Modicon M238 Hardware Guide

EIO0000000016 10/2010
M238 Logic Controller

Hardware Guide
10/2010
EIO0000000016.04
www.schneider-electric.com
The information provided in this documentation contains general descriptions and/or
technical characteristics of the performance of the products contained herein. This
documentation is not intended as a substitute for and is not to be used for
determining suitability or reliability of these products for specific user applications. It
is the duty of any such user or integrator to perform the appropriate and complete
risk analysis, evaluation and testing of the products with respect to the relevant
specific application or use thereof. Neither Schneider Electric nor any of its affiliates
or subsidiaries shall be responsible or liable for misuse of the information contained
herein. If you have any suggestions for improvements or amendments or have found
errors in this publication, please notify us.
No part of this document may be reproduced in any form or by any means, electronic
or mechanical, including photocopying, without express written permission of
Schneider Electric.
All pertinent state, regional, and local safety regulations must be observed when
installing and using this product. For reasons of safety and to help ensure
compliance with documented system data, only the manufacturer should perform
repairs to components.
When devices are used for applications with technical safety requirements, the
relevant instructions must be followed.
Failure to use Schneider Electric software or approved software with our hardware
products may result in injury, harm, or improper operating results.
Failure to observe this information can result in injury or equipment damage.
© 2010 Schneider Electric. All rights reserved.
2 EIO0000000016 10/2010
Table of Contents
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
About the Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Chapter 1 About the Modicon M238 Logic Controller . . . . . . . . . . 11
Modicon M238 Logic Controller Devices Overview. . . . . . . . . . . . . . . . . . 12
Communication Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fast Input/Output Functions and Availability . . . . . . . . . . . . . . . . . . . . . . . 16
Programming Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Physical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Additional Modules and Maximum Hardware Configuration . . . . . . . . . . . 21
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Chapter 2 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Installation and Maintenance Requirements . . . . . . . . . . . . . . . . . . . . . . . 30
First Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Internal and External Backup Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Mounting Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Minimum Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
The DIN Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Mounting on a DIN Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Mounting on a Metallic Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Chapter 3 Wiring and Electrical Specifications. . . . . . . . . . . . . . . . 51
3.1 AC/DC Power Supply Wiring and Specifications. . . . . . . . . . . . . . . . . . . . 52
Wiring Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
DC Power Supply Wiring and Specifications. . . . . . . . . . . . . . . . . . . . . . . 57
AC Power Supply Wiring and Specifications. . . . . . . . . . . . . . . . . . . . . . . 60
Grounding Shielded Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.2 Input Wiring Specifications for AC/DC Controllers . . . . . . . . . . . . . . . . . . 65
Regular Input Wiring Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Fast Input Wiring Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.3 Output Wiring Specifications for DC Controllers . . . . . . . . . . . . . . . . . . . . 72
Regular Output Wiring Specifications for DC Controllers . . . . . . . . . . . . . 73
Fast Output Wiring and Specifications for DC Controller . . . . . . . . . . . . . 77
EIO0000000016 10/2010 3
3.4 Output Wiring Specifications for AC Controllers . . . . . . . . . . . . . . . . . . . 82
Relay Output Wiring Specifications for AC Controllers . . . . . . . . . . . . . . 83
Transistor Output Wiring Specifications for AC Controllers . . . . . . . . . . . 87
Chapter 4 Connecting the Modicon M238 Logic Controller to a PC 91
Connecting the Controller to a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Chapter 5 Serial Line Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Serial Line Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Chapter 6 CANopen Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
CANopen Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Chapter 7 Controller Diagnostic and I/O Management . . . . . . . . . . 105
System Diagnostic Using LED Display . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Input Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Output Management for DC Controllers . . . . . . . . . . . . . . . . . . . . . . . . . 113
Output Management for AC Controllers. . . . . . . . . . . . . . . . . . . . . . . . . . 118
Chapter 8 Fast Inputs/Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
8.1 HSC (High Speed Counter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
HSC Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
HSC I/O Mapping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
8.2 PTO (Pulse Train Output) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
PTO Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
PTO I/O Mapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
8.3 PWM (Pulse Width Modulation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
PWM Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
PWM I/O Mapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
8.4 FG (Frequency Generator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Frequency Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
FG I/O Mapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Chapter 9 Wiring Diagram Examples. . . . . . . . . . . . . . . . . . . . . . . . . 145
Wiring Diagram Examples for 1 Encoder on Fast Inputs . . . . . . . . . . . . . 146
Wiring Diagram Examples for 2 Encoders on Fast Inputs . . . . . . . . . . . . 148
Wiring Diagram Examples on Regular Inputs . . . . . . . . . . . . . . . . . . . . . 150
Wiring Diagram Examples for PTO/PWM Actuator on Fast Outputs . . . . 151
Wiring the Modicon M238 Logic Controller to the LEXIUM 05 via the
Universal Signal Interface Converter (USIC) . . . . . . . . . . . . . . . . . . . . . . 152
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
4 EIO0000000016 10/2010
Safety Information
§
Important Information
NOTICE
Read these instructions carefully, and look at the equipment to become familiar with
the device before trying to install, operate, or maintain it. The following special
messages may appear throughout this documentation or on the equipment to warn
of potential hazards or to call attention to information that clarifies or simplifies a
procedure.
EIO0000000016 10/2010 5
PLEASE NOTE
Electrical equipment should be installed, operated, serviced, and maintained only by
qualified personnel. No responsibility is assumed by Schneider Electric for any
consequences arising out of the use of this material.
A qualified person is one who has skills and knowledge related to the construction
and operation of electrical equipment and the installation, and has received safety
training to recognize and avoid the hazards involved.
6 EIO0000000016 10/2010
About the Book
At a Glance
Document Scope
Use this document to:
z Install and operate your Modicon M238 Logic Controller.
z Connect the Modicon M238 Logic Controller to a programming device equipped
with SoMachine software.
z Interface the Modicon M238 Logic Controller with I/O modules, HMI and other
devices.
z Familiarize yourself with the Modicon M238 Logic Controller features.
NOTE: Read and understand this document and all related documents (see page 8)
before installing, operating, or maintaining your Modicon M238 Logic Controller.
The new Modicon M238 Logic Controller users should read through the entire
document to understand all features.
Validity Note
This document has been updated with the release of SoMachine V2.0.
The technical characteristics of the device(s) described in this manual also appear
online. To access this information online:
Step Action
1 Go to www.schneider-electric.com
2 In the Search box on the home page, type a model number. Do not type any
blank spaces in the model number. To get information on a grouping similar
modules, you can use the characters **; do not use dots or xx's.
3 Under All, click Products →Product Datasheets and select the model number
that interests you.
4 To save or print a data sheet as a .pdf file, click Export to PDF.
EIO0000000016 10/2010 7
The characteristics presented in this manual should be the same as those that
appear online. In line with our policy of constant improvement we may revise content
over time to improve clarity and accuracy. In the event that you see a difference
between the manual and online information, use the online information as your
reference.
Related Documents
Title of Documentation Reference Number

M238 Logic Controller Programming Guide EIO0000000384 (ENG);
EIO0000000385 (FRE);
EIO0000000386 (GER);
EIO0000000387 (ITA);
EIO0000000388 (SPA);
EIO0000000389 (CHS)
Modicon TM2 Digital I/O Modules Hardware Guide EIO0000000028 (ENG);
EIO0000000029 (FRE);
EIO0000000030 (GER);
EIO0000000031 (SPA);
EIO0000000032 (ITA);
EIO0000000033 (CHS)
Modicon TM2 Analog I/O Modules Hardware Guide EIO0000000034 (ENG);
EIO0000000035 (FRE);
EIO0000000036 (GER);
EIO0000000037 (ITA);
EIO0000000038 (SPA);
EIO0000000039 (CHS)
Modicon TM2 High Speed Counter Modules Hardware EIO0000000022 (ENG);
Guide EIO0000000023 (FRE);
EIO0000000024 (GER);
EIO0000000025 (SPA);
EIO0000000026 (ITA);
EIO0000000027 (CHS)
Modicon TWDNOI10M3 AS-Interface Master Module EIO0000000608 (ENG);
Hardware Guide EIO0000000609 (FRE);
EIO0000000610 (GER);
EIO0000000611 (SPA);
EIO0000000612 (ITA);
EIO0000000613 (CHS)
8 EIO0000000016 10/2010
499TWD01100 Gateway for M238 Hardware Guide EIO0000000414 (ENG);
EIO0000000415 (FRE);
EIO0000000416 (GER);
EIO0000000417 (SPA);
EIO0000000418 (ITA);
EIO0000000419 (CHS)
XBTZGCCAN, XBTZGCCANS0 Modules-Hardware Guide AAV87521
XBTZGCANM, XBTZGCANMS0 Modules-Hardware Guide BBV4422600
You can download these technical publications and other technical information from
our website at www.schneider-electric.com.
Product Related Information
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION OR ARC FLASH
z Disconnect all power from all equipment including connected devices prior to
removing any covers or doors, or installing or removing any accessories,
hardware, cables, or wires except under the specific conditions specified in the
appropriate hardware guide for this equipment.
z Always use a properly rated voltage sensing device to confirm the power is off
where and when indicated.
z Replace and secure all covers, accessories, hardware, cables, and wires and
confirm that a proper ground connection exists before applying power to the
unit.
z Use only the specified voltage when operating this equipment and any
associated products.
Failure to follow these instructions will result in death or serious injury.
This equipment has been designed to operate outside of any hazardous location.
Only install this equipment in zones known to be free of a hazardous atmosphere.
DANGER
EXPLOSION HAZARD
This equipment is suitable for use in non-hazardous locations only.
EIO0000000016 10/2010 9
WARNING
LOSS OF CONTROL
z The designer of any control scheme must consider the potential failure modes
of control paths and, for certain critical control functions, provide a means to
achieve a safe state during and after a path failure. Examples of critical control
functions are emergency stop and overtravel stop, power outage and restart.
z Separate or redundant control paths must be provided for critical control
functions.
z System control paths may include communication links. Consideration must be
given to the implications of unanticipated transmission delays or failures of the
link.
z Observe all accident prevention regulations and local safety guidelines.1
z Each implementation of this equipment must be individually and thoroughly
tested for proper operation before being placed into service.
Failure to follow these instructions can result in death, serious injury, or
equipment damage.
1 For additional information, refer to NEMA ICS 1.1 (latest edition), "Safety
Guidelines for the Application, Installation, and Maintenance of Solid State Control"
and to NEMA ICS 7.1 (latest edition), "Safety Standards for Construction and Guide
for Selection, Installation and Operation of Adjustable-Speed Drive Systems" or their
equivalent governing your particular location.
WARNING
UNINTENDED EQUIPMENT OPERATION
z Only use software approved by Schneider Electric for use with this equipment.
z Update your application program every time you change the physical hardware
configuration.
equipment damage.
User Comments
We welcome your comments about this document. You can reach us by e-mail at
techcomm@schneider-electric.com.
10 EIO0000000016 10/2010
M238 - About the Modicon M238 Logic Controller
EIO0000000016 10/2010
About the Modicon M238 Logic

Controller
1
Introduction
This chapter provides an overview of the Modicon M238 Logic Controller.
What's in this Chapter?

This chapter contains the following topics:
Topic Page
Modicon M238 Logic Controller Devices Overview 12
Communication Features 14
Fast Input/Output Functions and Availability 16
Programming Software 18
Physical Description 19
Additional Modules and Maximum Hardware Configuration 21
Accessories 23
EIO0000000016 10/2010 11
Modicon M238 Logic Controller Devices Overview
Overview
The Schneider Electric Modicon M238 Logic Controller has a variety of powerful
features. This controller can service a wide range of applications.
Key Features
The Modicon M238 Logic Controller is supported and programmed with the
SoMachine Programming Software, which provides the following IEC61131-3
programming languages:
z IL: Instruction List
z ST: Structured Text
z FBD: Function Block Diagram
z SFC: Sequential Function Chart
z LD: Ladder Diagram
z CFC: Continuous Function Chart
The Modicon M238 Logic Controller can manage up to 7 tasks (1 MAST task and up
to 6 other tasks).
The power supply of Modicon M238 Logic Controller is either:
z 24 Vdc
z 100...240 Vac
The Modicon M238 Logic Controller with DC power supply includes the following
features:
z 14 digital inputs, including 8 fast inputs
z 10 digital outputs, including 4 fast outputs
The Modicon M238 Logic Controller with AC power supply includes the following
features:
z 14 digital inputs, including 8 fast inputs
z 10 digital outputs, including 6 relay outputs
12 EIO0000000016 10/2010
Modicon M238 Logic Controller Range

The following table describes the M238 range (see page ) and features:
Reference Power Supply Serial Ports CANopen Digital Digital Memory

Master Inputs Outputs size
M238 DC Range
TM238LFDC24DT•••• SL1: 4 transistor 2 MB
24 Vdc RS232/RS485 Yes 8 fast fast
SL2: RS485 inputs(1) outputs(2)
TM238LDD24DT SL1: + + 1 MB
RS232/RS485 6 regular 6 transistor
24 Vdc No
inputs regular
outputs
M238 AC Range
TM238LFAC24DR•••• SL1: 8 fast 4 transistor 2 MB
100...240 Vac RS232/RS485 Yes inputs(1) outputs
SL2: RS485 + +
TM238LDA24DR SL1: 6 regular 6 relay 1 MB
100...240 Vac No outputs
RS232/RS485 inputs
(1) The fast inputs can be used either as regular inputs or as fast inputs for counting
or event functions.
(2) The fast outputs can be used either as regular outputs or as fast outputs for PTO
(Pulse Train Output), HSC (High Speed Counter), PWM (Pulse Width Modulation),
or FG (Frequency Generator) functions.
EIO0000000016 10/2010 13
Communication Features
Port SL1
On TM238LFDC24DT•• and TM238LFAC24DR••, the first serial line connector
supports RS232- and RS485-based communications:
z supports the ASCII protocol for communication with devices such as modems,
printers, and barcode readers.
z supports the SoMachine protocol.
z can act as either master or slave on a Modbus network.
z does not support the Ethernet/Modbus gateway 499TWD01100.
On TM238LDD24DT and TM238LDA24DR, the serial line connector supports

RS232- and RS485-based communications:
z provides 5 Vdc power supply on the serial line, for HMI connection.
z supports the Ethernet/Modbus gateway 499TWD01100.
For more information, refer to serial line connection. (see page 97)
Port SL2
On TM238LFDC24DT•• and TM238LFAC24DR••, the second serial line connector
supports RS485-based communications:
z provides 5 Vdc power on the serial line, which makes it the preferred port for HMI
connections.
z supports the Ethernet/Modbus gateway 499TWD01100.
For more information, refer to serial line connection. (see page 97)
14 EIO0000000016 10/2010
Port CANopen
On TM238LFDC24DT•• and TM238LFAC24DR••, the CANopen Master can
manage:
z digital and analog input/output modules (DS401)
z motor drives (DS402)
z control devices (DSP403)
z encoders (DS406)
z closed loop controllers (DSP404)
z controllers (DS405)
z Radio Frequency Identification Devices (RFID)
z third-party devices such as standard slaves
For more information, refer to CANopen connection. (see page 101)
EIO0000000016 10/2010 15
Fast Input/Output Functions and Availability
Fast Input/Output Functions

In accordance with the availability table (below), the Modicon M238 Logic Controller
can provide the following high-speed input and pulse output features that motion
control applications require:
z HSC (High Speed Counter) allows rapid sampling of sensors, encoders,
switches, etc.
z PTO (Pulse Train Output) facilitates the generation of pulses that are sent to
stepper motor and servo drives. This function implements digital technology for
precise positioning tasks.
z PWM (Pulse Width Modulation) allows your controller to output a wave signal with
a programmable frequency and a variable duty cycle resulting in the variation of
the average value of the waveform.
z FG (Frequency Generator) allows your controller to output a square wave signal
with a programmable frequency and a duty cycle equal to 50%.
Availability Table
This table shows the available fast I/O functions:
Reference Power Supply HSC PTO PWM FG

DC Reference
TM238LFDC24DT•• 24 Vdc Yes Yes Yes Yes
TM238LDD24DT 24 Vdc Yes Yes Yes Yes
DC Reference
TM238LFAC24DR•• 100...240 Vac Yes No No No
TM238LDA24DR 100...240 Vac Yes No No No
16 EIO0000000016 10/2010
The fallback settings that may be configured (fallback to 0, fallback to 1, or fallback

to the current state) do not apply to outputs Q0, Q1, Q2 or Q3 if these outputs are
configured for PTO, PWM, FG, or HSC operation. If a detected error results in the
controller entering fallback mode, these outputs will fallback to a value of 0
irrespective of the configured fallback setting.
WARNING
Design and program your system so that controlled equipment assumes a safe
state when the controller enters fallback mode if you use outputs Q0, Q1, Q2, or
Q3 for PTO, PWM, FG, or HSC operation.
equipment damage.
NOTE:
z Fallback configuration for outputs does not apply when outputs Q0,Q1, Q2, and
Q3 are used for PTO, PWM, FG or HSC operation. In these cases fallback value
is always 0.
z In case of fallback for PTO operation, any ongoing move is aborted and ramp-
down to 0 (controlled stop feature).
EIO0000000016 10/2010 17
Programming Software
SoMachine
Use the SoMachine software to program the Controller.
SoMachine is a professional, efficient and open OEM software solution that helps
you to develop, configure and commission the entire machine in a single
environment (including logic, motor control, HMI and related network automation
functions).
SoMachine allows you to program and commission the entire range of elements in
Schneider Electric’s Flexible Machine Control that helps you to achieve the most
optimized control solution for each machine’s requirements.
All information about SoMachine is included in the global online help.
18 EIO0000000016 10/2010
Physical Description
Physical Description
1 2 3 4 5
10 9 8
1 USB Mini-B port, marked Prg. Port, for connecting the programming terminal
2 Hinged access cover with 2 cable guides (1 removable for Prg. Port and 1 for the CANopen
cable)
3 Removable screw terminal block (12 terminals) for connecting the sensors (24 Vdc fast
inputs)
4 Removable screw terminal block (7 terminals) for connecting the sensors (24 Vdc inputs)
5 Connector for digital I/O TM2 D••, analog I/O TM2 A••, counter TM200 HSC206D•, and
AS-Interface TWDNOI10M3 expansion modules (7 modules max.)
6 Display showing the controller status
7 Display showing the I/O states (I0...I13 and Q0...Q9)
8 Removable screw terminal block (10 terminals) for connecting the 6 pre-actuators
10 Removable screw terminal block (5 terminals marked CANopen) for connecting the
CANopen bus, with model TM238LFDC24DT•• or TM238LFAC24DR••
EIO0000000016 10/2010 19
9 8
11 12 13
11 Removable screw terminal block (3 terminals):
On TM238LFDC24DT•• and TM238LDD24DT: +, -, marked 24 VDC for connecting the
24 Vdc power supply
On TM238LFAC24DR•• and TM238LDA24DR: L, N, marked 100-240 VAC for connecting
the 100...240 Vac power supply
12 1 RJ 45 connector marked SL1 (with model TM238LDD24DT or TM238LDA24DR) or 2
RJ 45 connectors (with model TM238LFDC24DT•• or TM238LFAC24DR••) marked SL1
and SL2 for connecting serial links.
13 Hinged cover for accessing the optional backup battery for the RAM memory and the real-
time clock inside the controller.
20 EIO0000000016 10/2010
Additional Modules and Maximum Hardware Configuration
Expansion Modules
The following table shows the expansion modules available for the Modicon M238
Logic Controller:
Module Number Description Characteristics Hardware Guide

TM2D •• Digital I/O Modules Digital I/O module features, with TM2 Digital I/O Modules
corresponding channel type, Hardware Guide, reference
voltage/current and terminal type EIO0000000028
are provided in the M238 catalog. (see Modicon TM2,
Digital I/O Modules, Hardware
Guide)
TM2A •• Analog I/O Modules Analog I/O module features, with TM2 Analog I/O Modules
corresponding channel type, Hardware Guide, reference
voltage/current and terminal type EIO0000000034
are provided in the M238 catalog. (see Modicon TM2,
Analog I/O Modules, Hardware
Guide)
TM200 HSC206D• Expert I/O Modules Expert I/O module features, with TM2 High-speed counter
corresponding performance and modules Hardware Guide,
terminal type are provided in the reference EIO0000000022
M238 catalog. (see Modicon TM2,
High Speed Counter Modules,
Hardware Guide)
Communication Modules
The following table shows the communication modules available for the Modicon
M238 Logic Controller:
Module Number Protocol

Modbus Communication Gateways
499 TWD 01100 Ethernet/Modbus
LUF P7 Profibus DP/Modbus
LUF P9 DeviceNet/Modbus
AS-Interface bus interface module
TWDNOI10M3 AS-Interface V2 bus interface master
module. TWD AS-Interface Module
(see Modicon TWDNOI10M3, AS-Interface
Master Module, Hardware Guide)
EIO0000000016 10/2010 21
Maximum Hardware Configuration

The Modicon M238 Logic Controller can support up to 7 expansion I/O modules.
However, no more than 3 Expert I/O Modules TM200HSC206D•, and no more than
2 AS-Interface modules TWDNOI10M3 may be included in any given configuration.
WARNING
UNEXPECTED EQUIPMENT OPERATION
z Verify that the Modicon M238 Logic Controller and its expansion modules are
securely locked together and to the DIN rail before adding or removing an
expansion module.
z Positively confirm that all expansion modules are fully connected before placing
your device into service.
equipment damage.
WARNING
configuration.
equipment damage.
22 EIO0000000016 10/2010
Accessories
Overview
This section describes accessories for the Modicon M238 Logic Controller and their
characteristics followed by details for solutions based on Modicon M238 Logic
Controller with RS 485 and CANopen communications.
Accessories Supplied with the Modicon M238 Logic Controller
Description Use Quantity Reference

Removable screw set of 5 removable screw connectors for digital I/O 1 TM238 RSSCT
connectors 5-way connector with a line terminator for a CANopen 1 TM238 CNTLSCT
link
Accessories

Terminal port/USB from the USB mini-B port on the Modicon M238 Logic 3m TCS XCNA MUM3P
port cordset Controller to the type A USB port on the PC terminal (10 ft)
RS 232 serial link 1 RJ 45 connector and 1 for DTE terminal (printer) 3m TCS MCN 3M4F3C2
cordset for SUB-D 9 connector (10 ft)
DTE/DCE terminal
for DCE terminal (modem, 3m TCS MCN 3M4M3S2
device
converter) (10 ft)
Removable spring set of 5 removable spring connectors. Replaces the 5 1 TM238 RSSPT
connectors for digital screw connectors supplied with Modicon M238 Logic
I/O Controller.
USB/RS 485 facilitates the updating the controller’s firmware through 1 TSX CUSB 485
converter RS 485 for product version < PV0.9.
Modbus Ethernet/Modbus 1 499 TWD 01100
communication Profibus DP/Modbus 1 LUF P7
gateways
DeviceNet/Modbus 1 LUF P9
Modbus cordset 2 RJ 45 connector for Ethernet gateway 2.5 m XBTZ9980
499 TWD 01100 (8.3 ft)
for Profibus DP LUF P7, 1m VW3 A8 306 R10
DeviceNet LUF P9 gateway (3.3 ft)
and transceiver
3m VW3 A8 306 R30
USB/RS485
(10 ft)
TSX CUSB 485
0.3 m VW3 A8 306 R03
(1 ft)
EIO0000000016 10/2010 23

Offset cordset for allows the offset of USB port from Modicon M238 Logic 1m HMI ZSUSBB
USB port Controller or XBTG terminals to panel or closet door. (3.3 ft)
Removable backup Lithium Thionyl Chloride type for Modicon M238 Logic Single TSX PLP 01
batteries Controller 10 pack TSX PLP 101
End brackets blocking Modicon M238 Logic Controller and I/O 1 AB1AB8P35
modules on a DIN Rail.
Grounding Bar connection of the cable shield and the module’s 1 TM2 XMTGB
functional ground
Shielding take-up Mounting and connecting the ground to the cable 25 pack TM200 RSRCEMC
clip shielding.
Modicon M238 Logic Controller Based Solution with RS 485 Serial Link
(1) Recommended device for connecting the Modbus trunk cable on screw terminal block and
for distances >30m
24 EIO0000000016 10/2010
N° Products Reference Description

1 Logic controller TM238LDD24DT, Controller with 24 I/O (including 2 Inputs use as
TM238LDA24DR fast inputs) and SL1 port (Modbus protocol)
2 Module with 8 analog inputs TM2 ARI 8LT Module with 8 temperature probe input (2 or 3
wires), connected on 2 screw terminal blocks
3 Phaseo 24Vdc power supply ABL 8REM24••• Optimum power supply,
•••: 030 for I=3A, 050 for I=5A
4 Programming PC MSD CHNSFUV20 SoMachine Software, 1-station license
5 TeSysU starter-controller LUB 320 32A power based with multifunction controller unit
LUCM 32BL and Modbus communication module
LUL C032
6 Power supply 24Vdc Phaseo ABL 7RM24025 Modular power supply 2.5A
7 Altivar 312 variable speed drive ATV 312•••••• Drive for asynchronous motor (integrated Modbus
and CANopen)
8 Advantys OTB distributed I/O OTB 1S0 DM9LP Modbus bus interface module, 12 x 24 Vdc inputs,
2 x 24 Vdc outputs and 6 relay outputs
9 Osicodeur incremental encoder XCC 14•K/15•Y/19•KN Rotary 40/58/90mm of diameter with Push-pull
outputs with extension cable XCC PM23121L•
1a Modbus trunk cable TSX SCA 100/200/500 RS 485 double shielded twisted pair cable, length
100/200/500m (300/600/1,500 ft)
1b Modbus junction box TWD XCA ISO Screw terminal block for trunk cable, 2 RJ45
connectors for tap junction, line isolation and end
line termination, 24 Vdc power supply
2a Grounding plate TM2 XMTGB Connection of cable shielding and functional
ground on the module 2
4a Terminal port/PC USB port TCS XCN AMUM3P Cordset from USB port on the controller to PC
cordset terminal USB port
5a Modbus drop cables VW3 A8 306 R03/10/30 Cordset with 2 RJ 45 connector, length 0.3/1/3 m
(1/3.3/10 ft)
EIO0000000016 10/2010 25
Modicon M238 Logic Controller Based Solution with CANopen Serial Link

1 Logic controller TM238LFDC24DT•• Controller with 24 I/O (including 2 outputs use as
PTO signals) and integrated CANopen port
TM238LFAC24DR•• Controller with 24 I/O (without PTO and PWM
functionality)
2 Module with 8 analog inputs TM2 ARI 8LT Module with 8 temperature probe input (2 or 3
wires), connected on 2 screw terminal blocks
3 High-speed counter module TM200 HSC 206 DF Module with 2 60kHz high-speed counting
channels, connected on 2 spring terminal blocks
4 Phaseo 24Vdc power supply ABL 8REM24••• Optimum power supply,
•••: 030 for I=3A, 050 for I=5A
ABL 8RPS24••• Universal power supply,
•••: 050 for I=5A, 100 for I=10A
5 Programming PC MSD CHNSFUV20 SoMachine Software, 1-station license
26 EIO0000000016 10/2010

6 Magelis HMI Terminals XBT N200/R400 + 6a Small Panel with keypad for displaying text
(Modbus protocol) XBT RT500/RT511 + 6a messages of 2...10 lines
Connection to controller serial port SL2, 5 Vdc
power supply via controller (1)
XBT N401/R410 + 6b Small Panel with keypad for displaying text
XBT R5410/R411 + 6b messages and control/configuration of data, 5.7”
screen, external 24 Vdc power supply
Connection to controller serial port SL1 or SL2
XBT GT11••/GT1335 + 6a Advanced Touch Panel with graphic display, 3.8”
screen, external 24 Vdc power supply
Connection on COM1 port to controller serial
port SL1 or SL2
Magelis HMI Terminals XBT GT2••0...7340 + 6c Advanced Touch Panel with graphic display,
(SoMachine-Network protocol) XBT GK•••0 + 6c 5.7”...15” screen, external 24 Vdc power supply
Connection on COM1 port to controller serial
port SL1 or SL2
7 Lexium 32 servo drive LXM 32•••• Servo drive on CANopen bus, to be used with
BRH/BSH motor
8 Lexium 32 servo drive LXM 32•••• Servo drive on CANopen bus, to be used with
BRH/BSH motor
9 Altivar 312 variable speed drive ATV 312•••••• Drive for asynchronous motor (integrated
Modbus and CANopen)
10 Advantys OTB distributed I/O OTB 1S0 DM9LP Modbus bus interface module, 12 x 24 Vdc
inputs, 2 x 24 Vdc outputs and 6 relay outputs
11 Osicodeur incremental encoder XCC 14•K/15•Y/19•KN Rotary 40/58/90mm of diameter with Push-pull
outputs with extension cable XCC PM23121L•
1a CANopen cable TSX CAN CA 50/100/300 Cable for standard environment, length
50/100/300 m (150/300/900 ft)
2a Grounding plate TM2 XMTGB Connection of cable shielding and functional
ground on modules 2 and 3
5a Terminal port/PC USB port TCS XCN AMUM3P Cordset from USB port on the controller to PC
cordset terminal USB port, length 3 m (10 ft)
6• Magelis HMI Cordsets 6a: XBT Z9980 2 RJ 45 connector, RS 485 Modbus, length 2.5m
(7.5 ft)
6b: XBT Z938 1 SUB-D25 and1 RJ 45 connector, RS 485
Modbus, length 2.5m (7.5 ft)
6c: XBT Z9008 1 SUB-D9 and1 RJ 45 connector, RS 485
Modbus, length 2.5m (7.5 ft)
8a IP20 junction box VW3 CAN TAP2 IP20 junction box with 2 CANopen RJ45
connectors and 1 diagnostic terminal RJ45
connector
EIO0000000016 10/2010 27

8b CANopen preassembled VW3 CAN CARR03/1 Cordset with 2 RJ 45 connectors, length 0.3/1m
cordset (1/3.3 ft)
10a IP20 SUB-D9 Connector TSX CAN KCDF 90T Connector with line terminator, straight/right-
TSX CAN KCDF 180T angled
(1) Except for XBT RT511, connection to controller serial port SL1 or SL2, external 24 Vdc power supply
28 EIO0000000016 10/2010
M238 - Installation
EIO0000000016 10/2010
Installation
2
Introduction
This chapter provides installation safety guidelines, device dimensions, mounting
instructions, and environmental specifications.

Topic Page
Installation and Maintenance Requirements 30
First Startup 32
Internal and External Backup Batteries 34
Dimensions 37
Mounting Positions 38
Minimum Clearances 41
The DIN Rail 43
Mounting on a DIN Rail 44
Mounting on a Metallic Panel 47
Environmental Specifications 49
EIO0000000016 10/2010 29
M238 - Installation
Installation and Maintenance Requirements
Before Starting
Read and understand this manual before beginning the installation of your Modicon
M238 Logic Controller.
Disconnecting Power
All options and modules should be assembled and installed before installing the
control system on a mounting rail, onto a mounting plate or in a panel. Remove the
control system from its mounting rail, mounting plate or panel before disassembling
the equipment.
DANGER
unit.
Programming Considerations
WARNING
configuration.
equipment damage.
30 EIO0000000016 10/2010
M238 - Installation
Operating Environment
This equipment has been designed to operate outside of any hazardous location.
Only install this equipment in zones known to be free of a hazardous atmosphere.
DANGER
EXPLOSION HAZARD
This equipment is suitable for use in non-hazardous locations only.
WARNING
z Use appropriate safety interlocks where personnel and/or equipment hazards
exist.
z Install and operate this equipment in an enclosure appropriately rated for its
intended environment.
z Use the sensor and actuator power supplies only for supplying power to the
sensors or actuators connected to the module.
z Power line and output circuits must be wired and fused in compliance with local
and national regulatory requirements for the rated current and voltage of the
particular equipment.
z Do not use this equipment in safety critical machine functions.
z Do not disassemble, repair, or modify this equipment.
z Do not connect any wiring to unused connections, or to connections designated
as Not Connected (N.C.).
equipment damage.
WARNING
z Install and operate this equipment according to the environmental conditions
described in the operating limits.
z Use the sensor and actuator power supplies only for supplying power to the
sensors or actuators connected to the module.
equipment damage.
EIO0000000016 10/2010 31
M238 - Installation
First Startup
Introduction
This procedure will help you through the first installation and start up of your
Modicon M238 Logic Controller.
Startup Procedure
Step Action Comment

1 Unpack your Modicon M238 Logic Package contents (see page 23)
Controller and check the contents of the
package.
2 Install the external backup battery Backup Battery type: Lithium Thionyl
(optional). Chloride
Backup Battery reference: TSX PLP 01
3 Plug your controller on DIN rail. Refer to Mounting on a DIN rail
(see page 44)
4 Connect your devices to the Inputs. Refer to the Input Wiring Chapter
(see page 65).
5 Connect your devices to the Outputs. Refer to the Output Wiring Chapter
(see page 72).
6 Connect your Modicon M238 Logic Refer to the DC/AC Power Supply Wiring
Controller to the power supply. and Specifications (see page 52).
7 Connect your Modicon M238 Logic SoMachine must be installed on your PC.
Controller to your PC. Refer to the Connecting to a PC
(see page 91).
8 Turn on power. Refer to the Controller State Diagram
(see Modicon M238 Logic Controller,
Programming Guide).
9 Login to your Modicon M238 Logic Refer to the M238 Programming Guide
Controller. (see Modicon M238 Logic Controller,
Programming Guide).
10 Create an application. Refer to the M238 Programming Guide
Programming Guide).
11 Load your application to the Modicon Refer to the M238 Programming Guide
M238 Logic Controller. (see Modicon M238 Logic Controller,
Programming Guide).
32 EIO0000000016 10/2010
M238 - Installation
Step Action Comment

12 Create your boot application. Refer to the M238 Programming Guide
Programming Guide).
13 Run the application. Refer to the M238 Programming Guide
Programming Guide).
EIO0000000016 10/2010 33
M238 - Installation
Internal and External Backup Batteries
Introduction
The Modicon M238 Logic Controller has 2 backup batteries:
z 1 embedded internal backup battery (rechargeable)
z 1 external backup battery (not rechargeable)
In the event of a power outage, both backup batteries will retain the internal clock,
system data and the values of variables associated with your SoMachine
application.
Internal Backup Battery

Use: In the event of a transient power outage or while replacing the external backup
battery, the internal backup battery will retain data.
Backup Time: 3 days
Battery Monitoring Features: None
Rechargeable: 22 hours to reach full charge
Replaceable: No
NOTE: For most applications, the internal backup battery is sufficient. For specific
applications that require long-term backup of data, the external backup battery
(see page 34) option provides extended backup duration.
External Backup Battery

Backup Battery Type: Lithium Thionyl Chloride
Reference: TSX PLP 01 for a single backup battery or TSX PLP 101 for a 10 pack.
Use: The external backup battery can store data longer than the internal backup
battery can.
Backup Time: Up to 1 years with the recommended backup battery.
Backup Battery Monitoring Features:
You can check the charge level of the external backup battery
z directly on the face of the controller using the LED (see page 106),
z by programming the GetBatteryLevel function (see Modicon M238 Logic
Controller, System Functions and Variables, M238 PLCSystem Library Guide) in
your application, or
z by reading the system variable PLC_R.i_wBatteryStatus (see Modicon M238
Logic Controller, System Functions and Variables, M238 PLCSystem Library
Guide).
Rechargeable: No
Replaceable: Yes
34 EIO0000000016 10/2010
M238 - Installation
While lithium batteries are preferred due to their slow discharge and long life, they
can present hazards to personnel, equipment and the environment, and must be
handled properly.
DANGER
EXPLOSION, FIRE, OR CHEMICAL HAZARD
Follow these instructions for the lithium batteries:
z Replace with identical type.
z Follow all battery manufacturer’s instructions.
z Remove all replaceable batteries before discarding unit.
z Recycle or properly dispose of used batteries.
z Protect battery from any potential short circuit.
z Do not recharge, disassemble, heat above 100 ° C (212 ° F), or incinerate.
z Use your hands or insulated tools to remove or replace the battery.
z Maintain proper polarity when inserting and connecting a new battery.
Installing and Replacing the External backup battery

Before installing or replacing the external backup battery, follow these steps so that
the data stored in RAM memory is not lost when the external backup battery is
removed from its compartment.
CAUTION
LOSS OF DATA
Before you replace the external backup battery, make sure that the controller has
been powered for at least 24 hours so that the internal backup battery is charged.
Failure to follow these instructions can result in equipment damage.
EIO0000000016 10/2010 35
M238 - Installation
To install or replace the external backup battery, follow these steps:
Step Action
1 Power off your controller.
2 Open the cover to access the backup battery compartment as shown below.
3 Remove the used battery from the compartment.

4 Insert the new battery in the compartment in accordance with the polarity markings
in the compartment and on the battery.
5 Close the cover and verify that the latch clicks into place.
6 Power up your Modicon M238 Logic Controller.
Note: If you do not power up your Modicon M238 Logic Controller immediately, the
external backup battery life might be significantly reduced.
36 EIO0000000016 10/2010
M238 - Installation
Dimensions
Dimensions
mm
in
86 157
3.39 6.18
0 G0 1 2 G2 3 4 G4 5 6 G6 7 8 9 10 11 12 13 C8
Expansion Module.
FAST INPUTS INPUTS

sticker to connect
Remove this
prg.
Port.
I10
I12
I13
I11
I0
I1
I2
I3
I4
I5
I6
I7
I8
I9
PWR BATT
4.64
118
RUN ERR
SL1 CAN R
SL2 CAN E
Q3
Q0
Q1
Q2
Q4
Q5
Q6
Q7
Q8
Q9
CAN open
Master M238
TM 238 D1 DDT24C
SL1 SL2 FAST OUTPUTS OUTPUTS

V0+ V0- 0 1 2 3 V1+ V1- 4 5 6 V2+ V2- 7 8 9
EIO0000000016 10/2010 37
M238 - Installation
Mounting Positions
Introduction
This section describes the correct mounting positions for the Modicon M238 Logic
Controller.
NOTE: Keep adequate spacing for proper ventilation and to maintain an ambient
temperature between -10° C (14° F) and 55° C (131° F).
Correct Mounting Position

Whenever possible, the Modicon M238 Logic Controller should be mounted
horizontally on a vertical plane as shown in the figure below:
0 G0 1 2 G2 3 4 G4 5 6 G6 7 8 9 10 11 12 13 C8
FAST INPUTS INPUTS
Expansion Module.
sticker to connect
Remove this
prg.
Port.
I10
I12
I13
I11
I0
I1
I2
I3
I4
I5
I6
I7
I8
I9
PWR BATT
RUN ERR
SL1 CAN R
SL2 CAN E
Q3
Q0
Q1
Q2
Q4
Q5
Q6
Q7
Q8
Q9
CANopen
Master M238
TM 238 D1 DDT24C

V0+ V0- 0 1 2 3 V1+ V1- 4 5 6 V2+ V2- 7 8 9
38 EIO0000000016 10/2010
M238 - Installation
Acceptable Mounting Positions

The Modicon M238 Logic Controller can also be mounted sideways on a vertical
plane as shown below.
11 12 13 C8
9
8
TM 238 D1 DDT24C
M238
V2+ V2- 7
INPUTS
OUTPUTS
10
9
6
8
5
I13
7
I12 V1+ V1- 4

I11
G6
I10
6
I9 Q9
5
Q8
FAST INPUTS
I8
2 3
FAST OUTPUTS
I7 Q7
G4
I6 Q6
1
4
I5 Q5
V0+ V0- 0
I4 Q4
3
I3 Q3
G2
I2 Q2
I1 Q1
2
I0 Q0
G0 1
SL2
CAN R
CAN E
0
BATT
ERR
SL1
PWR
RUN
SL1
SL2
CANopen
Master
Port.
prg.
NOTE: Expansion modules must be on top.
EIO0000000016 10/2010 39
M238 - Installation
Incorrect Mounting Position

The Modicon M238 Logic Controller should only be positioned as shown in Correct
Mounting Position (see page 38) figure. The figures below show the incorrect
mounting positions.
99
3.89
118
4.64
CANopen
Master
Port.
prg.
SL2
SL1
RUN
PWR
SL1
CAN E
CAN R
ERR
BATT
Expansion Module.
sticker to connect
0
SL2
Remove this
3.46
G0 1
88
Q0 I0
6.18
Q1 I1
2
157
V0+ V0- 0
FAST OUTPUTS
Q2 I2
G2
Q3 I3
FAST INPUTS
Q4 I4
3
Q5 I5
4
1
Q6 I6
Remove this
G4
2 3
Q7 I7
sticker to connect Q8 I8
5
Expansion Module. Q9 I9
V1+ V1- 4
I10
G6
I11
I12
7
I13
OUTPUTS
TM 238 D1 DDT24C
5
8
6
9
10
V2+ V2- 7
INPUTS
M238
11 12 13 C8
8
9
40 EIO0000000016 10/2010
M238 - Installation
Minimum Clearances
Minimum Clearances
WARNING
z Place devices dissipating the most heat at the top of the cabinet and ensure
adequate ventilation.
z Avoid placing this equipment next to or above devices that might cause
overheating.
z Install the equipment in a location providing the minimum clearances from all
adjacent structures and equipment as directed in this document.
z Install all equipment according to the drawings specified in the related
documentation.
equipment damage.
NOTE: Keep adequate spacing for proper ventilation and to maintain an ambient
temperature between -10° C (14° F) and 55° C (131° F).
EIO0000000016 10/2010 41
M238 - Installation
The Modicon M238 Logic Controller has been designed as an IP20 product and
must be installed in an enclosure. Clearances must be respected when installing the
product.
There are 3 types of clearances between:
z The Modicon M238 Logic Controller and all sides of the cabinet (including the
panel door). This type of clearance allows proper circulation of air around the
controller, and therefore keeps the sides of cabinet at the ambient temperature.
z The Modicon M238 Logic Controller terminal blocks and the wiring ducts. This
distance avoids electromagnetic impulse between the controller and the wiring
ducts.
z The Modicon M238 Logic Controller and other heat generating devices installed
in the same cabinet.
Front Panel
20 20
0.79 0.79
0 G0 1 2 G2 3 4 G4 5 6 G6 7 8 9 10 11 12 13 C8
FAST INPUTS INPUTS

Expansion Module.
40 40
sticker to connect
1.57 1.57
Remove this
prg.
Port.
I10
I12
I13
I11
I0
I1
I2
I3
I4
I5
I6
I7
I8
I9
80 PWR BATT
RUN ERR
3.15 SL1 CAN R
SL2 CAN E
Q3
Q0
Q1
Q2
Q4
Q5
Q6
Q7
Q8
Q9
CANopen
Master M238
TM 238 D1 DDT24C

V0+ V0- 0 1 2 3 V1+ V1- 4 5 6 V2+ V2- 7 8 9
20 20
mm 0.79 0.79
in
42 EIO0000000016 10/2010
M238 - Installation
The DIN Rail
Introduction
You can mount the M238 and its expansions on a DIN rail. A DIN rail can be
attached to a smooth mounting surface or suspended from a EIA rack or in a NEMA
cabinet.
Dimensions of the DIN Rail

The DIN rail measures 35 mm (1.38 in.) high and 15 mm (0.59 in.) deep, as shown
below.
Recommended Equipment
You can order the suitable DIN rail from Schneider Electric:
Rail depth Catalogue part number

15 mm (0.59 in.) AM1DE200
EIO0000000016 10/2010 43
M238 - Installation
Mounting on a DIN Rail
Introduction
This section describes mounting and removing of the Modicon M238 Logic
Controller and its expansions on a DIN rail.
NOTE: Your Modicon M238 Logic Controller may differ from the illustrations in this
section but the basic procedures are still applicable.
Installing the Modicon M238 Logic Controller on a DIN Rail
Step Action
1 Secure the DIN rail to a panel by tightening screws.
2 Place the top groove of the Modicon M238 Logic Controller on the DIN rail and press
the controller against the DIN rail until you hear the retaining clamp click into place.
44 EIO0000000016 10/2010
M238 - Installation
Step Action
3 Place end brackets on each side of the controller and its associated I/O.
AB1AB8P35
Note: Use end brackets to help prevent the Modicon M238 Logic Controller and its
I/O expansion modules assembly from moving sideways. It also provides better
resistance to shock and vibration.
EIO0000000016 10/2010 45
M238 - Installation
Removing the Modicon M238 Logic Controller from a DIN Rail
Step Action
1 Using a screwdriver, pull down the retaining clamp located on the bottom of the
Modicon M238 Logic Controller.
2 Pull the Modicon M238 Logic Controller off the DIN rail from the bottom.
NOTE: Before re-installing the Modicon M238 Logic Controller on the DIN rail, push
up the retaining clamp.
46 EIO0000000016 10/2010
M238 - Installation
Mounting on a Metallic Panel
Introduction
This section provides information on how to mount the Modicon M238 Logic
Controller on a metallic panel.
Mounting Holes
The following diagram shows the mounting holes for the Modicon M238 Logic
Controller:
EIO0000000016 10/2010 47
M238 - Installation
Mounting the Modicon M238 Logic Controller on a Metallic Panel
CAUTION
INOPERABLE EQUIPMENT
Do not tighten screw terminals beyond the specified maximum torque (Nm / lb-in.).
48 EIO0000000016 10/2010
M238 - Installation
Environmental Specifications
Environmental Specifications
Temperature Operation -10 to 55 ° C (14 to 131 ° F)

Storage -40 to 70 ° C (-40 to 158 ° F)
Relative humidity 95% maximum, non condensing
Degree of pollution 2
Degree of protection IP 20
Altitude Operation 0...2000 m (0 to 6560 ft)
Storage 0...3000 m (0 to 9842 ft)
Vibration Mounted on a DIN rail 3.5 mm fixed amplitude from 5...8.4 Hz
resistance 9.8 m/s2 (1 gn) fixed acceleration from
8.4...150 Hz
Plate or panel mounted 1.6 mm fixed amplitude from 2...25 Hz
39.2 m/s2 (4 gn) fixed acceleration from
25...100 Hz
Shock resistance 147 m/s2 (15 gn) for a duration of 11 ms
Weight 590 g (1.3 lb)
NOTE: Please see catalog for more specific information on the environmental
specifications.
EIO0000000016 10/2010 49
M238 - Installation
50 EIO0000000016 10/2010
M238 - Wiring and Electrical Specifications
EIO0000000016 10/2010
Wiring and Electrical

Specifications
3
Overview
This chapter provides power supply and input/output wiring rules and diagrams.

This chapter contains the following sections:
Section Topic Page
3.1 AC/DC Power Supply Wiring and Specifications 52
3.2 Input Wiring Specifications for AC/DC Controllers 65
3.3 Output Wiring Specifications for DC Controllers 72
3.4 Output Wiring Specifications for AC Controllers 82
EIO0000000016 10/2010 51
3.1 AC/DC Power Supply Wiring and Specifications
Overview
This section describes the wiring and electrical specifications of AC/DC power
supply on controllers.
What's in this Section?

This section contains the following topics:
Topic Page
Wiring Requirements 53
DC Power Supply Wiring and Specifications 57
AC Power Supply Wiring and Specifications 60
Grounding Shielded Cables 63
52 EIO0000000016 10/2010
Wiring Requirements
Overview
There are several rules that must be followed when wiring a Modicon M238 Logic
Controller.
DANGER
unit.
WARNING
LOSS OF CONTROL
z The designer of any control scheme must consider the potential failure modes
of control paths and, for certain critical control functions, provide a means to
achieve a safe state during and after a path failure. Examples of critical control
functions are emergency stop and overtravel stop, power outage and restart.
z Separate or redundant control paths must be provided for critical control
functions.
z System control paths may include communication links. Consideration must be
given to the implications of unanticipated transmission delays or failures of the
link.
z Observe all accident prevention regulations and local safety guidelines.1
z Each implementation of this equipment must be individually and thoroughly
tested for proper operation before being placed into service.
equipment damage.
EIO0000000016 10/2010 53
1 For additional information, refer to NEMA ICS 1.1 (latest edition), "Safety
Guidelines for the Application, Installation, and Maintenance of Solid State Control"
and to NEMA ICS 7.1 (latest edition), "Safety Standards for Construction and Guide
for Selection, Installation and Operation of Adjustable-Speed Drive Systems" or their
equivalent governing your particular location.
Rules
DANGER
unit.
54 EIO0000000016 10/2010
The following rules must be applied when wiring the M238:

z I/O and communication wiring must be kept separate from the power wiring.
Route these 2 types of wiring in separate cable ducting.
z Verify that the operating conditions and environment are within the specification
values.
z Use proper wire sizes to meet voltage and current requirements.
z Use copper conductors only.
z Use twisted-pair, shielded cables for analog, expert and/or fast I/O.
z Use twisted-pair, shielded cables for networks and field bus (CANopen, serial,
Ethernet).
WARNING
z Use shielded cables for all input, output and communication types specified
above.
z Properly ground the cable shields as indicated in the related documentation.
z Route communications and I/O cables separately from power cables.
equipment damage.
For more details, refer to Grounding Shielded Cables (see page 63).
Rules for Removable Screw Terminal Block

The following table shows the cable types and wire sizes for a removable screw
terminal block (I/Os and Power Supply):
6
0.23
mm
in
mm 2 0,2…1,5 0,25…1,5 0,2…1 0,2…1,5 0,25…1 0,5...1,5
AWG 24…14 24…14 26…16 24…14 24…16 20...14
N.m 0,6
C
Ø 3,5 mm (0.1 in) lb-in 5.3
Use copper conductors only.
EIO0000000016 10/2010 55
Rules for Removable Spring Terminal Block

The following table shows the cable types and wire sizes for a removable spring
terminal block (I/Os and Power Supply):
6
0.23
mm
in.
mm 2 0,2…1,5 0,25…1,5 0,25…1 0,5...1,5
AWG 24…14 24…14 24…16 20...14
Use copper conductors only.

The spring clamp connectors of the terminal block are designed for only one wire or
one cable end. Two wires to the same connector must be installed with a double wire
cable end to help prevent loosening.
DANGER
LOOSE WIRING CAUSES ELECTRIC SHOCK
Do not insert more than one wire per connector of the terminal block without a
double wire cable end.
56 EIO0000000016 10/2010
DC Power Supply Wiring and Specifications
Overview
This section provides the wiring diagrams and the specifications of the DC power
supply.
The information below refers to the following model numbers:
z TM238LFDC24DT••
z TM238LDD24DT
Power Supply Voltage Range

If the specified voltage range is not maintained, outputs may not switch as expected.
Use appropriate safety interlocks and voltage monitoring circuits.
DANGER
FIRE HAZARD
Use only the recommended wire sizes for I/O channels and power supplies.
WARNING
Do not exceed any of the rated values specified in the following tables.
equipment damage.
DC Power Supply Specifications
Model Number TM238LFDC24DT•• TM238LDD24DT

Voltage rated voltage (Un) 24 Vdc
limit (including ripple) 19.2...28.8 Vdc 20.4...28.8 Vdc
Sensor power supply Use an external 24 Vdc Phaseo power supply from the
Optimum range.
Maximum inrush current at Un 35 A
Duration of short transient power interruption 1 10 ms
Maximum consumption with expansion modules 17.2 W
EIO0000000016 10/2010 57
Model Number TM238LFDC24DT•• TM238LDD24DT

Dielectric between power supply terminals and 500 Vdc for 1 min. Not isolated, Internal Gnd is
Strength ground terminals connected to the controller
frame
between I/O terminals and ground 500 Vdc for 1 min.
terminals
Isolation between power supply terminals and > 10 ΜΩ (below 500 Vdc) -
Resistance ground terminals
between I/O terminals and ground > 10 ΜΩ (below 500 Vdc)
terminals
(1) The Modicon M238 Logic Controller has been designed to continue operation during short transient power
interruptions.
The duration of the interruptions where the Modicon M238 Logic Controller
continues normal operation is variable depending upon the load on the power supply
of the Modicon M238 Logic Controller, but generally a minimum of 10 ms is
maintained as specified by IEC standards.
If there is a minimum load on the Modicon M238 Logic Controller power supply, the
duration can be as great as 400 ms.
When planning the management of the power supplied to the controller, you must
consider this duration due to the fast cycle time.
There could potentially be many scans of the logic and consequential updates to the
I/O image table during the power interruption, while there is no external power
supplied to the inputs, the outputs or both depending on the power system
architecture and power interruption circumstances.
WARNING
z Individually monitor each source of power used in the Modicon M238 Logic
Controller system including input power supplies, output power supplies and the
power supply to the controller to allow appropriate system shutdown during
power system interruptions
z The inputs monitoring each of the power supply sources must be unfiltered
inputs.
equipment damage.
58 EIO0000000016 10/2010
Power Supply Wiring Diagram

The power supply of this equipment does not have built-in reverse polarity
protection. Incorrectly connecting polarity can permanently damage the output
circuits and the internal backup battery or otherwise result in unintended operation
of the equipment.
CAUTION
Verify the wiring conforms to the polarity markings on the connections of this
equipment and as described in the related documentation.
The following figure shows the power supply wiring diagram:
24 VDC
+ -
l y 80 mm
(3.15 in.)
Ø 1,5 mm2 min.
+
– AWG 14 max.
c 24 V
Use an external fast-blow fuse 2 A type F (UL recognized and CSA approved).
Terminal Tightening Torque
CAUTION
Wire Stripping and Cable Size

For the cable types and wire sizes, refer to Wiring Requirements (see page 53).
EIO0000000016 10/2010 59
AC Power Supply Wiring and Specifications
Overview
This section provides the wiring diagrams and the specifications of the AC power
supply.
z TM238LFAC24DR••
z TM238LDA24DR
Power Supply Voltage Range

If the specified voltage range is not maintained, outputs may not switch as expected.
Use appropriate safety interlocks and voltage monitoring circuits.
DANGER
FIRE HAZARD
WARNING
equipment damage.
AC Power Supply Specifications
Model Number TM238LFDC24DT••, TM238LDD24DT

Voltage rated voltage (Un) 100...240 Vac
limit (including ripple) 85...264 Vac
Sensor power supply Use an external 24 Vdc Phaseo power supply from the
Optimum range.
Maximum inrush current at Un 35 A
Duration of short transient power interruption 1 10 ms
Maximum consumption with expansion modules 25 W at 100 Vac

42 W at 264 Vac
60 EIO0000000016 10/2010
Model Number TM238LFDC24DT••, TM238LDD24DT

Dielectric between power supply terminals and 1000 Vdc for 1 min.
Strength ground terminals
between I/O terminals and ground 1000 Vdc for 1 min.
terminals
Isolation between power supply terminals and > 10 ΜΩ (below 500 Vdc)
Resistance ground terminals
between I/O terminals and ground > 10 ΜΩ (below 500 Vdc)
terminals
(1) The Modicon M238 Logic Controller has been designed to continue operation during short transient power
interruptions.
The duration of the interruptions where the Modicon M238 Logic Controller
continues normal operation is variable depending upon the load on the power supply
of the Modicon M238 Logic Controller, but generally a minimum of 10 ms is
maintained as specified by IEC standards.
If there is a minimum load on the Modicon M238 Logic Controller power supply, the
duration can be as great as 400 ms.
When planning the management of the power supplied to the controller, you must
consider this duration due to the fast cycle time.
There could potentially be many scans of the logic and consequential updates to the
I/O image table during the power interruption, while there is no external power
supplied to the inputs, the outputs or both depending on the power system
architecture and power interruption circumstances.
WARNING
z Individually monitor each source of power used in the Modicon M238 Logic
Controller system including input power supplies, output power supplies and the
power supply to the controller to allow appropriate system shutdown during
power system interruptions
z The inputs monitoring each of the power supply sources must be unfiltered
inputs.
equipment damage.
EIO0000000016 10/2010 61
Power Supply Wiring Diagram

The following figure shows the power supply wiring diagram:
100-240 VAC
L N
l y 80 mm
(3.15 in.)
Ø 1,5 mm2 min.
a AWG 14 max.
a 100...240V
Use an external fuse 2 A type T (UL recognized and CSA approved).
CAUTION

62 EIO0000000016 10/2010
Grounding Shielded Cables
Modicon M238 Logic Controller Grounding Shielded Cables

To help minimize the effects of electromagnetic interference, cables carrying the fast
I/O, analog I/O and field bus communication signals must be shielded.
WARNING
IMPROPER GROUNDING CAN CAUSE UNINTENDED EQUIPMENT OPERA-
TION
z Use cables with insulated shielded jackets for analog I/O, fast I/O and
communication signals.
z Ground shielded cables for analog I/O, fast I/O and communication signals at a
single point 1
z Always comply with local wiring requirements regarding grounding of cable a
shields.
equipment damage.
NOTE: 1Multipoint grounding is permissible if connections are made to an

equipotential ground plane dimensioned to help avoid cable shield damage in the
event of power system short circuit currents.
The use of shielded cables requires compliance with the following wiring rules:
z For protective ground connections (PE), metal conduit or ducting can be used for
part of the shielding length, provided there is no break in the continuity of the
ground connections. For functional ground (FE), the shielding is intended to
attenuate electromagnetic interference and the shielding must be continuous for
the length of the cable. If the purpose is both functional and protective, as is often
the case for communication cables, the cable should have continuous shielding.
z Wherever possible, keep cables carrying one type of signal separate from the
cables carrying other types of signals or power.
EIO0000000016 10/2010 63
The following figure shows the proper method for wiring an Modicon M238 Logic
Controller's shielded cables to ground:
8
0 G0 1 2 G2 3 4 G4 5 6 G6 7 8 9 10 11 12 13 C8
FAST INPUTS INPUTS
prg.
Port.
I10
I12
I13
I11
I0
I1
I2
I3
I4
I5
I6
I7
I8
I9
PWR BATT
RUN ERR
SL1
SL2
CAN R
CAN E
2
Q3
Q0
Q1
Q2
Q4
Q5
Q6
Q7
Q8
Q9
CANopen
Master M238
TM 238 D1 DDT24C
SL FAST OUTPUTS OUTPUTS

V0+ V0- 0 1 2 3 V1+ V1- 4 5 6 V2+ V2- 7 8 9
7 6 5 4
1 Metal plate or metal panel (ground casing) connected to the Frame Ground terminal.
2 Modicon M238 Logic Controller.
3 Shielding take-up clip TM200 RSRCEMC: attach the shielding for the cables (4) and (8) as
close as possible to the controller base and after stripping the cable insulation from the
shielding. Then attach the cable to the metal support (1) by attaching the clamp to the
exposed shielding. The shielding must be clamped tightly enough to the metal support to
permit good contact.
4 Shielded cables for connecting the outputs to the actuators with PTO/PWM/FG signals.
5 Shielded cordset for connecting the serial links SL1 and/or SL2 for TM238LFDC24DT••
and TM238LFAC24DR••. TCS MCN 3M4•••2 serial communication cords include the
grounding lug.
6 Shielded cable for connecting the CANopen bus.
7 Unshielded power supply wires or cable (2 conductors + ground)
8 Shielded cable for connecting the encoder and sensor signals used on the fast outputs in
counter mode.
NOTE: The shielding of the shielded cables for connecting sensors/actuators to the
analog I/O modules should be secured and grounded as shown in (3) (identical to
cables 4 and 8) using TM2 XMTGB ground connection plate.
64 EIO0000000016 10/2010
3.2 Input Wiring Specifications for AC/DC Controllers
Overview
This section describes the wiring and electrical specifications of inputs for
AC/DC Controllers.

Topic Page
Regular Input Wiring Specifications 66
Fast Input Wiring Specifications 69
EIO0000000016 10/2010 65
Regular Input Wiring Specifications
Overview
This section provides the wiring diagrams, specifications, and internal input circuit of
the regular inputs.
DANGER
FIRE HAZARD
WARNING
equipment damage.
Regular Input Specifications

The following table provides information about the main characteristics of the regular
inputs:
Model Number TM238LFDC24DT••,

TM238LDD24DT
TM238LFAC24DR••,
TM238LDA24DR
Number of Input Channels 6
Rated Input Voltage 24 Vdc sink/source input signal
Common 1
Input Voltage Range 19.2...30 Vdc
Rated Input Current 10.4 mA
Input Impedance 2.3 kΩ
Input Limit Values at state 1 (voltage / current) ≥ 15 Vdc / ≥ 2 mA
at state 0 (voltage / current) ≤5 Vdc / ≤1.5 mA
Anti-bounce filtering (configurable) 0 - 1.5 - 4 or 12 ms
66 EIO0000000016 10/2010

TM238LDD24DT
TM238LDA24DR
Turn on Time < 1 ms
Turn off Time < 1 ms
Isolation between channels None
between channels and internal 500 Vdc
logic
Input Type Type 1 (IEC 61131-2)
Input Signal Type sink/source
Maximum Cable Length 30 m (98.4 ft)
Source Input Principle

Current flows from the controller input terminal block to the switch if an input signal
turns on.
NOTE: Inputs from I8 to I13 are Sink or Source inputs.
Sink Input Principle

Current flows from the switch to the controller input terminal block if an input signal
turns on.
NOTE: Inputs from I0 to I7 are Sink inputs.
Regular Input Wiring Diagram

The following figure shows the regular input wiring diagram:
–
– PNP (1) NPN (3)
(1) (3) +
+ + – – +
(2) +
(1)
– (2) + (1)
–
I8 I9 I10 I11 I12 I13 C8
I9 I10 I13 C8 I9 I10 I13 C8
Inputs
(1) Fast-blow fuse 0.5 A

(2) Sink input (positive logic)
(3) Source input (negative logic)
EIO0000000016 10/2010 67
CAUTION

68 EIO0000000016 10/2010
Fast Input Wiring Specifications
Overview
This section provides the wiring diagrams, specifications, and internal input circuit of
the fast inputs. You must use shielded cable on the fast inputs.
DANGER
FIRE HAZARD
WARNING
equipment damage.
Fast Input Specifications

The following table provides information about the main characteristics of the fast
inputs:

TM238LDD24DT
TM238LDA24DR
Number of Input Channels 8
Rated Input Voltage 24 Vdc
Common 4
Input Voltage Range 19.2...30 Vdc
Rated Input Current 8 mA
Input Impedance 3 kΩ
Input Limit Values at state 1 (voltage / current) ≥ 15 V / ≥ 2 mA
at state 0 (voltage / current) ≤5 V / ≤1.5 mA
Bounce filtering (configurable) 0.004 - 0.4 - 1.2 or 4 ms
EIO0000000016 10/2010 69

TM238LDD24DT
TM238LDA24DR
Anti-bounce filtering (configurable) 0 - 1.5 - 4 or 12 ms
Turn on Time 300 ns

Turn off Time 300 ns
Isolation between channels 500 Vdc
between channels and internal 500 Vdc
logic
Input Type Type 1 (IEC 61131-2)
Input Signal Type sink
Maximum Cable Length 10 m (32.8 ft)
Shielded Cable Connection

To improve Electromagnetic Compatibility (EMC), use shielded cables for fast
inputs. The shielding must be securely connected to ground. The fast input shields
may be connected either to the functional ground (FE) of your system via the
TM2 XMTGB grounding bar or to the protective ground (PE).
WARNING
Properly ground the cable shields as indicated in the related documentation.
equipment damage.
70 EIO0000000016 10/2010
Fast Input Wiring Diagram

The following figure shows the fast inputs wiring diagram:
(1) (1) (1) (1)
+ + + +
– – – –
I0 G0 I1 I2 G2 I3 I4 G4 I5 I6 G6 I7
Fast Inputs
(1) Fast-blow fuse 0.5 A
CAUTION

EIO0000000016 10/2010 71
3.3 Output Wiring Specifications for DC Controllers
Overview
This section describes the wiring and electrical specifications of outputs for DC
controllers.

Topic Page
Regular Output Wiring Specifications for DC Controllers 73
Fast Output Wiring and Specifications for DC Controller 77
72 EIO0000000016 10/2010
Regular Output Wiring Specifications for DC Controllers
Overview
This section provides the wiring diagrams, the specifications, and the internal output
circuit of the regular outputs.
z TM238LDD24DT
DANGER
FIRE HAZARD
WARNING
equipment damage.
EIO0000000016 10/2010 73
Regular Output Specifications

The following table provides information about the main characteristics of the regular
outputs:

TM238LDD24DT
Number of Output Channels 6
Output Power Supply rated voltage 24 Vdc
limit 19.2...30 Vdc (including ripple)
Maximum Output Current 500 mA
Commons 2
Response Time < 1 ms
Protection against reverse polarity No
against short-circuits and Yes
overloads
Length of Connection Cables 30 m (98.4 ft) max.
between channels and 500 Vdc
internal logic
Regular Output Wiring Diagram

The outputs of this equipment do not have built-in reverse polarity protection.
Incorrectly connecting polarity can permanently damage the output circuits or
otherwise result in unintended operation of the equipment.
CAUTION
DAMAGED OUTPUT CIRCUITS
Verify the wiring conforms to the polarity markings on the output connections of this
74 EIO0000000016 10/2010
The following figure shows the regular outputs wiring diagram:
Outputs
V1+ V1- Q4 Q5 Q6 V2+ V2- Q7 Q8 Q9
(1) L L L (1) L L L (2)

+ +
– –
(1) Fast-blow fuse 2 A

(2) Protection for inductive load
In the case of a short-circuit or current overload, the common group of outputs
automatically enter into thermal protection mode (all outputs set to 0), and are then
periodically rearmed (each second) to test the connection state. However, you must
be aware of the effect of this rearming on the machine or process being controlled.
WARNING
UNINTENDED MACHINE STARTUP
Inhibit the automatic rearming of outputs if this feature is an undesirable behavior
for your machine or process.
equipment damage.
NOTE: The automatic rearming feature can be inhibited. For this controller, use the
GetShortcutStatus function to force the group of regular outputs to remain at 0
(OFF).
Depending on the load, a protection circuit may be needed for the outputs on the
controllers and certain modules. Inductive loads using DC voltages may create
voltage reflections resulting in overshoot that will damage or shorten the life of
output devices.
CAUTION
OUTPUT CIRCUIT DAMAGE DUE TO INDUCTIVE LOADS
Use an appropriate external protective circuit or device to reduce the risk of
inductive direct current load damage.
Failure to follow these instructions can result in injury or equipment damage.
EIO0000000016 10/2010 75
Choose a protection circuit from the following diagrams according to the power
supply used. Connect the protection circuit to the outside of the controller or relay
output module.
For more information about protecting outputs from inductive load damage see the
TM2 Digital I/O Module Hardware Guide (see Modicon TM2, Digital I/O Modules,
Hardware Guide).
CAUTION

76 EIO0000000016 10/2010
Fast Output Wiring and Specifications for DC Controller
Overview
This section provides the wiring diagrams, specifications, and internal output circuit
of the fast outputs.
z TM238LDD24DT
DANGER
FIRE HAZARD
WARNING
equipment damage.
Fast Output Specifications

The following table provides information about the main characteristics of the fast
outputs:

TM238LDD24DT
Maximum Output regular mode 500 mA
Current PWM/FG/PTO modes 100 mA
Commons 1
Response Time regular mode < 1 ms
HSC reflex mode < 0.25 ms
Leakage Current 0.3 mA
EIO0000000016 10/2010 77

TM238LDD24DT
against short-circuits to 0 V Yes
and overloads
against short-circuits to No
+24 V
Maximum Cable Length regular mode 30 m (98.4 ft)
PWM/FG/PTO modes 10 m (32.8 ft) with shielded cable
internal logic
Selecting Cables
To select the correct cables for your application, proceed as follows:
If... Then...
you use the PTO/PWM/FG function use shielded cables. (see page 63)
you don’t use the PTO/PWM/FG function use standard cables.
Shielded Cable Connection

To improve Electromagnetic Compatibility (EMC), use shielded cables for fast
outputs. The shielding must be securely connected to ground. The fast output shield
may be connected either to the functional ground (FE) of your system via the
TM2 XMTGB grounding bar or to the protected ground (PE).
WARNING
Properly ground the cable shields as indicated in the related documentation.
equipment damage.
78 EIO0000000016 10/2010
Fast Output Wiring Diagram

The following figure shows the fast outputs source wiring diagram:
Fast Ouputs
V0+ V0- Q0 Q1 Q2 Q3
(1) (2) (2) (2) (2)

+
– L L L L (3)
(4)
(5)
(1) 2 A fast-blow fuse

(2) Fast-blow fuse:
0.5 A in standard use
0.1 A in PTO use
(4) Positive logic output wiring
(5) Negative logic output wiring
CAUTION
DAMAGE TO FAST OUTPUTS
z Ensure adequate protection against short-circuits on the power supply to the
fast outputs.
z Do not connect positive voltage to any of the DC fast outputs terminals (Q0, Q1,
Q2, Q3).
z Comply with the wiring diagrams in this documentation.
Example of an incorrect wiring on Q2:
V0+ V0- Q2
(2) (2)
(1)
+ L
–

(2) Incorrect wiring
EIO0000000016 10/2010 79

WARNING
equipment damage.
GetShortcutStatus function to force the group of fast outputs to remain at 0
(OFF).
output devices.
CAUTION
output module.
Hardware Guide).
80 EIO0000000016 10/2010
CAUTION

EIO0000000016 10/2010 81
3.4 Output Wiring Specifications for AC Controllers
Overview
This section describes the wiring and electrical specifications of outputs for
AC Controllers.

Topic Page
Relay Output Wiring Specifications for AC Controllers 83
Transistor Output Wiring Specifications for AC Controllers 87
82 EIO0000000016 10/2010
Relay Output Wiring Specifications for AC Controllers
Overview
of the relay outputs.
z TM238LDA24DR
DANGER
FIRE HAZARD
WARNING
equipment damage.
Relay Output Specifications

The following table provides information about the main characteristics of the relay
outputs:
Model Number TM238LFAC24DR••,

TM238LDA24DR
Output Power Supply rated voltage 24 Vdc / 240 Vac
limit 30 Vdc / 250 Vac
Output Current rated current C4, C6: 4 A per common and 2 A
per channel (Q4, Q5, Q6, Q7)
C8: 2 A
C9: 5 A
limit -
EIO0000000016 10/2010 83

TM238LDA24DR
Commons C4: 2 N/O contacts
C6: 2 N/O contacts
C8: 1 N/O contact
C9: 1 N/O contact
Minimum Switching Load 10 mA per 5 Vdc (reference
value)
Contact Resistance when new 50mΩ
Loads on Relay Output resistive 2 A at 240 Vac or 2 A at 30 Vdc
Q4...Q8 (with 600 operations per hour
max.
minimum electrical service 1x105 operations
life
minimum mechanical 20x106 operations
service life
inductive without protection See note 1.
device / Capacitive
Loads on relay output resistive 5 A at 240 Vac or 5 A at 30 Vdc
Q9 (with 1800 operations per hour
max).
minimum electrical service 5x104 operations
life
minimum mechanical 20x106 operations
service life
inductive without protection See note 1.
device / Capacitive
Isolation between channels 500 Vrms for 1min
between channels and 500 Vrms for 1min
internal logic
1
Carefully read the information concerning inductive and capacitive loads in the Relay
Output Wiring Diagram below.
84 EIO0000000016 10/2010
Relay Output Wiring Diagram

The following figure shows the relay outputs wiring diagram:
Relay Outputs
C4 Q4 Q5 C6 Q6 Q7 C8 Q8 C9 Q9
(3) (1) (1) (3) (1) (1) (4) (5)
L1 L1 L1 L1
+ + + +
L L L L L L (2)
- - - -

(2) Load protected against inductive charge
(3) 4 A slow-blow fuse
L1 All relays use the same phase across relay groups for alternate current connections
Depending on the load, a protection circuit may be needed for the relay outputs.
Inductive loads using DC voltages may create voltage reflections resulting in
overshoot that will damage or shorten the life of output devices.
CAUTION
EIO0000000016 10/2010 85
Relay outputs can support up to 240 Vac. Inductive damage to these types of
outputs can result in welded contacts and loss of control. Each inductive load must
be equipped with a protection device such as a peak limiter, RC circuit or flyback
diode. Capacitive loads are not supported by these relays.
WARNING
RELAY OUTPUTS WELDED CLOSED
z Always protect relay outputs from inductive alternating current load damage
using an appropriate external protective circuit or device.
z Do not connect relay outputs to capacitive loads.
equipment damage.
output module.
Hardware Guide).
CAUTION

86 EIO0000000016 10/2010
Transistor Output Wiring Specifications for AC Controllers
Overview
of the transistor outputs.
z TM238LDA24DR
DANGER
FIRE HAZARD
WARNING
equipment damage.
Transistor Output Specifications

The following table provides information about the main characteristics of the
transistor outputs:

TM238LDA24DR
Maximum Output Current 500 mA
Commons 1
Response Time < 0.25 ms
EIO0000000016 10/2010 87

TM238LDA24DR
against short-circuits to 0 V Yes
and overloads
against short-circuits to No
+24 V
Length of Connection Cables 30 m (98.4 ft) max.
internal logic
Transistor Output Wiring Diagram

CAUTION
DAMAGED OUTPUT CIRCUITS
Verify the wiring conforms to the polarity markings on the output connections of this
The following figure shows the transistor outputs wiring diagram:
Transistor Outputs
V0+ V0- Q0 Q1 Q2 Q3
(1) L L L L (2)
+
-

88 EIO0000000016 10/2010

WARNING
equipment damage.
GetShortcutStatus function to force the group of transistor outputs to remain at
0 (OFF).
output devices.
CAUTION
output module.
EIO0000000016 10/2010 89
CAUTION

90 EIO0000000016 10/2010
M238 - Connecting the Modicon M238 Logic Controller to a PC
EIO0000000016 10/2010
Connecting the Modicon M238

Logic Controller to a PC
4
Connecting the Controller to a PC
Overview
To transfer, run and monitor the applications, connect the controller to a computer,
that has SoMachine installed. Use one of the following USB cables:
TCS XCNA MUM3P : This USB cable is suitable for short duration connection like
quick updates or retrieving data values.
BMX XCA USBH045 : Grounded and shielded, this USB cable is suitable for long
duration connection.
NOTE: You can only connect 1 controller to the PC at the same time.
The USB Mini-B Port is the programming port you can use to connect a PC with a
USB host port using SoMachine software. Using a typical USB cable, this
connection is suitable for quick updates of the program or short duration connections
to perform maintenance and inspect data values. It is not suitable for long term
connections such as commissioning or monitoring without the use of specially
adapted cables to help minimize electromagnetic interference.
WARNING
INOPERABLE EQUIPMENT OR UNINTENDED EQUIPMENT OPERATION
z You must use a shielded USB cable such as a BMX XCAUSBH0•• secured to
the functional ground (FE) of the system for any long term connection.
z Do not connect more than one controller at a time using USB connections.
equipment damage.
EIO0000000016 10/2010 91
The communication cable should be connected to the PC first to minimize the

possibility of electrostatic discharge affecting the controller.
CAUTION
Always connect the communication cable to the PC before connecting it to the
controller.
USB Mini-B Port Connection

The following figure shows the USB connection to a PC:
BMXXCAUSBH045
So
Machine USB (4.5 m / 14.8 ft) USB Mini-B
TCSXCNAMUM3P
USB (3 m / 9.8 ft) USB Mini-B
BMXXCAUSBH045
So
Machine USB (4.5 m / 14.8 ft) USB Mini-B
FAST INPUTS INPUTS
TCSXCNAMUM3P Prog.
Port

CANopen
TRANSISTOR
RELAY OUTPUTS
SL1 SL2 OUTPUTS
100-240VAC
BMXXCAUSBH045 PULL PULL
So
Eth LA RUN / MS
Eth ST
Eth NS
USB Host
MBS COM BATTERY
LMC058
(4.5 m / 14.8 ft)

CAN0 STS APP0
Machine
CAN1 STS APP1
USB USB Mini-B TM258LF42DT

EthMAC Address : xx-xx-xx-xx-xx-xx BATTERY (RTC)
1
1
21
11
21
11
21
11
21
11
21
11
2
1
1 21 21 21 21 21 2
2 22 22 22 22 22 2
PWR
CAN1 CAN0
TCSXCNAMUM3P
5V Off 24V 1 21 21 21 21 21 2
Host 3 33 33 33 33 33 3
1 21 21 21 21 21 2
4 44 44 44 44 44 4
Pgr Port
1 21 21 21 21 21 2
MBS Ethernet 5 55 55 55 55 55 5

1 21 21 21 21 21 2
ENCODER 6 66 66 66 66 66 6
RS485 / RS232
92 EIO0000000016 10/2010
BMXXCAUSBH045 PULL PULL
So
Eth LA MS
Eth ST
Eth NS
USB Host
MBS COM BATTERY
TM258
(4.5 m / 14.8 ft)

CAN0 STS APP0
Machine
APP1
USB USB Mini-B TM258LF42DT

EthMAC Address : xx-xx-xx-xx-xx-xx BATTERY (RTC)
1
1
21
11
21
11
21
11
21
11
21
11
2
1
1 21 21 21 21 21 2
2 22 22 22 22 22 2
CAN0
TCSXCNAMUM3P
1 21 21 21 21 21 2
Host 3 33 33 33 33 33 3
1 21 21 21 21 21 2
4 44 44 44 44 44 4
Pgr Port
1 21 21 21 21 21 2
MBS Ethernet 5 55 55 55 55 55 5

1 21 21 21 21 21 2
6 66 66 66 66 66 6
RS485 / RS232
To connect the USB cable to your controller, do the following:
Step Action
1 1a If making a long term connection using the cable BMX XCA USBH045, or
other cable with a ground shield connection, be sure to securely connect the
shield connector to the functional ground (FE) or protective ground (PE) of
your system before connecting the cable to your controller and your PC.
1b If making a short term connection using the cable TCS XCNA MUM3P or
other non-grounded USB cable, proceed to step 2.
2 Connect the USB cable connector to the PC.
3 Connect the Mini connector of your USB cable to the controller USB connector.
Step Action
1 1a If making a long term connection using the cable BMX XCA USBH045, or
other cable with a ground shield connection, be sure to securely connect the
shield connector to the functional ground (FE) or protective ground (PE) of
your system before connecting the cable to your controller and your PC.
1b If making a short term connection using the cable TCS XCNA MUM3P or
other non-grounded USB cable, proceed to step 2.
2 Connect your USB cable to the computer.
3 Open the hinged access cover.
4 Connect the Mini connector of your USB cable to the controller USB connector.
EIO0000000016 10/2010 93
Step Action
1 1a If making a long term connection using the cable BMX XCA USBH045, or other
cable with a ground shield connection, be sure to securely connect the shield
connector to the functional ground (FE) or protective ground (PE) of your system
before connecting the cable to your controller and your PC.
1b If making a short term connection using the cable TCS XCNA MUM3P or other
non-grounded USB cable, proceed to step 2.
2 Open the USB cover to have access to the Programming Port:
2
8
23
M
T
BAT
PW
R ERR
NR
. RU
N CA
prg . NE
rt 1
SL1 CA
po
SL2
o pen
CAN
SL2
SL1
D C
24V
1 Push horizontally on the USB cover and hold down.

2 Slide the USB cover downward.
3 Connect the USB cable connector to the PC.
4 Connect the Mini connector of your USB cable to the M238 USB connector.
Ethernet Port Connection

You can also connect the controller to a PC using an Ethernet cable.
The following figure shows the Ethernet connection to a PC:
PULL PULL
Eth LA RUN / MS
Eth ST
Eth NS
USB Host
MBS COM BATTERY
So
LMC058 CAN0 STS
CAN1 STS
APP0
APP1
Machine
1 2 1 2 1 2 1 2 1 2 1 2
1 1 1 1 1 1 1 1 1 1 1 1
LMC058LF42DT4LS0 BATTERY (RTC)

EthMAC Adress : 12345-789ABCD
1 2 1 2 1 2 1 2 1 2 1 2
2 2 2 2 2 2 2 2 2 2 2 2
PWR
CAN1 CAN0
5V Off 24V 1 2 1 2 1 2 1 2 1 2 1 2
Host 3 3 3 3 3 3 3 3 3 3 3 3
PCI 0
VW3 A8 306 Rpp

1 2 1 2 1 2 1 2 1 2 1 2
4 4 4 4 4 4 4 4 4 4 4 4
Pgr Port
1 2 1 2 1 2 1 2 1 2 1 2
MBS Ethernet 5 5 5 5 5 5 5 5 5 5 5 5
1 2 1 2 1 2 1 2 1 2 1 2
ENCODER 6 6 6 6 6 6 6 6 6 6 6 6
RS485 / RS232
RJ45 RJ45
94 EIO0000000016 10/2010
The following figure shows the Ethernet connection to a PC:

PULL PULL
Eth LA MS
Eth ST
Eth NS
USB Host
So
MBS COM BATTERY
M258 CAN0 STS APP0
APP1
Machine
1 2 1 2 1 2 1 2 1 2 1 2
1 1 1 1 1 1 1 1 1 1 1 1
TM258LF42DT4L BATTERY (RTC)

EthMAC Adress : 0080F-4816531
1 2 1 2 1 2 1 2 1 2 1 2
2 2 2 2 2 2 2 2 2 2 2 2
CAN0
Host 1 2 1 2 1 2 1 2 1 2 1 2
3 3 3 3 3 3 3 3 3 3 3 3
VW3 A8 306 Rpp

1 2 1 2 1 2 1 2 1 2 1 2
4 4 4 4 4 4 4 4 4 4 4 4
Pgr Port
1 2 1 2 1 2 1 2 1 2 1 2
MBS Ethernet 5 5 5 5 5 5 5 5 5 5 5 5
1 2 1 2 1 2 1 2 1 2 1 2
6 6 6 6 6 6 6 6 6 6 6 6
RS485 / RS232
RJ45 RJ45
To connect the controller to the PC, do the following:
Step Action
1 Connect your Ethernet cable to the PC.
2 Connect your Ethernet cable to the Ethernet port on the controller.
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96 EIO0000000016 10/2010
M238 - Serial Line Connection
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Serial Line Connection
5
Serial Line Connection
Serial Link Capabilities

To enable communications through serial links, the standard Modicon M238 Logic
Controller includes an RS 232/485 serial link and an RS 485 serial link with 5 Vdc
power supply (SL1 or SL2 depending on the model).
This isolated serial port allows Modicon M238 Logic Controller to communicate
according to 3 protocols:
SoMachine for link with SoMachine compliant device (routing or variable access)
Modbus in order to meet the needs of master/slave architectures with
Schneider Electric or third party devices
ASCII in character mode for links with serial devices (printer, modem, or barcode
reader)
NOTE: Under most circumstances, you should avoid connecting multiple instances
of SoMachine to the same controller via the serial line, Ethernet and/or the USB port
simultaneously. While it is possible, there could arise conflicts in actions taken by
the various instances of SoMachine such as program, configuration or data edits, or
control commands to the controller or its application. For more information, see the
programming guide for your particular controller.
Serial Lines Connectors Pinout

The Modicon M238 Logic Controller has two 8-pin RJ45 connectors that provide
serial link connection:
z 1 marked SL1 (Serial Line 1) for the RS 232/485 serial line
z 1 marked SL2 (Serial Line 2) for the RS 485 serial line
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SL1
Pin RS232 RS485 Description

1 RXD N.C. received data
2 TXD N.C. transmitted data
3 RTS N.C. request to send
4 – D1 (A+) differential pair
5 – D0 (B-)
6 CTS N.C. clear to send
7 + 5 Vdc / 200 mA (1) HMI power supply (1)
8 0V Signal Common
NOTE: (1) Pin 7 is dedicated to supply power to HMI devices such as

XBT Nx00/R400/RT500 or small equipment such as Ethernet Gateway through the
serial link cable. Only for TM238LDD24DT and TM238LDA24DR controllers.
SL2
Pin RS485 Description

1 N.C. N.C.
2 N.C. N.C.
3 N.C. N.C.
4 D1 (A+) differential pair
5 D0 (B-)
6 N.C. N.C.
98 EIO0000000016 10/2010
Pin RS485 Description

7 + 5 Vdc / 200 mA (1) HMI power supply (1)
8 0V Signal Common
NOTE: (1) Pin 7 is dedicated to supply power to HMI devices such as

XBT Nx00/R400/RT500 or small equipment such as Ethernet Gateway, through
serial link cable.
Serial Line Specifications
Characteristics Serial Line 1 (1) Serial Line 2 (1)

Model Number TM238LDD24DT, TM238LFDC24DT••, TM238LFDC24DT••,
TM238LDA24DR TM238LFAC24DR•• TM238LFAC24DR••
Type Master/slave type isolated serial link
Standards RS485/RS232 RS485
Protocol selection User programmable in SoMachine
Number of wires RS485: 4 4
RS232: 5
Connector RJ45 female
Supply output 5 Vdc/200 mA - 5 Vdc/200 mA
Short circuit protection Yes
Overload protection Yes
Reverse polarity protection No
Data rate 1.2...115.2 Kbps 1.2...38.4 Kbps (19.2 Kbps 1.2...115.2 Kbps
(115.2 Kbps by default) by default) (115.2 Kbps (115.2 Kbps by default)
with SoMachine Protocol)
Line Polarization User programmable in SoMachine -
Shield ground Yes
Shield ground to signal lines 500 Vdc
rigidity
(1) Serial link 1 and serial link 2 are not isolated from one another.
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Modbus and ASCII Network Characteristics
Protocol Modbus Character Mode

Physical Interface
RS232 RS485, RS232 RS485,
2-wire 2-wire
Structure Type Isolated serial link
Access method Master/slave type
Transmission Mode Asynchronous in basic band
Frame RTU/ASCII, Half duplex Full duplex Half duplex
Data rate refer to Serial Line Specifications (see page 99)
Format 7 or 8 data bits, 1 or 2 stop bits
Parity Without, even or odd
Medium Shielded twisted pair Single or Shielded twisted
double pair
shielded
twisted pair
Configuration Number of devices 2 (point to point 32 max per 2 (point to 32 max per
segment point) segment
Services Frame 250 bytes of data – – –
per request
Security, check One CRC on each frame (RTU) One LRC on each frame (ASCII)
parameter One LRC on each frame (ASCII)
Monitoring Diagnostic counters, event counters –
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M238 - CANopen Connection
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CANopen Connection
6
CANopen Connection
CANopen Capabilities
The Modicon M238 Logic Controller CANopen master has the following features:
Maximum number of slaves on the bus 16 CANopen slave devices

Maximum length of CANopen fieldbus cables According to the CAN specification (see
Cable Length and Transmission Speed).
Maximum number of PDOs managed by the 32 TPDOs + 32 RPDOs
master
For each additional CANopen slave,

z the application size increases by an average of 10 kbytes that can result a
memory size overload.
z the configuration initialization time at the startup increases that can lead to
watchdog condition.
Although SoMachine does not restrict you from doing so, we recommend that you
not exceed more than 16 CANopen slave modules (and/or 32 TPDOs and 32
RPDOs) in order to have a sufficient performance tolerance and to avoid any
performance degradation.
WARNING
Do not connect more than 16 CANopen slave devices to the controller to avoid
system overload watchdog condition.
equipment damage.
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CAUTION
DEGRADATION OF PERFORMANCE
Do not exceed more than 32 TPDOs and 32 RPDOs for the Modicon M238 Logic
Controller.
CANopen Wiring Diagram
CAN_GND 1 GND
CAN_L 2 CanL
R
CAN_SHLD 3 Shld
CAN_H 4 CanH
N.C. 5 NC
R Line termination resistor (120 Ω)
Pin Signal Description Marking Color of Cable

1 CAN_GND CAN Ground GND black
2 CAN_L CAN_L bus line (dominant low) CanL blue
3 CAN_SHLD Optional CAN shield Shld -
4 CAN_H CAN_H bus line (dominant high) CanH white
5 Not used Reserved N.C. red
CAUTION
102 EIO0000000016 10/2010

Cable Length
Transmission speed is limited by the bus length and the type of cable used.
The following table describes the relationship between the maximum transmission
speed and the bus length (on a single CAN segment without a repeater).
Maximum transmission baud rate Bus length

1000 Kbps 20 m (65 ft)
800 Kbps 40 m (131 ft)
500 Kbps 100 m (328 ft)
250 Kbps 250 m (820 ft)
125 Kbps 500 m (1,640 ft)
50 Kbps 1000 m (3280 ft)
20 Kbps 2500 m (16,400 ft)
CANopen Wiring
The CANopen network cable is a shielded twisted double-pair cable that complies
with the CANopen standard CiA DR-303-1.
The CANopen network cable must be properly grounded to the Modicon M238 Logic
Controller Shield Ground (Shld), or CANopen communications may be interrupted
or operate improperly.
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The following figure shows the wiring of the cable CANopen to the Modicon M238
Logic Controller
1
2
3
4
5
1 CAN_GND
2 CAN_L
3 CAN_SHLD
4 CAN_H
5 N.C.
104 EIO0000000016 10/2010

M238 - Controller Diagnostic and I/O Management
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Controller Diagnostic and I/O

Management
7
Introduction
This chapter provides information about controller diagnostic and I/O management.

Topic Page
System Diagnostic Using LED Display 106
Input Management 109
Output Management for DC Controllers 113
Output Management for AC Controllers 118
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System Diagnostic Using LED Display
Introduction
This section provides information about the controller operating status and
troubleshooting using LEDs on the front of the Modicon M238 Logic Controller.
This controller has either 5 or 8 LED, depending on the Controller model, that report
different states of the system. In addition, there are 24 LEDs that report the input and
output logic states.
System LED Display
PWR Batt PWR Batt
RUN Err RUN Err
SL1 CAN Run SL1
SL2 CAN Err
Display 1 Display 2
Display 1: LEDs on the TM238LFDC24DT•• and TM238LFAC24DR•• Controllers

Display 2: LEDs on the TM238LDD24DT and TM238LDA24DR Controllers
The table below shows system LED description:
LED Color Description

PWR green z ON: power on
z OFF: power off
Batt red z ON: The external backup battery is depleted or absent and needs
to be replaced as soon as possible. The remaining charge may not
be sufficient to maintain data in persistent memory.
z Regular flashes: The backup battery needs to be replaced but still
maintains data.
z OFF: The backup battery charge is ok.
z This LED can be deactivated using the InhibitBatLowLed
(see Modicon M238 Logic Controller, System
Functions and Variables, M238 PLCSystem Library
Guide) function.
RUN green z ON: The controller is in RUN state.
z OFF: No program in the controller.
z Regular flashes: The controller is in STOP state.
z Slow flashes (25% ON, 75% OFF): The controller is stopped on a
breakpoint.
106 EIO0000000016 10/2010

LED Color Description

Err red z ON, with RUN LED flashing: EXCEPTION state due to application
watchdog or system overload.
z Fast flashes: Internal error detected.
z 3 flashes, with RUN LED in OFF state: no application in the
controller.
z Slow flashes (25% ON, 75 % OFF), Non-blocking detected error:
Current application has not been saved as a boot project or
detected error on expansion bus.
z Regular flashes, with RUN LED in OFF state: Corrupted or
missing firmware.
SL1 yellow Shows the activity of the serial line 1.
SL2 (1) yellow Shows the activity of the serial line 2.
CAN Run(1) green Indicates the status of the CANopen network. See table below.
CAN Err.(1) red Indicates errors detected by the CANopen Master or the CANopen
physical layer. See table below.
(1) Only for TM238LFDC24DT•• and TM238LFAC24DR••.
CANopen LEDs Description (only for TM238LFDC24DT•• and TM238LFAC24DR••)

The CAN Run LED indicates the status of the CANopen network. the CAN Err. LED
indicates the status of the CANopen physical layer and the presence or absence of
regularly recurring CAN messages (sync, guard or heartbeat).
The following table describes the status of CANopen LEDs:
LED Status Meaning

CAN Run green off No CANopen master configured
flashing The CANopen bus is in initialization phase
1 flash per second The CANopen bus is stopped
on The CANopen bus is operational
CAN Err. red off No CANopen fault detected
flashing CANopen configuration not valid
1 flash per second Alarm threshold exceeded (too many errors
detected)
2 flashes per second A “Node Guarding” or “Heartbeat” event has
occurred
on The CANopen bus is stopped (BUS OFF)
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I/O LED Display
I0 I1 I2 I3 I4 I5 I6 I7 I8 I9 I10 I11 I12 I13
Q0 Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8 Q9
The LEDs indicate the logic state of each input and output:
z ON: Input or output state is active.
z OFF: Input or output state is inactive.
108 EIO0000000016 10/2010

Input Management
Introduction
The Modicon M238 Logic Controller includes 14 digital inputs, including 8 fast
inputs.
The following functions are configurable on regular and/or fast inputs:
z Filters (depends on the function associated with the input).
z 8 fast inputs can be either latched or used for events (rising edge, falling edge, or
both) and thus be linked to an external task (up to 4).
z Any input can be used for the RUN/STOP function.
z Some of the inputs can be used by HSC, PTO, PWM, and FG functions.
NOTE: All inputs by default can be used as regular inputs.
Input Management Functions Availability

An input is either not configured, or used for RUN/STOP, or used for events, or used
by HSC, PTO, PWM, and FG functions. See the table below:
Model Number TM238LFDC24DT••, TM238LDD24DT TM238LFDC24DT•• TM238LFAC24DR••

TM238LFAC24DR••, TM238LDA24DR , TM238LDD24DT , TM238LDA24DR
Input function HSC/PTO/PWM/FG
Function
None RUN/STOP Latch Event
Filter type Integrator Integrator Bounce Bounce
I0 X X X X HSC
I1 X X X X HSC
I2 X X X X HSC
Fast I3 X X X X HSC
Input I4 X X X X HSC
I5 X X X X HSC
I6 X X X X HSC
I7 X X X X HSC
I8 X X – – PWM/FG –
I9 X X – – PWM/FG/PTO –
Regular I10 X X – – – –
Input I11 X X – – PWM/FG –
I12 X X – – PWM/FG/PTO –
I13 X X – – – –
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Integrator Filter Principle

The integrator filter is designed to reduce the effect of noise. Setting a filter value
allows the controller to ignore some sudden changes of input levels caused by
noise.
The following timing diagram illustrates the integrator filter effects for a value of
4 ms:
NOTE: The value selected for the filter's time parameter specifies the cumulative
time in ms that must elapse before the input can be 1.
Bounce Filter Principle

The bounce filter is designed to reduce the bouncing effect at the inputs. Setting a
bounce filter value allows the controller to ignore some sudden changes of input
levels caused by noise. The bounce filter is only available on the fast inputs.
110 EIO0000000016 10/2010

The following timing diagram illustrates the anti-bounce filter effects:
Input
Delay Delay
Filtered Signal
Bounce Filter Availability

The bounce filter can be used on a fast input when:
z Latch is used, or Event is used, and
z No HSC is enabled
Latching
Latching is a function that can be assigned to the Modicon M238 Logic Controller
fast inputs. This function is used to memorize (or latch) any pulse with a duration that
is less than the Modicon M238 Logic Controller scan time. When a pulse is shorter
than one scan, the controller latches the pulse, which is then updated in the next
scan. This latching mechanism only recognizes rising edges. Falling edges cannot
be latched. Assigning inputs to be latched is done with the I/O configuration screen
in SoMachine.
The following timing diagram illustrates the latching effects:
Event
An input configured for Event can be associated with an External Task (see Modicon
M238 Logic Controller, Programming Guide).
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RUN/STOP
The RUN/STOP function is used to start or stop a program using an input:
z When the configured RUN/STOP input is at logic 0, the controller is put into a
STOP state and any other outside command to enter the RUN state is ignored.
z A rising edge (passing from 0 to 1) of the RUN/STOP input provokes
automatically a start-up of the application as the controller enters a RUN state.
z When the configured RUN/STOP input is at logic 1, then the controller program
is running unless otherwise commanded by SoMachine (RUN/STOP commands
from SoMachine are allowed).
WARNING
UNINTENDED MACHINE OR PROCESS START UP
z Be sure of the state of security of your machine or process environment before
applying power to the Run/Stop input.
z Use the Run/Stop input to help prevent the unintentional start up from a remote
location.
equipment damage.
For more information, refer to Embedded I/O configuration (see Modicon M238
Logic Controller, Programming Guide).
112 EIO0000000016 10/2010

Output Management for DC Controllers
Introduction
z TM238LDD24DT
The Modicon M238 Logic Controller with DC power supply includes 10 digital
outputs, including 4 fast outputs.
The following output functions are configurable on regular and/or fast outputs:
z HSC (reflex features on HSC threshold)
z PTO
z PWM
z FG
NOTE: All outputs by default can be used as regular outputs.
Output Management Functions Availability
Function HSC PWM

PTO
Type Main Simple(1) Main Simple(2) FG
Channel 0 0...3 4 4...7 PTO0 PTO1 PWM0 PWM1

Number FG0 FG1
Q0 – – – – PTO0 – PWM0/FG0 –
Output0 Output
Q1 – – – – PTO0 – – –
Fast Output1
Output Q2 – – – – – PTO1 – PWM1/FG1
Output0 Output
Q3 – – – – – PTO1 – –
Output1
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Function HSC PWM

PTO
Type Main Simple(1) Main Simple(2) FG
Channel 0 0...3 4 4...7 PTO0 PTO1 PWM0 PWM1

Number FG0 FG1
Q4 HSC0 – – – – – – –
reflex
Output0(3)
Q5 HSC0 – – – – – – –
reflex
Output1(3)
Regular Q6 – – – – – – – –
Output Q7 – – HSC4 – – – – –
reflex
Output0(3)
Q8 – – HSC4 – – – – –
reflex
Output1(3)
Q9 – – – – – – – –
(1) Channels HSC0 to HSC3 are usable as a Simple HSC only if HSC0 is not used
as a Main HSC (see page 125).
(3) Reflex output used or not according to configuration. If not configured, the output
is a regular output by default.
Fallback Modes (Behaviour for outputs in Stop)

When the controller enters the STOP or EXCEPTION state for any reason, the Local
(Embedded and Expansion) outputs are set to fallback values. Two modes are
available:
Set all outputs to default Each output is set to the configured default value, either
0 or 1 (initially set to 0 in the configuration).
Keep current values Each output remains in its current state
114 EIO0000000016 10/2010


WARNING
equipment damage.
NOTE:
is always 0.
Short-circuit or Over-current on Outputs

In the case of short-circuit or over-current on outputs, there are different consider-
ations for the 3 groups of outputs:
z Group 1 (Q0 to Q3): 4 fast outputs
z Group 2 (Q4 to Q6): 3 regular outputs
z Group 3 (Q7 to Q9): 3 regular outputs
The following table describes the detection:
If... then...
you have a short-circuit at 0V on group 1 the group 1 automatically go into thermal
protection mode (all fast, PWM or FG outputs
set to 0 and PTO outputs runs a quick stop
deceleration) and are then periodically
rearmed every 10 seconds to test the
connection state (see warning below).
For more information, refer to fast output
wiring diagram (see page 79).
you have short-circuit at 24V on group 1 nothing is detected and can result in
equipment damage (see caution below).
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If... then...
you have a short-circuit at 0V on group 2 or 3 the impacted group automatically go into
thermal protection mode (all regular or HSC
outputs set to 0) and are then periodically
rearmed every 10 seconds to test the
connection state (see warning below).
For more information, refer to regular output
wiring diagram (see page 73).
you have short-circuit at 24V on group 2 or 3 nothing is detected and no heating.
the current crossing the group 1, 2, or 3 is too a thermal disjunction occurs shutting down
high the outputs.The outputs are forced to 0, and
cannot be set to 1 until the temperature
decreases.
NOTE: The short-circuit diagnostic for each group is provided by the function
GetshortcutStatus (see Modicon M238 Logic Controller, System Functions and
Variables, M238 PLCSystem Library Guide).
WARNING
equipment damage.
GetshortcutStatus function to force the group of outputs to remain at 0 (OFF).
CAUTION
DAMAGE TO FAST OUTPUTS
z Ensure the use of adequate protection against short-circuits on the power
supply to the fast outputs.
z Do not connect positive voltage to any of the DC fast outputs terminals (Q0, Q1,
Q2, Q3).
z Comply with the wiring diagrams immediately after this message.
116 EIO0000000016 10/2010

Example of an incorrect wiring on Q2:
V0+ V0- Q2
(2) (2)
(1)
+ L
–

(2) Incorrect wiring
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Output Management for AC Controllers
Introduction
z TM238LDA24DR
The Modicon M238 Logic Controller with AC power supply includes 10 digital
outputs, including 6 relay outputs.
The following output function are configurable on transistor outputs:
z HSC (reflex features on HSC threshold)
NOTE: All outputs by default can be used as regular outputs.
Output Management Functions Availability
Function HSC
Type Main Simple(1) Main Simple(2)
Channel Number 0 0...3 4 4...7
Q0 HSC0 reflex – – –
Output0(3)
Q1 HSC0 reflex – – –
(3)
Transistor Output1
Output Q2 – – HSC4 reflex –
Output0(3)
Q3 – – HSC4 reflex –
Output1(3)
(3) Reflex output used or not according to configuration. If not configured, the output
is a regular output by default.
118 EIO0000000016 10/2010

Fallback modes (Behaviour for outputs in Stop)

When the controller enters the STOP or EXCEPTION state for any reason, the Local
(Embedded and Expansion) outputs are set to fallback values. Two modes are
available:
Set all outputs to default Each output is set to the configured default value, either
0 or 1 (initially set to 0 in the configuration).
Keep current values Each output remains in its current state
WARNING
equipment damage.
NOTE:
is always 0.
Short-circuit or Over-current on Outputs

In the case of short-circuit or over-current on outputs, there are different consider-
ations for the 2 groups of outputs:
z Group 1 (Q0 to Q3): Transistor outputs
z Group 2 (Q4 to Q9): Relay outputs
EIO0000000016 10/2010 119

The following table describes the detection:
If... then...
you have short-circuit at 0V on group 1 the group 1 automatically go into thermal
protection mode (all regular or HSC outputs
set to 0) and are then periodically rearmed
(each 10 second) to test the connection state
(see warning below).
For more information, refer to transistor
output wiring diagram (see page 88).
you have short-circuit at 24V on group 1 nothing is detected and no heating.
you have short-circuit at 0V or 24V on group 2 nothing is detected.
the current crossing the group 1 is too high a thermal disjunction occurs shutting down
the group 1.The outputs of group 1 are forced
to 0, and cannot be set to 1 until the
temperature decreases.
NOTE: The short-circuit diagnostic for each group is provided by the function
GetshortcutStatus (see Modicon M238 Logic Controller, System Functions and
Variables, M238 PLCSystem Library Guide).
WARNING
equipment damage.
GetshortcutStatus function to force the group of outputs to remain at 0 (OFF).
120 EIO0000000016 10/2010

Relay outputs are electromechanical switches capable of carrying significant levels

of current and voltage. All electromechanical devices have a limited operational life
and must be installed so as to minimize the potential for unintended consequences.
The relay outputs of this device can remain ON or OFF regardless of logical control.
WARNING
MALFUNCTION OF OUTPUTS
Use appropriate, external safety interlocks on outputs where personnel and/or
equipment hazards exist.
equipment damage.
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122 EIO0000000016 10/2010

M238 - Fast I/Os
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Fast Inputs/Outputs
8
Introduction
This chapter provides information about the Fast I/Os (Input/Outputs) and their
associated functions.

This chapter contains the following sections:
Section Topic Page
8.1 HSC (High Speed Counter) 124
8.2 PTO (Pulse Train Output) 132
8.3 PWM (Pulse Width Modulation) 138
8.4 FG (Frequency Generator) 141
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M238 - Fast I/Os
8.1 HSC (High Speed Counter)
Overview
This section will help you use the HSCfunctions (see Modicon LMC058 Motion
Controller, High Speed Counting, LMC058 Expert I/O Library Guide) and the
mapping of I/O.
Fast Input/Outputs that are not configured by the HSC functions can be used as
regular Input/Outputs (see Modicon M238 Logic Controller, Programming Guide).

Topic Page
HSC Overview 125
Modes 127
HSC I/O Mapping 129
124 EIO0000000016 10/2010

M238 - Fast I/Os
HSC Overview
Introduction
All Modicon M238 Logic Controller include embedded HSC inputs which can be
activated and setup using the HSC counting modes.
Concept
The HSC function is used for counting pulses and depending on the configuration
update outputs, regardless of the scan time of the application. The maximum
frequency is 100 kHz.
The Simple HSC only uses 1 counting input and no output. Two counting modes
allow to program an action in the context of an application task (no event
management) when a predefined count is reached.
The Main HSC can use up to 4 inputs and 2 outputs, depending on the input mode
and configured functions: 5 counting modes are supported, with optional capture,
thresholds and event management.
NOTE: The fallback settings that may be configured (fallback to 0, fallback to 1, or
fallback to the current state) will not have the expected effect on outputs Q0, Q1, Q2
or Q3 if these outputs are configured for HSC operation. If a detected error results
in the controller entering fallback mode, these outputs will fallback to a value of 0
Input Mapping for 2 Main HSC

The following illustration shows the differences in configuration between the 2 Main
HSCs.
HSC
Channel 1 Main HSC 1 Main HSC 2 Main HSC
I0 A A
I1 B/EN B/EN
HSC0
I2 Synchronization Synchronization
I3
Fast Inputs
Capture Capture
I4 A A
I5 B/EN B/EN
I6 HSC4
Synchronization Synchronization
I7
Capture Capture
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M238 - Fast I/Os
Input Mapping for 8 Simple HSC
HSC 8
Channel Simple HSC
I0 HSC0 A
I1 HSC1 A
I2 HSC2 A
Fast Inputs
I3 HSC3 A
I4 HSC4 A
I5 HSC5 A
I6 HSC6 A
I7 HSC7 A
NOTE: An HSC channel can be assigned any fast input address. There is no
preferred addressing order.
Input Mapping for 1 Main HSC + 4 Simple HSC

The following illustration shows the different configurations of 1 Main + 4 Simple
HSC.
HSC 1 Main HSC HSC 4 Simple HSC

Channel + 4 Simple HSC Channel + 1 Main HSC
I0 A HSC0 A
I0
I1 B/EN I1 HSC1 A
HSC0
I2 Synchronization I2 HSC2 A
HSC3
Fast Inputs
Fast Inputs
I3 Capture I3 A
I4 HSC4 A A
I4
I5 HSC5 A I5 B/EN
HSC4
I6 HSC6 A I6 Synchronization
I7 HSC7 A I7 Capture
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M238 - Fast I/Os
Modes
Introduction
This section provides informations about the following HSC modes:
z One Shot
z Modulo Loop
z Free Large
z Event Counting
z Frequency Meter
One Shot
The One Shot counter mode allows you to count a predefined number of pulses and
stop.
Principle: The counter decreases from a preset value and stops when its current
value reaches 0. At this point, the done bit is set and the current counter value is not
modified by any new pulses from the input. The counter waits for the next synchroni-
zation to restart.
Example: The preset value may be a number of pieces to be packaged.
Modulo Loop
The Modulo Loop counter mode is used for applications for which actions are
repetitive.
Principle: In this mode the counter repeatedly counts from 0 to a user-defined
maximum value then returns to 0 and moves on, in a direct way. In reverse, the
counter counts down from the maximum value to 0 then presets to the maximum
value and continues to decrease. This mode can be used with a single Encoder.
Free Large
The Free Large counter mode is for axis monitoring or labeling when the incoming
position of each part has to be known.
Principle: In the Free Large Counter mode, the module behaves like a high-range
Up/Down counter. This mode can be used with a single Encoder.
Event Counting
The Event Counting mode is used to count a sequence of events over a given period
of time.
Principle: The counter assesses the number of pulses applied on the input for a
predefined period of time. The counting register is updated at the end of each period
with the number of events received.
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M238 - Fast I/Os
Frequency Meter
The Frequency Meter mode allows the measurement of an event's frequency,
speed, rate, or flow.
Principle: The measured frequency is a mean frequency: number of events in the
time interval converted to number of events per second (Hz).
Implementation in SoMachine
To configure HSC parameters, refer to the HSC Library (see Modicon M238 Logic
Controller, Programming Guide) Online Help.
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M238 - Fast I/Os
HSC I/O Mapping
HSC I/O Mapping for DC Controllers

The table below shows the availability of the HSC functions according to the inputs
and outputs:
Function HSC
Channel 0 0 1 2 3 4 4 5 6 7
I0 A A – – – – – – – –
I1 B (3)(4) – A – – – – – – –
I2 Sync (4) – – A – – – – – –
I3 Cap(4) – – – A – – – – –
Fast
Input I4 – – – – – A A – – –
I5 – – – – – B (3)(4) – A – –
I6 – – – – – Sync(4) – – A –
I7 – – – – – Cap(4) – – – A
Q4 HSC0 – – – – – – – – –
reflex
Output0(4)
Q5 HSC0 – – – – – – – – –
reflex
Output1(4)
Regular Q6 – – – – – – – – – –
Output Q7 – – – – – HSC4 – – – –
reflex
Output0(4)
Q8 – – – – – HSC4 – – – –
reflex
Output1(4)
Q9 – – – – – – – – – –
A Input counting signal
B Input counting signal or enable depending configuration of HSC block
Sync Reset and start counting
Cap Capture current position signal
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M238 - Fast I/Os
(3) A and B functions depend on the configuration of Main HSC mode
(see page 127).
(4)Used or not according to the configuration of Main HSC mode.
HSC I/O Mapping for AC Controllers

The table below shows the availability of the HSC functions according to the inputs
and outputs:
Function HSC
Channel 0 0 1 2 3 4 4 5 6 7
I0 A(3) A – – – – – – – –
I1 B(3)(4) – A – – – – – – –
I2 Sync(4) – – A – – – – – –
I3 Cap (4) – – – A – – – – –
Fast
Input I4 – – – – – (3) A – – –
A
I5 – – – – – B (3)(4) – A – –
I6 – – – – – Sync (4) – – A –
I7 – – – – – Cap (4) – – – A

Cap Capture current position
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M238 - Fast I/Os
Function HSC
Channel 0 0 1 2 3 4 4 5 6 7
Q0 HSC0 – – – – – – – – –
reflex
Output0(4)
Q1 HSC0 – – – – – – – – –
reflex
Transistor Output1(4)
Output Q2 – – – – – HSC4 – – – –
reflex
Output0(4)
Q3 – – – – – HSC4 – – – –
reflex
Output1(4)
Cap Capture current position
(3) A and B functions depend on the configuration of Main HSC mode
(see page 127).
(4) Optional: used or not according to the configuration of Main HSC mode.
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M238 - Fast I/Os
8.2 PTO (Pulse Train Output)
Overview
This section will help you use the PTO functions (see Modicon M238 Logic
Controller, Programming Guide) and the mapping of I/O.
Fast Input/Outputs that are not configured by the PTO functions can be used as

Topic Page
PTO Overview 133
PTO I/O Mapping 137
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M238 - Fast I/Os
PTO Overview
Introduction
z TM238LDD24DT
The PTO (Pulse Train Output) function implements digital technology for precise
positioning tasks.
Concept
Pulse Train Output (PTO) function is used to control a stepper or servo motor. It
provides a square wave output for a specified number of pulses and frequency, with
controlled acceleration and deceleration.
A set of function blocks are provided with the PTO library to command a move:
PTOMoveVelocity, PTOMoveRelative, PTOHome, PTOStop (see M238 PTO
Library) (see Modicon M238 Logic Controller, Pulse Train Output, Pulse Width
Modulation, M238 PTOPWM Library Guide).
The following diagram gives an example of a move:
Target Frequency
Start/Stop Frequency
Target Position
Trapezoidal Profile
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M238 - Fast I/Os
PTO Function Use

The PTO function is used to control Lexium 05 - SD3 motion controllers or third-party
servo-drives with an open collector input and an integrated position loop.
Position, speed and

direction Set point
M 238
0 G0 1 2 G2 3 4 G4 5 6 G6 7 8 9 10 11 12 13 C8 PulseTrain Output Servo Drive
M238
FAST INPUTS INPUTS
Variable frequency Motor
Up to 100 kHz Speed
I13
I10
I11
I12
I4
I5
I6
I0
I1
I2
I3
I7
I8
I9
PWR BATT
RUN
SL1
ERR
CAN R
Pulses Position Speed Torque
SL2 CAN E
Integrator loop loop loop
Q1
Q2
Q3
Q4
Q5
Q6
Q7
Q8
Q9
Q0
TM 238 D1 DDT24C
Position completed
SL 1 SL 2 FAST OUTPUTS OUTPUTS
V0+ V0- 0 1 2 3 V1+ V1- 4 5 6 V2+ V2- 7 8 9
A pulse profile can be used to control a stepper motor through a basic ramp up, run,
and ramp down sequence or more complicated sequences. The control positioning
is relative without feedback. The position loop may be integrated in the servo-drive.
The Hardware
2 PTO channels are available on the controller. Each PTO channel is associated to
2 fast outputs and 1 regular auxiliary input (see page 137).
Modes
4 PTO modes are available to drive a motor:
z Pulse/Direction
z Direction/Pulse
z ClockWise/CounterClockWise
z CounterClockWise/ClockWise
Optional input can be configured as:

z Drive ready input, to control correct operation of the drive.
z Origin input, to be used as reference point detection signal in combination with
PTOHome function.
NOTE: You must configure the Origin input to use PTOHome function.
Pulse/Direction and Direction/Pulse modes generate 2 signals:
z output Pulse signal provides the motor operating speed.
z the Direction signal provides the motor rotation direction.
ClockWise/CounterClockWise and CounterClockWise/ClockWise modes generate

1 signal that defines the motor operating speed. This signal is implemented either
on the PTO output 0 or on the PTO output 1 depending on the motor rotation
direction.
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M238 - Fast I/Os
The following table determines the signal applied on each PTO output:
PTO mode PTO Output0 PTO Output1

Pulse/Direction Pulse -
- Direction
Direction/Pulse - Pulse
Direction -
ClockWise/CounterClockWise ClockWise -
- CounterClockWise
CounterClockWise/ClockWise - ClockWise
CounterClockWise -
Motion Functions
4 motion functions are available:
z Move Velocity: moving at a programmed speed
z Move Relative: moving of a programmed distance
z Homing: moving to the reference position
z Stop: stop moving
Performance
The maximum generated frequency is 100 kHz.
The 2 PTO channels can be used simultaneously but can only control independent
axes. Therefore the embedded PTO function can be used for:
z single axis point-to-point motion
z 2-axis simultaneous point-to-point motion (each axis is managed independently)
But you should not use it for:

z 2-axis synchronized point-to-point motion
z 2-axis interpolation motion
WARNING
UNEXPECTED EQUIPMENT OPERATION
Do not use the PTO channels to perform 2-axis synchronized point-to-point motion
control or 2-axis motion interpolation.
equipment damage.
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M238 - Fast I/Os
To configure PTO parameters, refer to the PTO/PWM Library (see Modicon M238
Logic Controller, Pulse Train Output, Pulse Width Modulation, M238 PTOPWM
Library Guide).
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M238 - Fast I/Os
PTO I/O Mapping
PTO I/O Mapping

The table below shows the availability of the PTO functions according to the inputs
and outputs:
Function PTO
Channel PTO0 PTO1
I8 – –
I9 Auxiliary input PTO0 –
Regular I10 – –
Input I11 – –
I12 – Auxiliary input PTO1
I13 – –
Q0 PTO0 Output0 –
Fast Q1 PTO0 Output1 –
Output Q2 – PTO1 Output0
Q3 – PTO1 Output1
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M238 - Fast I/Os
8.3 PWM (Pulse Width Modulation)
Overview
This section will help you use the PWM functions (see Modicon M238 Logic
Controller, Pulse Train Output, Pulse Width Modulation, M238 PTOPWM Library
Guide)and the mapping of I/O.
Fast Input/Outputs that are not configured by the PWM functions can be used as

Topic Page
PWM Overview 139
PWM I/O Mapping 140
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M238 - Fast I/Os
PWM Overview
Introduction
z TM238LDD24DT
The Pulse Width Modulation (PWM) function generates a square wave signal with
programmable frequency and variable width (duty cycle). The module uses one
internal clock generator and provides an output signal on a dedicated output
channel. This output signal can directly to command a variable motion of the axis.
The target frequency is always positive.
For more information on the PWM functionality. (see Modicon M238 Logic
Controller, Pulse Train Output, Pulse Width Modulation, M238 PTOPWM Library
Guide)
Main Characteristics
The signal form depends on the following output parameters:
z Frequency configurable from 0.1 Hz to 20 kHz with a 0.1 Hz step
z Duty Cycle of the output signal from 0% to 100%
The Hardware
2 PWM channels are available on the controller. Each PWM channel is associated
to 1 fast output and 2 regular auxiliary inputs (see page 140).
To configure PWM parameters, refer to the PTO/PWM Library (see Modicon M238
Library Guide).
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M238 - Fast I/Os
PWM I/O Mapping
PWM I/O Mapping

The table below shows the availability of the PWM functions according to the inputs
and outputs:
Function PWM
Channel PWM0 PWM1
I8 Auxiliary input (Enable) –
PWM0
I9 Auxiliary input (Sync) –
PWM0
Regular I10 – –
Input I11 – Auxiliary input (Enable)
PWM1
I12 – Auxiliary input (Sync)
PWM1
I13 – –
Q0 PWM0 Output –
Fast Q1 – –
Output Q2 – PWM1 Output
Q3 – –
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M238 - Fast I/Os
8.4 FG (Frequency Generator)
Overview
This section will help you use the FG functions (see Modicon M238 Logic Controller,
Pulse Train Output, Pulse Width Modulation, M238 PTOPWM Library Guide) and
the mapping of I/O.
Fast Input/Outputs that are not configured by the FG functions can be used as

Topic Page
Frequency Generator 142
FG I/O Mapping 143
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M238 - Fast I/Os
Frequency Generator
Introduction
z TM238LDD24DT
The Frequency Generator (FG) function generates a square wave signal with
programmable frequency and duty cycle equal to 50%. The controller uses an
internal clock generator and provides an output signal on dedicated output channel.
This output signal can directly to command a constant motion of the axis. The target
frequency is always positive.
For more information on the FG functionality. (see Modicon M238 Logic Controller,
Pulse Train Output, Pulse Width Modulation, M238 PTOPWM Library Guide)
Main characteristics
The signal form depends on the following input parameter:
z Frequency configurable from 1 Hz to 100 kHz with a 1 Hz step
The Hardware
2 FG channels are available on the controller. Each FG channel is associated to 1
fast output and 2 regular auxiliary inputs (see page 143).
To configure FG parameters, refer to the PTO/PWM Library (see Modicon M238
Library Guide).
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M238 - Fast I/Os
FG I/O Mapping
FG I/O Mapping
The table below shows the availability of the FG functions according to the inputs
and outputs:
Function FG
Channel FG0 FG1
I8 Auxiliary input (Enable) –
FG0
I9 Auxiliary input (Sync) –
FG0
Regular I10 – –
Input I11 – Auxiliary input (Enable)
FG1
I12 – Auxiliary input (Sync)
FG1
I13 – –
Q0 FG0 Output –
Fast Q1 – –
Output Q2 – FG1 Output
Q3 – –
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M238 - Fast I/Os
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M238 - Wiring Diagram Examples
EIO0000000016 10/2010
Wiring Diagram Examples
9
Introduction
This chapter provides wiring diagram examples.

Topic Page
Wiring Diagram Examples for 1 Encoder on Fast Inputs 146
Wiring Diagram Examples for 2 Encoders on Fast Inputs 148
Wiring Diagram Examples on Regular Inputs 150
Wiring Diagram Examples for PTO/PWM Actuator on Fast Outputs 151
Wiring the Modicon M238 Logic Controller to the LEXIUM 05 via the Universal 152
Signal Interface Converter (USIC)
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Wiring Diagram Examples for 1 Encoder on Fast Inputs
Introduction
This section provides wiring diagram examples for 1 encoder on fast inputs.
Incremental Encoder with Phase-Shifted Signals with TDC and 3-Wire PNP Detector
(4)
(2)
PNP –
+
– A 0V B Z
+
–
I0 G0 I1 I2 G2 I3 I4 G4 I5 I6 G6 I7
+
Fast Inputs
(2) Dual-phase encoder with index

(4) PNP sensor
NOTE:
z Use a specific auxiliary power supply for the encoders and sensors connected to
the fast inputs and used in fast counter mode.
z Use cordsets with mandatory shielding to connect to the metal support for
mounting the Modicon M238 Logic Controller. 10 m (32.8 ft) max.
z Use a 0.5 A fast-blow fuse.
146 EIO0000000016 10/2010

Incremental Encoder with Phase-Shifted Signals without TDC and Electromechanical Sensor
(1) (3)
– A 0V B
+
–
+
I0 G0 I1 I2 G2 I3 I4 G4 I5 I6 G6 I7
Fast Inputs
(1) Dual-phase encoder without index

(3) Limit switch
NOTE:
the fast inputs and used in fast counter mode.
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Wiring Diagram Examples for 2 Encoders on Fast Inputs
Introduction
This section provides wiring diagram examples for 2 encoders on fast inputs.
NOTE: The hardware limitation is 2 incremental encoders with phase-shifted
signals.
Incremental Encoders with Phase-Shifted Signals with TDC
(2) (2)
– A 0V B Z Z A 0V B –
+
I0 G0 I1 I2 G2 I3 I4 G4 I5 I6 G6 I7
–
+
Fast Inputs
(2) Dual-phase encoder with index

NOTE:
the fast inputs and used in the fast counter mode.
148 EIO0000000016 10/2010

Incremental Encoders with Phase-Shifted Signals without TDC
(1) (1)
– A 0V B – A 0V B
+
+
–
+
I0 G0 I1 I2 G2 I3 I4 G4 I5 I6 G6 I7
Fast Inputs
(1) Dual-phase encoder without index

NOTE:
the fast inputs and used in the fast counter mode.
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Wiring Diagram Examples on Regular Inputs
Introduction
This section provides a wiring diagram example for Inputs.
3-wire PNP and 3-wire NPN Sensors Wiring Diagram

The following figure shows an example of connection of 3-wire PNP and 3-wire NPN
sensors on regular inputs:
–
PNP (1) NPN (3)
+
+ – – +
(2) + (1)
–
I9 I10 I13 C8 I9 I10 I13 C8
(1) 0.5 A fast-blow fuse

(2) Sink input (positive logic)
(3) Source input (negative logic)
NOTE:
z For improved electromagnetic compatibility (EMC), use the same power supply
for the inputs as the Modicon M238 Logic Controller.
150 EIO0000000016 10/2010

Wiring Diagram Examples for PTO/PWM Actuator on Fast Outputs
Introduction
This section provides wiring diagram examples for a PTO/PWM actuator on fast
outputs.
z TM238LDD24DT
PTO/PWM Actuator SD 326 Type
FAST OUTPUTS
24VDC
+ - V0+ V0- Q0 Q1 Q2 Q3
+
2
White
Green
Brown
Yellow
1
CN1
1 Actuator SD 326 with PTO/PWM signals delivering a 24 Vdc power supply

2 VW3S8202R30 cable
NOTE: Use cordsets with mandatory shielding to connect to the metal support for
PTO/PWM Actuator Universal Signal Interface Converter (USIC)

Refer to the Modicon M238 Logic Controller wiring example to the Lexium via USIC
(see page 152).
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Wiring the Modicon M238 Logic Controller to the LEXIUM 05 via the Universal
Signal Interface Converter (USIC)
Introduction
This section provides an example of an implementation with the PTO function.
z TM238LDD24DT
Principle
The pulse/direction input of a drive receives pulses and converts them to make the
motor move.
Hardware Configuration
The following illustration shows the connections between the different parts of the
hardware configuration.
0 G0 1 2 G2 3 4 G4 5 6 G6 7 8 9 10 11 12 13 C8
FAST INPUTS INPUTS
prg.
Port. 1
I10
I12
I13
I11
I0
I1
I2
I3
I4
I5
I6
I7
I8
I9
PWR BATT
RUN ERR
SL1 CAN R
SL2 CAN E
Q3
Q0
Q1
Q2
Q4
Q5
Q6
Q7
Q8
Q9
CANopen
Master M238
TM 238 D1 DDT24C
CN2 CN2
CN2 CN2
CN5 CN5
3
0162501532009
0162501532009
VW3M3102
VW3M3102
USIC
USIC
R-network R-network
CN1 CN1
CN4 CN3 CN4 CN3
CN1 CN1
CN4 CN3 CN4 CN3
CN5 Resistor network
152 EIO0000000016 10/2010

Label Description Reference Quantity

1 Modicon M238 Logic Controller TM238LFDC24DT•• or 1
TM238LDD24DT
2 Modicon M238 Logic VW3M8210R30 2
Controller/USIC cable
cable length = 3 m (9.8 ft)
3 USIC VW3M3102 2
4 Lexium 05 – 2
5 USIC/Lexium05 cable VW3M8209R30 2
cable length = 3 m (9.8 ft)
NOTE: At the USIC, the CN5 resistor connected at the CN1 inputs is designed for a
maximum of 5 Vdc. Excessive voltage can damage the product either immediately
or over time.
CAUTION
UNEXPECTED EQUIPMENT OPERATION OR INOPERABLE EQUIPMENT
Remove the CN5 Resistor Network from the USIC.
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Wiring Modicon M238 Logic Controller to USIC

The VW3M8210R30 cable is required for this wiring.
FAST OUTPUTS
24VDC
+ - V0+ V0- Q0 Q1 Q2 Q3
White
Green
+ 2
-
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
Yellow
Brown
Yellow
Pink
CN1
1 White
1 Actuator with USIC type PTO/PWM signals

2 VW3M8210R30 cable
154 EIO0000000016 10/2010

Wiring USIC to Lexium 05

This wiring can be done by using the prefabricated cable reference: VW3M8209R30
USIC Lexium 05
CN2 CN5
Active2 8 4 Active2_OUT
Pulse 1 1 Pulse
Pulse 9 6 Pulse
Dir 2 2 Dir
Dir 10 7 Dir
Enable 3 3 Enable
Enable 11 8 Enable
0 VDC 15 9 POS_0V
5 Shield
PG
Wiring USIC
The CN4 and CN3 USIC pins need to be wired as shown:
CN4 CN3
1 2 3 4 5 6 7 8 9 10 11 12
+24 VDC
0 VDC
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USIC Implementation
PTO signals generated by the Modicon M238 Logic Controller are in 24 Vdc. The
USIC (Universal Signal Interface Converter) converts 24 Vdc signal into 5 Vdc
signal.
For more information, refer to the documentation of the USIC.
Lexium Implementation
Refer to the documentation of the Lexium 05.
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Glossary
EIO0000000016 10/2010
Glossary
ASCII
The american standard code for information interchange is a communication
protocol for representing alphanumeric characters (letters, numbers, and certain
graphic and control characters).
CANopen
CANopen is an open industry-standard communication protocol and device profile
specification.
CFC
The continuous function chart (an extension of the IEC61131-3 standard) is a
graphical programming language that works like a flowchart. By adding simple
logicals blocks (AND, OR, etc.), each function or function block in the program is
represented in this graphical format. For each block, the inputs are on the left and
the outputs on the right. Block outputs can be linked to inputs of other blocks in order
to create complex expressions.
controller
A controller (or “programmable logic controller,” or “programmable controller”) is
used to automate industrial processes.
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Glossary
EEPROM
Electrically erasable programmable read-only memory is a type of non-volatile
memory used to store data that must be saved when power is removed.
EIA rack
An electronic industries alliance rack is a standardized (EIA 310-D, IEC 60297 and
DIN 41494 SC48D) system for mounting various electronic modules in a stack or
rack that is 19 inches (482.6 mm) wide.
expansion bus
The expansion bus is an electronic communication bus between expansion modules
and a CPU.
expansion I/O modules

An expansion input or output module is either a digital or analog module that adds
additional I/O to the base controller.
FAST task
The FAST task is a periodic, high-priority task of a short duration that is run on a
processor through its programming software. The task’s fast speed keeps it from
interfering with the execution of lower priority master (MAST) tasks. A FAST task is
useful when fast periodic changes in discrete inputs need to be monitored.
FB
A function block performs a specific automation function, such as speed control,
interval control, or counting. A function block comprises configuration data and a set
of operating parameters.
FBD
A function block diagram is a graphically oriented programming language, compliant
with IEC 61131-3. It works with a list of networks whereby each network contains a
graphical structure of boxes and connection lines which represents either a logical
or arithmetic expression, the call of a function block, a jump, or a return instruction.
158 EIO0000000016 10/2010

Glossary
firmware
The firmware represents the operating system on a controller.
HSC
high-speed counter
IEC 61131-3
The IEC 61131-3 is an international electrotechnical commission standard for
industrial automation equipment (like controllers). IEC 61131-3 deals with controller
programming languages and defines 2 graphical and 2 textual programming
language standards:
z graphical: ladder diagram, function block diagram
z textual: structured text, instruction list
IL
A program written in the instruction list language is composed of a series of
instructions executed sequentially by the controller. Each instruction includes a line
number, an instruction code, and an operand. (IL is IEC 61131-3 compliant.)
IP 20
Ingress protection rating according to IEC 60529. IP20 modules are protected
against ingress and contact of objects larger than 12.5 mm. The module is not
protected against harmful ingress of water.
latching input
A latching input module interfaces with devices that transmit messages in short
pulses. Incoming pulses are captured and recorded for later examination by the
application.
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Glossary
LD
A program in the ladder diagram language includes a graphical representation of
instructions of a controller program with symbols for contacts, coils, and blocks in a
series of rungs executed sequentially by a controller. IEC 61131-3 compliant.
master/slave
The single direction of control in a network that implements the master/slave model
is always from a master device or process to one or more slave devices.
Modbus
The Modbus communication protocol allows communications between many
devices connected to the same network.
NEMA
The national electrical manufacturers association publishes standards for the
performance of various classes of electrical enclosures. The NEMA standards cover
corrosion resistance, ability to protect from rain and submersion, etc. For IEC
member countries, the IEC 60529 standard classifies the ingress protection rating
for enclosures.
network
A network includes interconnected devices that share a common data path and
protocol for communications.
node
A node is an addressable device on a communication network.
protocol
A protocol is a convention or standard that controls or enables the connection,
communication, and data transfer between two computing endpoints.
160 EIO0000000016 10/2010

Glossary
PTO
Pulse train outputs are used to control for instance stepper motors in open loop.
PWM
Pulse width modulation is used for regulation processes (e.g. actuators for
temperature control) where a pulse signal is modulated in its length. For these kind
of signals, transistor outputs are used.
real-time clock (RTC)

See RTC
reflex output
In a counting mode, the high speed counter’s current value is measured against its
configured thresholds to determine the state of these dedicated outputs.
RFID
Radio-frequency identification is an automatic identification method that relies on
the storage and remote retrieval of data using RFID tags or transponders.
RPDO
A receive PDO sends data to a device in a CAN-based network.
RTC
The real-time clock option keeps the time for a limited amount of time even when the
controller is not powered.
scan
A controller’s scanning program performs 3 basic functions: [1] It reads inputs and
places these values in memory; [2] it executes the application program 1 instruction
at a time and stores results in memory; [3] It uses the results to update outputs.
EIO0000000016 10/2010 161

Glossary
SFC
A program written in the sequential function chart language can be used for
processes that can be split into steps. SFC is composed of steps with associated
actions, transitions with associated logic condition, and directed links between steps
and transitions. (The SFC standard is defined in IEC 848. It is IEC 61131-3
compliant.)
Structured Text
A program written in the structured text (ST) language includes complex statements
and nested instructions (such as iteration loops, conditional executions, or
functions). ST is compliant with IEC 61131-3.
task
A group of sections and subroutines, executed cyclically or periodically for the MAST
task, or periodically for the FAST task.
A task possesses a level of priority and is linked to inputs and outputs of the
controller. These I/O are refreshed in consequence.
A controller can have sereval tasks.
threshold output
Threshold outputs are controlled directly by the HSC according to the settings
established during configuration.
TPDO
A transmit PDO reads data from a device in a CAN-based system.
162 EIO0000000016 10/2010

Index
EIO0000000016 10/2010
Index
B
AC
A cooling, 41
AC power supply
wiring, 60 D
accessories, 23
DC Physical Description, 19
allocation, I/Os, 129, 130, 137, 140, 143
DC power supply
wiring, 57
B digital I/O assignment
FG, 143
battery, backup
HSC, 129, 130
external, 34
PTO, 137
internal, 34
PWM, 140
dimensions, 37
C DIN rail, 43
CANopen communication, 14, 101, 107
clearance, minimum, 41, 41 E
communication
electrical specification
CAN LEDs, 107
fast input, 69
CANopen, 14, 101
fast output, 77
serial line, 14, 97
regular inputs, 66
communication modules, 21
regular output, 74
connect a AC power supply, 60
relay output, 83
connect a DC power supply, 57
transistor output, 87
connect fast input, 69
end bracket, 44
connect fast output, 77
environmental specifications, 49
connect regular input, 66
Example
connect regular output, 73
Wiring the controller and the Lexium, 152
connect relay output, 83
expansion modules, 21
connect transistor output, 87
external backup battery, 34
connections
to CANopen slaves, 101
to external devices, 97
EIO0000000016 10/2010 163

Index
F L
fast input latching input, 111
specifications, 69 LEDs
fast inputs status, 106
wiring diagram, 71
fast output
specifications, 77 M
wiring diagram, 79 M238 based solution
features CANopen serial link, 26
communication, 14 RS 485 serial link, 24
fast I/Os, 16 main features, 12
key features, 12 maximum hardware configuration, 21
filtering, input, 110 modules, communication, 21
modules, expansion, 21
mounting holes layout, 47
G mounting positions, 38
Grounding Shielded Cables, 63 mounting procedure
on a DIN rail, 44
on a metallic panel, 47
H
high speed counter, 125
HSC, 125 O
features, 125 Output Management
modes, 127 AC controller, 118
DC controller, 113
output specification
I fast, 77
I/O allocation regular, 74
FG, 143 relay, 83
HSC, 129, 130 transistor, 87
PTO, 137 output wiring diagram
PWM, 140 fast, 79
input specifications regular, 75
fast, 69 relay, 85
regular, 66 transistor, 88
inputs wiring diagram overview, 12
fast, 71
regular, 67
Installation and Maintenance Requirements P
installation, 30 programming
installation preparation, 32 software, 18
installing programming languages
on a DIN rail, 44 IL, ST, FBD, SFC, LD, CFC, 12
on a metallic panel, 47 PTO, 133, 133
164 EIO0000000016 10/2010

Index
pulse train output, 133 status, LEDs, 106

pulse width modulation, 139 system diagnostic, using LEDs, 106
PWM, 139, 139
T
R tightening torque
regular inputs inputs terminals, 68, 71
specifications, 66 outputs terminals, 76, 81, 86, 90
wiring diagram, 67 transistor output
regular output specifications, 87
specifications, 74 wiring diagram, 88
wiring diagram, 75
relay output
specifications, 83 U
wiring diagram, 85 USIC, 152, 156
RUN/STOP input, 112
W
S wiring diagrams
safety guidelines AC power supply, 60
external battery disposal, 34 DC power supply, 57
wiring, 53 fast inputs, 71
serial line fast output, 79
specifications, 99 regular inputs, 67
serial line communication, 97 regular output, 75
software, programming, 18 relay output, 85
SoMachine, 18 transistor output, 88
special functions wiring rules, 53
Frequency Generator, 142
HSC, 125
latching input, 111
PTO, 133
PWM, 139
RUN/STOP input, 112
special I/Os, 123
specifications
environmental, 49
fast input, 69
fast output, 77
regular inputs, 66
regular output, 74
relay output, 83
serial line, 99
transistor output, 87
starting, 32
EIO0000000016 10/2010 165

Index
166 EIO0000000016 10/2010

Modicon M238 Hardware Guide

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EIO0000000016 10/2010

M238 Logic Controller

Title of Documentation Reference Number

Product Related Information

About the Modicon M238 Logic

What's in this Chapter?

Modicon M238 Logic Controller Devices Overview

Modicon M238 Logic Controller Range

Reference Power Supply Serial Ports CANopen Digital Digital Memory

On TM238LDD24DT and TM238LDA24DR, the serial line connector supports

For more information, refer to CANopen connection. (see page 101)

Fast Input/Output Functions and Availability

Fast Input/Output Functions

Reference Power Supply HSC PTO PWM FG

The fallback settings that may be configured (fallback to 0, fallback to 1, or fallback

Additional Modules and Maximum Hardware Configuration

Module Number Description Characteristics Hardware Guide

Module Number Protocol

Maximum Hardware Configuration

Accessories Supplied with the Modicon M238 Logic Controller

Description Use Quantity Reference

Description Use Quantity Reference

Description Use Quantity Reference

N° Products Reference Description

N° Products Reference Description

N° Products Reference Description

N° Products Reference Description

What's in this Chapter?

Installation and Maintenance Requirements

Step Action Comment

Step Action Comment

Internal and External Backup Batteries

Internal Backup Battery

External Backup Battery

Failure to follow these instructions will result in death or serious injury.

Installing and Replacing the External backup battery

To install or replace the external backup battery, follow these steps:

3 Remove the used battery from the compartment.

FAST INPUTS INPUTS

SL1 SL2 FAST OUTPUTS OUTPUTS

Correct Mounting Position

FAST INPUTS INPUTS

SL1 SL2 FAST OUTPUTS OUTPUTS

Acceptable Mounting Positions

I12 V1+ V1- 4

NOTE: Expansion modules must be on top.

Incorrect Mounting Position

FAST INPUTS INPUTS

SL1 SL2 FAST OUTPUTS OUTPUTS

The DIN Rail

Dimensions of the DIN Rail

Rail depth Catalogue part number

Mounting on a DIN Rail

Installing the Modicon M238 Logic Controller on a DIN Rail

Removing the Modicon M238 Logic Controller from a DIN Rail

Mounting on a Metallic Panel

Mounting the Modicon M238 Logic Controller on a Metallic Panel

Temperature Operation -10 to 55 ° C (14 to 131 ° F)

Wiring and Electrical

What's in this Chapter?