Block I/O Cat. No IOBX and -IOVX. User Manual

Transcription

1 Block I/O Cat. No. 9-IOBX and -IOVX User Manual

2 Important User Information 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 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., Safety Guidelines For The Application, Installation and Maintenance of Solid State Control (available from 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: Tells readers where people may be hurt if procedures are not followed properly. ATTENTION: Tells readers where machinery may be damaged or economic loss can occur if procedures are not followed properly. Attention helps you: Identify a hazard. Avoid the hazard. Recognize the consequences. Important: We recommend you frequently backup your application programs on appropriate storage medium to avoid possible data loss.

3 Preface Using This Manual Purpose of Manual This manual shows you how to use your Block I/O with an Allen-Bradley programmable controller. It helps you: install program and troubleshoot your module. Audience You must be able to program and operate an Allen-Bradley programmable controller (PLC) to make efficient use of Block I/O modules. 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. Vocabulary Manual Organization In this manual, we refer to: the block I/O module as the block or the module the programmable controller as the controller or processor. This manual is divided into 4 chapters. The following chart shows each chapter with its corresponding title and brief overview of the topics covered in that chapter. Chapter Title Topics Covered Introducing Block I/O Description of the module, including general and hardware features Installing the Module Module power requirements, location, and wiring information 3 Configuring your block I/O How to set the configuration switches and address the block I/O. 4 Troubleshooting How to use the indicators to troubleshoot your block I/O module. How to replace the fuse. Appendix A Specifications Specifications for the block I/O. P-

4 Preface Using This Manual About Block I/O Block I/O consists of small, self contained remote I/O devices complete with power supply, programmable controller interface, input/output connections and signal conditioning circuitry. This publication covers the 9 IOBX and IOVX block I/O modules. The 9 IOBX has 64 sinking inputs and 64 sourcing outputs; the 9 IOVX has 64 sourcing inputs and 64 sinking outputs. In all other aspects, they are identical. Related Publications For a list of publications with information on Allen-Bradley programmable controller products, consult our publication index (SD499). P-

5 Table of Contents Introducing Block I/O Chapter Chapter Objectives General Description How the Block I/O Fits in a PLC System Summary Installing Block I/O Chapter Chapter Objectives Pre installation Considerations Installing the Block I/O Connecting Wiring Remote I/O Link Wiring Extended Node Capability Compatibility of 7 I/O Products with Extended Node Operation Fusing Summary Configuring Your Block I/O Chapter 3 Chapter Objectives Setting the Configuration Switches Summary Troubleshooting Chapter 4 Chapter Objectives Indicators Replacing a Fuse Summary Specifications Appendix A Specifications A- I

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7 Chapter Introducing Block I/O Chapter Objectives In this chapter you will learn what block I/O is, its features, and how it functions. General Description Block I/O consists of small, self-contained remote I/O devices complete with power supply, programmable controller interface, input/output connections and signal conditioning circuitry. The 9-IOBX 4V dc module has 64 sink input channels, and 64 source output channels. The 9-IOVX 4V dc module has 64 source input channels, and 64 sink output channels. Complete specifications for these modules are contained in Appendix A. The blocks are compatible with PLC-, PLC-3, and PLC-5 family programmable controllers, and the SLC 5 modular controllers. When used with PLC- family programmable controllers, a sub-scanner module is used to communicate with the blocks. When used with PLC-3 and PLC-5 family programmable controllers, they can be connected directly to the controller or to a scanner module. When used with SLC 5 controllers, a 47-SN remote I/O scanner is used to communicate with the blocks. ATTENTION: When using PLC-3 programmable controllers, you must use a 75-S5 or -SR5 scanner module. Do not use 75-SR, -S4A or -S4B scanner modules. Note: The 9-IOBX and -IOVX block modules are not compatible with the 47-DSN scanner module. Connections are made to removable terminal blocks mounted on the sides of the block. Physical features of the block I/O are shown in Figure.. -

8 Chapter Introducing Block I/O Figure. Major Features of the 9-IOBX and -IOVX Block I/O Modules (-IOBX shown) Rack Address Switch CONFIGURATION SWITCHES Configuration Switches (on top of unit) RACK ADDR Power, Active, Comm and Fuse LED Indicators POWER ACTIVE M FUSE DISPLAY SELECT INPUT OUTPUT Input/Output Status LED Array Display Select Pushbuttons Removable Input Blocks 9-IOBX 8 POINT 4V DC DISTRIBUTED I/O MODULE 64 4VDC SINK INPUTS 64 4VDC SOURCE OUTPUTS Removable Output Blocks CONFIGURATION SWITCHES Block Removal Screws (same on all 4 terminal blocks) GROUP No. GROUP No. RIO Wiring Block +4V dc Power Termination Resistor Switch 9-I Wiring s - The remote I/O field wiring is made to 4 separate removable 37-pin terminal blocks mounted on the sides of the module. assignments are shown in chapter 3. A separate nonremovable terminal block is provided for connection of the remote I/O link and external 4V dc power supply. -

9 Chapter Introducing Block I/O Switch Assemblies - Two DIP switches are provided for setting the I/O configuration and rack address. The configuration switch lets you select baud rate, last state, processor restart lockout, last rack and I/O group. The rack address switch lets you select the system rack address for the block. A third switch is provided for selection of the termination resistor. Status Indicators - Indicators are provided for power, active, communication and fuse blown indications. An LED array provides input/output status. Status Indicators - Bi-color LED indicators provide power, active, communication and fuse blown indications. An LED array provides input/output status. Indicator Power (green/wht) Active (green/red) Comm (green/wht) Fuse (red/wht) Indication On (green) Customer voltage is present Off (wht) No customer voltage (less than V) On (green) CPU operating correctly Off (red) CPU not running On (green) Communication correctly established Off (wht) Communication not established On (red) One of the 4 output fuses is open Off (wht) All fuses are intact The I/O status array is an 8 by 8 array of 64 LEDs capable of displaying the status of 3 inputs and 3 outputs at any one time. Pushbuttons are provided to toggle the display between the lower 3 bits and the upper 3 bits. How the Block I/O Fits in a PLC System Block I/O is a complete I/O interface that includes the functionality of the I/O rack, adapter, power supply, and I/O modules in a single unit. Simply connect sensors and actuators to the module and use the remote I/O cable to connect the block I/O to your programmable controller (Figure.6). The 9-IOBX block uses sinking inputs and sourcing outputs. -3

10 Chapter Introducing Block I/O In sinking inputs, the dc common is bussed on the block. and the current is sourced from the field device. The sourcing field device switches the hot side of the power supply bus causing current to flow through the sourcing device to the sinking input on the block. Refer to Figure.. Figure. Sinking Input Example +V Bus Field Device Block I/O DC Power Supply Field Device -V Sinking Input Common 86-I Sourcing outputs have the power bussed in the block. When the output is on, current is supplied to the field control device, which sinks the current. The field circuit and the equipment remain at ground potential until the output is turned on. Refer to Figure.3. Note: The outputs must be externally fused to protect the device output against overcurrent or short circuit conditions. Figure.3 Sourcing Output Example Block I/O +V DC Power Supply Fuse Field Device -V Fuse Field Device Common Common Bus 87-I The 9-IOVX block uses sourcing inputs and sinking outputs. -4

11 Chapter Introducing Block I/O In sourcing input modules (Figure.4), the +V on dc circuits is bussed on the module supplying (sourcing) the current for each input circuit. The field device switches the circuit to the common (side of the power supply, sinking the circuit and causing current to flow from the module s input. Figure.4 Sourcing Input Example DC Power Supply -V +V Block I/O Field Device Input dc Common Bus 9-I In sinking outputs (Figure.5), the current flow is reversed. The dc common is bussed on the module and the current is sourced from the field device being actuated. When an output is turned on, the output switch in the module sinks the circuit, causing current to flow from the +V bus through the field device to the module. Note: The outputs must be externally fused to protect the device output against overcurrent or short circuit conditions. Figure.5 Sinking Output Example Block I/O Fuse Fuse Field Device Field Device +V Bus DC Power Supply Common -V Common 98-I -5

12 Chapter Introducing Block I/O Block I/O functions exactly like any Allen-Bradley remote I/O product. Input and output data is scanned asynchronously and transferred back and forth between the block and the controller input and output image table. You connect the block I/O to your remote I/O link as you would any other device. The block looks like a / I/O rack to the processor, and uses 4 words of input image table memory and 4 words of output image table memory. The block is addressed directly on the remote I/O link. Figure.6 Block I/O Connection in a PLC System Blocks are daisy-chained to a programmable controller, or scanner. Programmable Controller, or Scanner Block I/O - each block is / I/O rack. 9-I Summary In this chapter you learned what block I/O is, its features and how it functions. -6

13 Chapter Installing Block I/O Chapter Objectives In this chapter you will learn how to mount the block, how to connect the remote I/O link, how to connect the input and output wiring to the block, and how to terminate the remote I/O link. Pre-installation Considerations Before installation, you must determine: the number of blocks desired the total distance of the installation transmission rate desired Installing the Block I/O Mounting dimensions for the block I/O module are shown in Figure.. Mount the blocks horizontally with a minimum of between blocks. This air gap is necessary to maintain proper cooling air flow through the block. -

14 Chapter Installing Block I/O Figure. Mounting Dimensions for the Block I/O Module (Cat. No. 9-IOBX and -IOVX) 0.67 (.5) 6. (6.) 4.8 (.0) CONFIGURATION SWITCHES RACK ADDR POWER ACTIVE M FUSE DISPLAY SELECT INPUT OUTPUT Dimensions: 6.W x.0h x.7d (6.W x 334.0H x 43.7D).7 (3.0) 9-IOBX 8 POINT 4V DC DISTRIBUTED I/O MODULE.8 (3.0).0 (334.0) CONFIGURATION SWITCHES Inches (Millimeters) GROUP No. GROUP No. 9-I The operating temperature in the air gap between block I/O modules must not exceed 60 o C (0 o F). The dimensions of the air gap required are shown in Figure.. -

15 Chapter Installing Block I/O Figure. Clearance Required for Block I/O Modules (50.8) (50.8) (50.8) Inches (Millimeters) (50.8) 99-I Connecting Wiring Connections to the block I/O module are made to the removable terminal blocks on each side of the module. Input connections are on the left side, and output connections are on the right side. The input terminal blocks are keyed differently than the output blocks to prevent incorrect insertion. ATTENTION: Both input terminal blocks are keyed alike. If removed for wiring, or module replacement, make certain that the terminal blocks are placed in their proper position when reinstalling. Wiring connections for the 9-IOBX and -IOVX are shown in Tables.A through.h. Catalog 94-IOBX Input Wiring Catalog 94-IOVX Input Wiring Groups 0 and (TRM) Table.A, page -4 Groups 0 and (TRM) Table.E, page -8 Groups and 3 (TRM) Table.B, page -5 Groups and 3 (TRM) Table.F, page -9 Output Wiring Output Wiring Groups 0 and (TRM3) Table.C, page -6 Groups 0 and (TRM3) Table.G, page - Groups and 3 (TRM4) Table.D, page -7 Groups and 3 (TRM4) Table.H, page - Remote I/O link wiring connections are shown in Figure.3. -3

16 Chapter Installing Block I/O Input Assignment Group 0 PLC SLC Table.A 9-IOBX Input Wiring for Groups 0 and (TRM) for PLC Family Controllers and SLC Processors Input Assignment Group PLC SLC Common A Common A 9 Common B Common B Input Input 0 Input Input 3 Input Input Input Input 4 Input Input Input Input 5 Input Input 3 Input Input 6 Input Input 4 Input Input 7 Input Input 5 Input Input 8 Input Input 6 Input Input 9 Input Input 7 Input Input Input Input 08 8 Input Input 08 Input Input 09 9 Input Input 09 Input Input 30 Input Input Input Input 3 Input Input Input Input 3 Input Input Input Input 33 Input Input Input Input 34 Input Input Input Input 35 Input Input 8 N.C. N.C. 36 N.C. N.C. 37 N.C. N.C. +V INPUT PLC 0 SLC INPUT Common I -4

17 Chapter Installing Block I/O Table.B 9-IOBX Input Wiring for Groups and 3 (TRM) for PLC Family Programmable Controllers and SLC Processors Input Assignment Group PLC SLC Input Assignment Group 3 PLC SLC Common C Common C 9 Common D Common D Input Input 0 Input Input 3 Input Input Input Input 4 Input Input Input Input 5 Input Input 3 Input Input 6 Input Input 4 Input Input 7 Input Input 5 Input Input 8 Input Input 6 Input Input 9 Input Input 7 Input Input Input Input 08 8 Input Input 08 Input Input 09 9 Input Input 09 Input Input 30 Input Input Input Input 3 Input Input Input Input 3 Input Input Input Input 33 Input Input Input Input 34 Input Input Input Input 35 Input Input 8 N.C. N.C. 36 N.C. N.C. 37 N.C. N.C. +V PLC GROUP No. 3 SLC GROUP No. 3 Common I -5

18 Chapter Installing Block I/O Table.C 9-IOBX Output Wiring for Groups 0 and (TRM3) for PLC Family Programmable Controllers Output Assignment Group PLC SLC Output Assignment Group 0 PLC SLC N.C. N.C. 0 Common A Common A Common B Common B Output Output 3 Output Output Output Output 4 Output Output 3 Output Output 5 Output Output 4 Output Output 6 Output Output 5 Output Output 7 Output Output 6 Output Output 8 Output Output 7 Output Output 09 9 Output Output 09 8 Output Output 08 Output Output 08 9 Output Output Output Output 30 Output Output Output Output 3 Output Output Output Output 3 Output Output Output Output 33 Output Output Output Output 34 Output Output Output Output 35 Output Output Output Output 36 Output Output 8 Output Output 37 VDC A VDC A 9 VDC B VDC B 0 SLC OUTPUT L L OUTPUT 0 PLC L L Field Device Field Device Field Device Field Device Common 49-I -6

19 Chapter Installing Block I/O Table.D 9-IOBX Output Wiring for Groups and 3 (TRM4) for PLC Family Programmable Controllers Output Assignment Group 3 PLC SLC Output Assignment Group PLC SLC N.C. N.C. 0 Common C Common C Common D Common D Output Output 3 Output Output Output Output 4 Output Output 3 Output Output 5 Output Output 4 Output Output 6 Output Output 5 Output Output 7 Output Output 6 Output Output 8 Output Output 7 Output Output 09 9 Output Output 09 8 Output Output 08 Output Output 08 9 Output Output Output Output 30 Output Output Output Output 3 Output Output Output Output 3 Output Output Output Output 33 Output Output Output Output 34 Output Output Output Output 35 Output Output Output Output 36 Output Output 8 Output Output 37 VDC C VDC C 9 VDC D VDC D 3 SLC L L PLC L L Field Device Field Device Field Device Field Device Common 49-I -7

20 Chapter Installing Block I/O Table.E 9-IOVX Input Wiring for Groups 0 and (TRM) for PLC Family Programmable Controllers Input Assignment Group 0 PLC SLC Input Assignment Group PLC SLC VDC A VDC A 9 VDC B VDC B Input Input 0 Input Input 3 Input Input Input Input 4 Input Input Input Input 5 Input Input 3 Input Input 6 Input Input 4 Input Input 7 Input Input 5 Input Input 8 Input Input 6 Input Input 9 Input Input 7 Input Input Input Input 08 8 Input Input 08 Input Input 09 9 Input Input 09 Input Input 30 Input Input Input Input 3 Input Input Input Input 3 Input Input Input Input 33 Input Input Input Input 34 Input Input Input Input 35 Input Input 8 N.C. N.C. 36 N.C. N.C. 37 N.C. N.C. PLC INPUT 0 SLC INPUT I -8

21 Chapter Installing Block I/O Table.F 9-IOVX Input Wiring for Groups and 3 (TRM) for PLC Family Programmable Controllers Input Assignment Group PLC SLC Input Assignment Group 3 PLC SLC VDC C VDC C 9 VDC D VDC D Input Input 0 Input Input 3 Input Input Input Input 4 Input Input Input Input 5 Input Input 3 Input Input 6 Input Input 4 Input Input 7 Input Input 5 Input Input 8 Input Input 6 Input Input 9 Input Input 7 Input Input Input Input 08 8 Input Input 08 Input Input 09 9 Input Input 09 Input Input 30 Input Input Input Input 3 Input Input Input Input 3 Input Input Input Input 33 Input Input Input Input 34 Input Input Input Input 35 Input Input 8 N.C. N.C. 36 N.C. N.C. 37 N.C. N.C. PLC SLC I -9

22 Chapter Installing Block I/O Table.G 9-IOVX Output Wiring for Groups 0 and (TRM3) for PLC Family Programmable Controllers Output Assignment Group PLC SLC Output Assignment Group 0 PLC SLC N.C. N.C. 0 Common A Common A Common B Common B Output Output 3 Output Output Output Output 4 Output Output 3 Output Output 5 Output Output 4 Output Output 6 Output Output 5 Output Output 7 Output Output 6 Output Output 8 Output Output 7 Output Output 09 9 Output Output 09 8 Output Output 08 Output Output 08 9 Output Output Output Output 30 Output Output Output Output 3 Output Output Output Output 3 Output Output Output Output 33 Output Output Output Output 34 Output Output Output Output 35 Output Output Output Output 36 Output Output 8 Output Output 37 VDC A VDC A 9 VDC B VDC B 0 SLC OUTPUT L L PLC OUTPUT L - L Field Device Field Device Field Device Field Device Common 494-I -

23 Chapter Installing Block I/O Table.H 9-IOVX Output Wiring for Groups and 3 (TRM4) for PLC Family Programmable Controllers Output Assignment Group 3 PLC SLC Output Assignment Group PLC SLC N.C. N.C. 0 Common C Common C Common D Common D Output Output 3 Output Output Output Output 4 Output Output 3 Output Output 5 Output Output 4 Output Output 6 Output Output 5 Output Output 7 Output Output 6 Output Output 8 Output Output 7 Output Output 09 9 Output Output 09 8 Output Output 08 Output Output 08 9 Output Output Output Output 30 Output Output Output Output 3 Output Output Output Output 3 Output Output Output Output 33 Output Output Output Output 34 Output Output Output Output 35 Output Output Output Output 36 Output Output 8 Output Output 37 VDC C VDC C 9 VDC D VDC D 3 SLC L L PLC L - L Field Device Field Device Field Device Field Device Field Device Common 494-I Table.I Wiring Block Designations Connector Designation Description (BLU) Blue wire - RIO (CLR) Clear wire - RIO Remote I/O Connector Shield Shield - RIO Chassis GND Chassis Ground 4VDC RET +4V ground 4VDC +4V dc Input s thru 37 See Tables Output s thru 37 See Tables -

24 Chapter Installing Block I/O Power Supply Requirements An external 4V dc (+/-5%) power supply is required to power the block. Total current required to power the block is equal to 3mA. In addition, the external power supply should have current limiting capabilities. The voltage range must not exceed V dc. Wiring Requirements Wiring cable requirements are shown in Table.J. Table.J Acceptable Wiring Cables for Block I/O Connection Use Cable Type With Remote I/O Link Belden 9463 PLC-, PLC-3, PLC-5 family programmable controllers and SLC controllers Input and Output wiring Up to AWG (mm ) Stranded with 3/64 inch (.mm) insulation All Figure.3 Remote I/O Link Wiring GROUP No. GROUP No. (CLR) Shield (BLU) Chassis GND 4VDC RET 4VDC TERMINATION RESISTOR - 0 OHM -OFF - 8 OHM Connection Clear wire Blue wire Shield wire (BLU) X (CLR) X Shield X 98-I -

25 Chapter Installing Block I/O Remote I/O Link Wiring Blocks must be wired in series as shown in Figure.4. Do not attempt to wire any block in parallel. The number of blocks used depends not only on the user requirements but also on the system used. Figure.4 Series Connection for Block I/O Using PLC-, PLC-3 or PLC-5 Family Programmable Controllers To Programmable Controller or I/O Scanner Module I/O Rack I/O Rack I/O Rack I/O Rack Install terminating resistor on last block. 99-I -

26 Chapter Installing Block I/O Termination Resistor A termination resistor must be used on the last block in the series. A 0 ohm and 8 ohm termination resistors are built into the unit. To select the termination resistor, position the switch to the desired position as shown in Figure.5. Figure.5 Installing the Termination Resistor (CLR) Shield (BLU) Chassis GND 4VDC RET 4VDC TERMINATION RESISTOR - 0 OHM -OFF - 8 OHM Position switch to connect termination resistor across and as follows: 0 ohm - position switch at top; 8 ohm - position switch at bottom; OFF - no resistor - position switch in middle. 930-I Extended Node Capability If this is the last remote I/O adapter on the RIO link in a PLC system, you must use a terminating resistor to terminate both ends of the remote I/O link (scanner end and last block end). The size of the terminator is determined by the system configuration. Older configurations can use a 0 ohm resistor at both ends. With newer devices that can support it, you can use an 8 ohm termination resistor at both ends. The 8 ohm terminators provide extended node capability which allows you to have up to 3 physical devices on the RIO link. (The number of logical racks capable of being addressed by the scanner is not affected.) ATTENTION: Devices that are operating at 30.4K baud must have 8 ohm terminators in place for proper operation. -

27 Chapter Installing Block I/O Compatibility of 7 I/O Products with Extended Node Operation Certain products are not compatible with extended node capabilities obtained with the use of 8 ohm terminators. The following table lists those products that are not compatible. Device Series Scanners -7-SN 7-SD 7-SD 75-SR 75-S4A 75-S4B All All All All All All Adapters - 7-AS All 7-ASB 7-DCM Series A All Miscellaneous - 7-AF All 7-AF When using PLC-3 programmable controllers, you must use a 75-S5 or -SR5 scanner module. Do not use 75-SR, -S4A or -S4B scanner modules. All Fusing 9 high-density block I/O modules (64 and 8 input/output) have internal fusing. Each group of output points is protected by a 5.0A fuse. These fuses protect the user output devices. They do not protect each individual output from overload. It is recommended that individual outputs be fused externally to protect the individual output circuit. Catalog Voltage Maximum Output Rating at: 30 o C 60 o C Maximum Surge Current 9-IOBX 9-IOVX 4V dc 4V dc 3mA per point.4a continuous per point group maximum surge current.0a Afor 5ms pulse per second maximum Consult the factory for fuse recommendations. Summary In this chapter you learned how to physically mount your block I/O, make power wiring connections, how to make the input/output wiring connections to the block, and how to terminate the remote I/O link. -

28 Chapter Installing Block I/O (This page left intentionally blank.) -

29 Chapter 3 Configuring Your Block I/O Chapter Objectives In this chapter you will learn how to configure your block I/O when used with PLC family programmable controllers. This includes the following: setting the configuration switches addressing the block I/O To learn how to configure your block I/O when used with SLC 5 processors, refer to the publication for the 47-SN Remote I/O Scanner Module. Setting the Configuration Switches Each block I/O module has multiple-position switches for setting: transmission (baud) rate - used to set the communication rate chosen for the remote I/O link last state - when last state is enabled, a processor reset will keep the outputs in their present (last) state; when last state is disabled, the outputs will reset processor restart lockout (PRL) - when PRL is enabled (switch 4 on), the programmable controller cannot automatically start up the module s communications if the power has been cycled to either the module or the programmable controller. Press Input and Output pushbuttons simultaneously to reset PRL. last rack - used to identify if the module contains the highest numbered I/O group for the associated rack number I/O group address - used to identify which module group (0-3 or 4-7) the module should assign to its inputs/outputs rack address - used to select the rack address of the module RIO termination resistor - used to connect an internal resistor (8 ohm, 0 ohm, or no resistor) across LINE and on the remote I/O terminals These switches are all accessible on the front or top of the module, as shown in Figure

30 Chapter 3 Configuring Your Block I/O Figure 3. Switch Setting Locations (9-IOBX shown) Configuration Switch Rack Address Switch RACK ADDR POWER ACTIVE M FUSE CONFIGURATION SWITCHES INPUT DISPLAY SELECT OUTPUT 9-IOBX 8 POINT 4V DC DISTRIBUTED I/O MODULE L L Termination Resistor Switch BAUD RATE 57.6K BPS 5.KBPS 30.4KBPS UNUSED PRL GROUP No. 64 4VDC SINK INPUTS 64 4VDC SOURCE OUTPUTS 4 NO OFF YES ON CONFIGURATION SWITCHES OFF OFF ON OFF OFF ON ON ON LAST RACK 5 NO OFF YES ON LAST STATE LATCH RESET NOT USED I/O GROUP 0 to 3 4 to 7 3 OFF ON OFF ON GROUP No. Termination Resistor 0 Ohm Off 8 Ohm 93-I 3-

31 Chapter 3 Configuring Your Block I/O Figure 3. Configuration Switch Settings (PLC designations shown) Rack Address Switch (Refer to Table 3.A) ON RACK ADDR CONFIGURATION SWITCHES L Configuration Switch (Top View of Switch) ON Not Used - set to off I/O Group 0 to 3 4 to 7 LAST RACK NO YES OFF ON OFF ON Last Rack Switch 5 PLC- OFF - When module does not contain the highest numbered I/O group for the associated rack number. ON - When module does contain the highest numbered I/O group for the associated rack number. PLC-3 This switch must always be set to OFF. PLC-5 This switch not used. PRL 4 Disabled OFF Enabled ON BAUD RATE 57.6kbps 5.kbps 30.4kbps Unused LAST STATE Latch Reset 3 OFF ON Last State Switch 3 CAUTION: Set switch 3 to the ON position to deenergize outputs wired to this module when a fault is detected. If switch 3 is set to the OFF position, outputs connected to this module remain in their last state when a fault occurs and machine motion may continue after fault detection. Processor Restart Lockout (PRL) Switch 4 - When PRL is enabled (on), the programmable controller cannot automatically start up the module s communications if the power has been cycled to either the module or the programmable controller OFF ON OFF ON OFF OFF ON ON 93-I 3-3

32 Chapter 3 Configuring Your Block I/O 47-SN Rack 7-SN Rack Table 3.A Rack Address Switch Settings PLC- Rack PLC-5 Rack PLC-5/50 Rack PLC-3 Rack Address Switch Position Rack Rack 0 Rack Rack Not Valid Rack 0 Rack Rack Rack Rack Rack Rack Rack Rack Rack 3 Rack 3 Rack Rack Rack Rack 3 Rack 4 Rack 4 Rack 3 Rack 3 Rack Rack 5 Rack 5 Rack 4 Rack 4 Rack Rack 6 Rack 6 Rack 5 Rack 5 Rack Rack 7 Rack 7 Rack 6 Rack 6 Rack Rack 7 Rack 7 Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack 0 0 Rack 0 Rack 0 Rack Rack Rack Rack Rack Rack Rack Rack 3 Rack 3 Rack Rack 4 Rack 4 Rack Rack 5 Rack 5 Rack Rack 6 Rack 6 Rack Rack 7 Rack 7 Rack Rack 30 Rack Rack 3 Rack Rack 3 Rack Rack 33 Rack Rack 34 Rack Rack 35 Rack Rack 36 Rack Rack 37 Rack 37 0 Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack 57 0 Rack Rack Rack

33 Chapter 3 Configuring Your Block I/O 47-SN Rack 7-SN Rack PLC- Rack PLC-5 Rack PLC-5/50 Rack PLC-3 Rack Rack Address Switch Position Rack address 77 is an illegal configuration. PLC-5/ processors can scan rack. PLC-5/ and PLC-5/0 processors can scan racks -. PLC-5/5 and PLC-5/30 processors can scan racks -. PLC-5/40 and PLC-5/40L processors can scan racks -. PLC-5/60 and PLC-5/60L processors can scan racks -7. PLC-5/50 processors can scan racks -37. PLC-3 processors can scan racks -76. Rack Rack Rack Rack Rack 67 0 Rack Rack Rack Rack 73 0 Rack Rack 75 0 Rack 76 0 Not Valid Each block uses 4 words of output image table memory and 4 words of input image table memory. Each block occupies / rack of data table, with blocks comprising logical rack. Image table usage for one assigned rack number is shown in Figure 3.3. An example of image table usage is shown in Figure 3.4. Figure 3.3 I/O Image Table for One Assigned Rack Input Image 7 Block Inputs Block Inputs IOBX 9-IOBX or 9-IOVX per rack st / rack = module group 0-3 nd / rack = module group 4-7 Rack 9-IOVX Block Outputs Block Outputs Output Image I 3-5

34 Chapter 3 Configuring Your Block I/O Figure 3.4 Input Table Usage Example for One Starting I/O Group with 9-IOBX and -IOVX Example Type of I/O = Input 0 = Output I/O Rack I/O Bit I/O Group Starting I/O Group 0 (Configuration Switch 6 = OFF) Input Image Output Image Starting I/O Group 4 (Configuration Switch 6 = ON) Input Image Output Image 934-I 3-6

35 Chapter 3 Configuring Your Block I/O Table 3.B 9-IOBX Input Addressing for Groups 0 and (TRM) Input Assignment Group 0 Program Address Input Assignment Group Common A 9 Common B Program Address Input XY 0 Input X(Y+) 3 Input XY Input X(Y+) 4 Input XY Input X(Y+) INPUT 5 Input XY 3 Input X(Y+) 6 Input XY 4 Input X(Y+) 7 Input XY 5 Input X(Y+) 8 Input XY 6 Input X(Y+) 9 Input XY 7 Input X(Y+) Input XY 8 Input X(Y+) Input XY 9 Input X(Y+) Input XY 30 Input X(Y+) Input XY 3 Input X(Y+) Input XY 3 Input X(Y+) Input XY 33 Input X(Y+) 0 Input XY 34 Input X(Y+) Input XY 35 Input X(Y+) 8 N.C. 36 N.C. 37 N.C. Where: X = Rack (,, 3...) Y = Module Group (0-7) I 3-7

36 Chapter 3 Configuring Your Block I/O Table 3.C 9-IOBX Input Addressing for Groups and 3 (TRM) Input Assignment Group Program Address Input Assignment Group 3 Common C 9 Common D Program Address Input X(Y+) 0 Input X(Y+3) 3 Input X(Y+) Input X(Y+3) 4 Input X(Y+) Input X(Y+3) 5 Input X(Y+) 3 Input X(Y+3) 6 Input X(Y+) 4 Input X(Y+3) 7 Input X(Y+) 5 Input X(Y+3) 8 Input X(Y+) 6 Input X(Y+3) 9 Input X(Y+) 7 Input X(Y+3) Input X(Y+) 8 Input X(Y+3) Input X(Y+) 9 Input X(Y+3) Input X(Y+) 30 Input X(Y+3) Input X(Y+) 3 Input X(Y+3) Input X(Y+) 3 Input X(Y+3) Input X(Y+) 33 Input X(Y+3) Input X(Y+) 34 Input X(Y+3) Input X(Y+) 35 Input X(Y+3) 8 N.C. 36 N.C. Where: X = Rack (,, 3...) Y = Module Group (0-7) 37 N.C. GROUP No I 3-8

37 Chapter 3 Configuring Your Block I/O Table 3.D 9-IOBX Output Addressing for Groups 0 and (TRM3) Output Assignment Group Program Address Output Assignment Group 0 N.C. 0 Common A Program Address Common B Output 0XY 3 Output 0X(Y+) Output 0XY 4 Output 0X(Y+) 3 Output 0XY 5 Output 0X(Y+) 4 Output 0XY 6 Output 0X(Y+) 5 Output 0XY 7 Output 0X(Y+) 6 Output 0XY 8 Output 0X(Y+) 7 Output 0XY 9 Output 0X(Y+) 8 Output 0XY Output 0X(Y+) 9 Output 0XY Output 0X(Y+) 30 Output 0XY Output 0X(Y+) 3 Output 0XY Output 0X(Y+) 3 Output 0XY Output 0X(Y+) 33 Output 0XY Output 0X(Y+) 34 Output 0XY Output 0X(Y+) 35 Output 0XY Output 0X(Y+) 36 Output 0XY 8 Output 0X(Y+) 37 VDC A 9 VDC B Where: X = Rack (,, 3...) Y = Module Group (0-7) OUTPUT 0 L L I 3-9

38 Chapter 3 Configuring Your Block I/O Table 3.E 9-IOBX Output Addressing for Groups and 3 (TRM4) Output Assignment Group 3 Program Address Output Assignment Group Program Address N.C. 0 Common C Common D Output 0X(Y+) 3 Output 0X(Y+3) Output 0X(Y+) 4 Output 0X(Y+3) 3 Output 0X(Y+) 5 Output 0X(Y+3) 4 Output 0X(Y+) 6 Output 0X(Y+3) 5 Output 0X(Y+) 7 Output 0X(Y+3) 6 Output 0X(Y+) 8 Output 0X(Y+3) 7 Output 0X(Y+) 9 Output 0X(Y+3) 8 Output 0X(Y+) Output 0X(Y+3) 9 Output 0X(Y+) Output 0X(Y+3) 30 Output 0X(Y+) Output 0X(Y+3) 3 Output 0X(Y+) Output 0X(Y+3) 3 Output 0X(Y+) Output 0X(Y+3) 33 Output 0X(Y+) Output 0X(Y+3) 34 Output 0X(Y+) Output 0X(Y+3) 35 Output 0X(Y+) Output 0X(Y+3) 36 Output 0X(Y+) 8 Output 0X(Y+3) 37 VDC C 9 VDC D Where: X = Rack (,, 3...) Y = Module Group (0-7) GROUP No. 3 L L 938-I 3-

39 Chapter 3 Configuring Your Block I/O Table 3.F 9-IOVX Input Addressing for Groups 0 and (TRM) Input Assignment Group 0 Program Address VDC A 9 VDC B Input Assignment Group Program Address Input XY 0 Input X(Y+) 3 Input XY Input X(Y+) 4 Input XY Input X(Y+) 5 Input XY 3 Input X(Y+) 6 Input XY 4 Input X(Y+) 7 Input XY 5 Input X(Y+) 8 Input XY 6 Input X(Y+) 9 Input XY 7 Input X(Y+) Input XY 8 Input X(Y+) INPUT 0 Input XY 9 Input X(Y+) Input XY 30 Input X(Y+) Input XY 3 Input X(Y+) Input XY 3 Input X(Y+) Input XY 33 Input X(Y+) Input XY 34 Input X(Y+) Input XY 35 Input X(Y+) 8 N.C. 36 N.C. Where: X = Rack (,, 3...) Y = Module Group (0-7) 37 N.C I 3-

40 Chapter 3 Configuring Your Block I/O Table 3.G 9-IOVX Input Addressing for Groups and 3 (TRM) Input Assignment Group Program Address Input Assignment Group 3 Program Address VDC C 9 VDC D Input X(Y+) 0 Input X(Y+3) 3 Input X(Y+) Input X(Y+3) 4 Input X(Y+) Input X(Y+3) 5 Input X(Y+) 3 Input X(Y+3) 6 Input X(Y+) 4 Input X(Y+3) 7 Input X(Y+) 5 Input X(Y+3) 8 Input X(Y+) 6 Input X(Y+3) 9 Input X(Y+) 7 Input X(Y+3) Input X(Y+) 8 Input X(Y+3) Input X(Y+) 9 Input X(Y+3) Input X(Y+) 30 Input X(Y+3) Input X(Y+) 3 Input X(Y+3) Input X(Y+) 3 Input X(Y+3) Input X(Y+) 33 Input X(Y+3) Input X(Y+) 34 Input X(Y+3) Input X(Y+) 35 Input X(Y+3) 8 N.C. 36 N.C. Where: X = Rack (,, 3...) Y = Module Group (0-7) 37 N.C. GROUP No I 3-

41 Chapter 3 Configuring Your Block I/O Table 3.H 9-IOVX Output Addressing for Groups 0 and (TRM3) Output Assignment Group Program Address Output Assignment Group 0 N.C. 0 Common A Program Address Common B Output 0XY 3 Output 0X(Y+) Output 0XY 4 Output 0X(Y+) 3 Output 0XY 5 Output 0X(Y+) 4 Output 0XY 6 Output 0X(Y+) 5 Output 0XY 7 Output 0X(Y+) 6 Output 0XY 8 Output 0X(Y+) 7 Output 0XY 9 Output 0X(Y+) 8 Output 0XY Output 0X(Y+) 9 Output 0XY Output 0X(Y+) 30 Output 0XY Output 0X(Y+) 3 Output 0XY Output 0X(Y+) 3 Output 0XY Output 0X(Y+) 33 Output 0XY Output 0X(Y+) 34 Output 0XY Output 0X(Y+) 35 Output 0XY Output 0X(Y+) 36 Output 0XY 8 Output 0X(Y+) 37 VDC A 9 VDC B Where: X = Rack (,, 3...) Y = Module Group (0-7) OUTPUT 0 L - L I 3-

42 Chapter 3 Configuring Your Block I/O Table 3.I 9-IOVX Output Addressing for Groups and 3 (TRM4) Output Assignment Group 3 Program Address Output Assignment Group N.C. 0 Common C Program Address Common D Output 0X(Y+) 3 Output 0X(Y+3) Output 0X(Y+) 4 Output 0X(Y+3) 3 Output 0X(Y+) 5 Output 0X(Y+3) 4 Output 0X(Y+) 6 Output 0X(Y+3) 5 Output 0X(Y+) 7 Output 0X(Y+3) 6 Output 0X(Y+) 8 Output 0X(Y+3) 7 Output 0X(Y+) 9 Output 0X(Y+3) 8 Output 0X(Y+) Output 0X(Y+3) 9 Output 0X(Y+) Output 0X(Y+3) 30 Output 0X(Y+) Output 0X(Y+3) 3 Output 0X(Y+) Output 0X(Y+3) 3 Output 0X(Y+) Output 0X(Y+3) 33 Output 0X(Y+) Output 0X(Y+3) 34 Output 0X(Y+) Output 0X(Y+3) 35 Output 0X(Y+) Output 0X(Y+3) 36 Output 0X(Y+) 8 Output 0X(Y+3) 37 VDC C 9 VDC D Where: X = Rack (,, 3...) Y = Module Group (0-7) GROUP No. 3 L - L I Summary In this chapter you learned how to set the configuration switches and the rack addresses for input and output terminals. 3-

43 Chapter 4 Troubleshooting Chapter Objectives In this chapter you will learn about the indicators on the block I/O module, and how to use them to troubleshoot the unit. Indicators Each block I/O module has indicators (Figure 4.) which provide indication of specific functions. Each module has the following: Status Indicators - Indicators are provided for power, active, communication and fuse blown indications. An LED array provides input/output status. POWER Indicator - - green -on continuously if customer voltage is present; off if power is not applied or there is an internal power supply problem. ACTIVE Indicator - - red if the CPU is not running; green if the CPU is operating correctly. M Indicator - indicates the status of the RIO link. - green when communication is correctly established; off when communication is not established; flashing when programmable controller is in PROG mode. FUSE Indicator - indicates the status of the 4 output fuses. - off if all 4 fuses are intact; red if any one of the fuses opens. The I/O status array is an 8 by 8 array of 64 LEDs capable of displaying the status of 3 inputs and 3 outputs at any one time. Pushbuttons are provided to toggle the display between the lower 3 bits and the upper 3 bits. Refer to Table 4.A below for status indications reported by the indicators. 4-

44 Chapter 4 Troubleshooting Figure 4. Indicators on the 9-IOBX and -IOVX Block I/O Modules (PLC labels shown) POWER ACTIVE M FUSE RACK ADDR POWER ACTIVE M FUSE CONFIGURATION SWITCHES INPUT DISPLAY SELECT OUTPUT INPUT 0: :3 LED GROUP 0: :3 OUTPUT DISPLAY SELECT indicates LED off - lower 3 bits are displayed indicates LED on - upper 3 bits are displayed INPUT OUTPUT Press Input and Output pushbuttons simultaneously to reset Processor Restart Lockout. 943-I 4-

45 Chapter 4 Troubleshooting Table 4.A Troubleshooting Chart Indication Probable Cause Corrective Action POWER (green) Green I/O status on/off Off Normal indication No 4V dc power connected, or hardware fault. None required Check 4V dc power to block Solid green Normal indication - module is communicating with the programmable controller None required M (green) Off Flashing green No communication with adapter, scanner etc. Reset command (or output disable bit for SLC) has been issued by processor, scanner or adapter. SLC or programmable controller not in run mode. Check that power LED is on. Make sure that proper number of blocks are configured. Check program. Correct as necessary. Place in run mode. ACTIVE (green/red) Green Red Normal indication Internal CPU fault None Return module for repair FUSE (red) Red Off One or more fuses are open Normal indication Replace blown fuse None required Replacing a Fuse The block I/O module has one fuse for each group of outputs. To replace a fuse, proceed as follows.. Remove power to the block I/O module. ATTENTION: Remove power to the block I/O module before attempting to replace the fuse. Failure to remove power from the block I/O module could cause injury or equipment damage due to possible unexpected operation. Failure to remove power from the module could cause module damage, degradation of performance or injury.. Remove the 5 screws securing the cover to the block I/O module. 3. Locate and remove the blown fuse. 4-3

46 Chapter 4 Troubleshooting 4. Replace the blown fuse with a 5.0A slow blow fuse. 5. Reinstall cover and secure with 5 screws removed in step. 6. Reapply power to the module. Summary In this chapter you learned what the LED indicators represent, and how to interpret them. 4-4

47 Appendix A Specifications General Specifications External power Power Dissipation Thermal Dissipation Remote I/O Isolation Interconnect cable length PLC or SLC Range: 8 to 6.4V dc 4V dc; initial surge.0a for msec 5. Watts (maximum);. Watts (typical) 86. BTU/hr (maximum); 5.9 BTU/hr (typical) 850V dc (transformer) for second RIO: 57.6K,0 cable feet 5.K 5,0 cable feet 30.4K,5 cable feet Cable requirements RIO Belden 9463 Dimensions Conductors Wire Size Category Inches: 6.W x.0h x.7d Millimeters: 6.W x 334.0H x 43.7D gauge (mm ) stranded (maximum) 3/64 inch (.mm) insulation (maximum) Environmental Conditions Operating Temperature Storage Temperature Relative Humidity Operating Non-operating 3 to 0 o F (0 to 60 o C) 40 to 85 o F ( 40 to 85 o C) 5 to 95% noncondensing 5 to 80% noncondensing Refer to publication 70 4., Programmable Controller Wiring and Grounding Guidelines Input Specifications of Inputs 64 (4 groups of ) Input type On-state voltage range On state input current Off state voltage Off state current Turn On time Turn Off time Input to System Isolation Group to Group Isolation 9 IOBX Sinking; 9 IOVX Sourcing.0 to 6.4V dc.56ma (minimum) 7.0V dc (maximum).0ma dc (maximum) msec (maximum) (+4msec) msec (maximum) (+4msec) V ac (opto) for second V ac (air gap) for second A-

48 Appendix A Specifications Output Specifications of outputs 64 (4 groups of ) Output type Maximum output range Maximum on state voltage drop Maximum on state current Minimum on state current Output Current per output group Surge Current Off state voltage Off state leakage current Turn on time Turn off time Fuse Type Output to System Isolation Group to Group Isolation 9 IOBX Source; 9 IOVX Sink 8.0 to 6.4V 3mA resistive.5v dc 5 o C at rated current 3mA per point (maximum) 5mA (minimum).4a maximum continuous.0a for 5ms (maximum), pulse per second max. 6.4V dc (maximum) 0.5mA (maximum).0ms (maximum).0ms (maximum) 5.0A slow blow (5 X 0mm size) one per group V ac (opto) for second V ac (air gap) for second A-

49 Index B baud rate, 3-, 3-3 C compatibility, - extended node numbers, - configuration switches, 3-3 setting, 3- connection, in a PLC system, -6 connections, wiring, -3 D description, - IOBX, -3 IOVX, -4 dimensions, mounting, - E extended node capability, - F fuses, removing and replacing, 4-3 G group address, 3-, 3-3 inputs, sinking, -4 installation, termination resistor, - L last rack, 3-, 3-3 LED indicators, 4- M mounting, clearance, -3 O output, sinking, -5 output terminal addressing IOBX groups 0 and, 3-9 IOBX groups and 3, 3- IOVX groups 0 and, 3- IOVX groups and 3, 3- outputs, sourcing, -4 P power requirements, - processor restart lockout, 3-, 4- R rack address, 3- I image table usage, 3-5 indicator active, -3 communication, -3 fuse blown, -3 power, -3 indicators I/O status array, -3 locations, 4- status, -3 status reported, 4- input, sourcing, -5 input terminal addressing IOBX groups 0 and, 3-7 IOBX groups and 3, 3-8 IOVX groups 0 and, 3- IOVX groups and 3, 3- S sinking inputs, -3 description, -4 sourcing outputs, -3 description, -4 specifications, A- switch configuration, -3 rack address, -3 termination resistor, -3 switch assemblies, -3 switch settings, 3-3 T termination resistor installation, - internal, 3- troubleshooting chart, 4-3 I-

50 Index W wiring block designations, - cable requirements, - IOBX input terminals 0 and, -4 and 3, -5 IOBX output terminals 0 and, -6 and 3, -7 IOVX input terminals 0 and, -8 and 3, -9 IOVX output terminals 0 and, - and 3, - remote I/O link, - wiring connections, -3 wiring terminals, Allen Bradley Company, Inc. PLC is a registered trademark of Allen Bradley Company, Inc. PLC is a registered trademark of Allen Bradley Company, Inc. PLC 3 is a registered trademark of Allen Bradley Company, Inc. PLC 5 is a registered trademark of Allen Bradley Company, Inc. PLC 5/50 is a registered trademark of Allen Bradley Company, Inc. SLC is a registered trademark of Allen Bradley Company, Inc. I-

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52 Allen-Bradley, a Rockwell Automation Business, has been helping its customers improve productivity and quality for more than 90 years. We design, manufacture and support a broad range of automation products worldwide. They include logic processors, power and motion control devices, operator interfaces, sensors and a variety of software. Rockwell is one of the worlds leading technology companies. Worldwide representation. Argentina Australia Austria Bahrain Belgium Brazil Bulgaria Canada Chile China, PRC Colombia Costa Rica Croatia Cyprus Czech Republic Denmark Ecuador Egypt El Salvador Finland France Germany Greece Guatemala Honduras Hong Kong Hungary Iceland India Indonesia Ireland Israel Italy Jamaica Japan Jordan Korea Kuwait Lebanon Malaysia Mexico Netherlands New Zealand Norway Pakistan Peru Philippines Poland Portugal Puerto Rico Qatar Romania Russia CIS Saudi Arabia Singapore Slovakia Slovenia South Africa, Republic Spain Sweden Switzerland Taiwan Thailand Turkey United Arab Emirates United Kingdom United States Uruguay Venezuela Yugoslavia Allen-Bradley Headquarters, South Second Street, Milwaukee, WI 53 USA, Tel: () Fax: () Publication February 995 Supersedes publication August 993 P/N 955 Copyright 995 Allen-Bradley Co. Inc. Printed in USA