ lead) 11 Input 4 (- lead) 10 Not Used

9 Not used 8 Input 5 (+ lead)

7 Input 5 (- lead) 6 Input 6 (+ lead) 5 Input 6 (- lead) 4 Input 7 (+ lead) 3 Input 7 (- lead) 2 Input 8 (+ lead) 1 Input 8 (- lead)

Wiring Arm Cat. No. 1771-WI

–

15 14 13

6 5 4 3

2 1

Do not use

Short circuit unused pins

Connect positive thermocouple leads to even-numbered terminals, negative leads to odd-numbered terminals.

Ground cable shield to I/O chassis mounting bolt.

Channel 1

Channel 2

10527-I

Grounding the Input Modules

34

Do not connect an input to terminals 9 and 10. They are reserved for the cold junction temperature sensor inside the wiring arm. Short circuit unused input terminals by connecting a jumper wire between the positive and negative input terminals of each unused channel. Refer to appendix A to determine maximum cable length.

When using shielded cable or shielded thermocouple extension wire, ground the foil shield and drain wire only at one end of the cable. We recommend that you wrap the foil shield and drain wire together and connect them to a chassis mounting bolt (Figure 3.3). At the opposite end of the cable, tape exposed shield and drain wire with electrical tape to insulate it from electrical contact.

Figure 3.3

Grounding

Cable

Chapter 3

Installing the High Resolution Thermocouple/Millivolt Input Module

Ground Shield at

I/O chassis

mounting bolt

Shield and drain

twisted into

single strand

Field Wiring Arm

Refer to Wiring and Grounding Guidelines, publication 1770-4.1 for additional information.

17798

35

Chapter 3

Installing the High Resolution Thermocouple/Millivolt Input Module

Installing the Input Module

When installing your module in an I/O chassis:

1. First, turn off power to the I/O chassis:

WARNING: Remove power from the 1771 I/O chassis backplane

and wiring arm before removing or installing an I/O module.

Failure to remove power from the backplane could cause injury or equipment damage due to possible unexpected operation.

Failure to remove power from the backplane or wiring arm could cause module damage, degradation of performance, or injury.

2. Place the module in the plastic tracks on the top and bottom of the slot that

guides the module into position.

3. Do not force the module into its backplane connector. Apply firm even

pressure on the module to seat it properly.

4. Snap the chassis latch over the top of the module to secure it.

5. Connect the wiring arm to the module.

Interpreting the Indicator Lights

The front panel of the input module contains a green RUN and a red FLT (fault) indicator (Figure 3.4). At power–up, the green and red indicators are on. An initial module self–check occurs. If there is no fault, the red indicator turns off. The green indicator will blink until the processor completes a successful write block transfer to the module. If a fault is found initially or occurs later, the red FLT indicator lights. Possible module fault causes and corrective action are discussed in Chapter 8, Troubleshooting.

Figure 3.4 Diagnostic

Indicators

TC/MV Module

RUN

FLT

10528-I

36

Chapter 3

Installing the High Resolution Thermocouple/Millivolt Input Module

Chapter Summary

In this chapter you learned how to install your input module in an existing programmable controller system and how to wire to the field wiring arm.

37

+ 42 hidden pages