I am currently working on a project to convert a milling machine to VFD speed control. I am using a Micrologix 1761-L16BWA. I had the system working and taking control commands from a Panelview 300 micro, but this was with all outputs being 24vdc. I had to make a few changes that required switching 120vac outputs when this voltage was added to O:0/4 and O:0/5 via thier common terminal. The 24vdc power supply feeding devices (namely the Panelview) gets dragged down. When panelview com is disconnected sytem 24vdc comes back and I can measure 24v potential on metal shroud of the 8pin mini din connector on the processor. The "Relay"outputs are labled as A/C or D/C up tp 230 volts, but it seems to me that something has gone south in the processor. I tested the panelview on another set up and it is fine. Any thoughts?

Don't know if this helps but the User manual http://literature.rockwellautomation.com/i...um003_-en-p.pdf
shows AC on O/0 and O/1 and dc on o/4 and o/5.

There is nothing wrong with having AC on output 4 and 5. I would suggest you look at your DC Common and AC Neutral and make sure they have not got crossed. Sounds like you are getting feedback on the DC Common through your device that is hooked to the output.

At least for the 1200 and I would assume the 1000, it has miniature relays on the outputs so not much chance of it being a problem inside the controller

And they have OMRON stamped on the side of them! Kinda funny.