Rockwell Automation 2080-LC50 User Manual
User Manual
Micro830 and Micro850 Programmable Controllers
Catalog Numbers
Bulletin 2080-LC30 and 2080-LC50
Important User Information
IMPORTANT
Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety
Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1
your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/
important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference,
and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment
must satisfy themselves that each intended application of this equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from
the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or
software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous
environment, which may lead to personal injury or death, property damage, or economic loss.
available from
) describes some
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death,
property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the
consequence
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that
dangerous voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that
surfaces may reach dangerous temperatures.
Identifies information that is critical for successful application and understanding of the product.
Allen-Bradley, Rockwell Software, Rockwell Automation, Micro800, Micro830, Micro850, Connected Components Workbench, and TechConnect are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Preface
Read this preface to familiarize yourself with the rest of the manual. It provides
information concerning:
• who should use this manual
• the purpose of this manual
• related documentation
• supporting information for Micro800™
Who Should Use this Manual
Purpose of this Manual
Additional Resources
Use this manual if you are responsible for designing, installing, programming, or
troubleshooting control systems that use Micro800 controllers.
You should have a basic understanding of electrical circuitry and familiarity with
relay logic. If you do not, obtain the proper training before using this product.
This manual is a reference guide for Micro800 controllers, plug-in modules and
accessories. It describes the procedures you use to install, wire, and troubleshoot
your controller. This manual:
• explains how to install and wire your controllers
• gives you an overview of the Micro800 controller system
Refer to the Online Help provided with Connected Components Workbench™
software for more information on programming your Micro800 controller.
These documents contain additional information concerning related Rockwell
Automation products.
Resource Description
Micro800 Analog and Discrete Expansion I/O
Modules 2080-UM003
Micro800 Plug-in Modules 2080-UM004 Information on features, configuration,
Micro800 Programmable Controllers: Getting
Started with CIP Client Messaging 2080-QS002
Micro800 Programmable Controller External AC
Power Supply Installation Instructions
2080-IN001
Micro830 Programmable Controllers Installation
Instructions 2080-IN002
Micro830 Programmable Controllers Installation
Instructions 2080-IN003
Micro830 Programmable Controllers Installation
Instructions 2080-IN004
Information on features, configuration, wiring,
installation, and specifications for the Micro800
expansion I/O modules.
installation, wiring, and specifications for the
Micro800 plug-in modules.
Provides quickstart instructions for using CIP
GENERIC and CIP Symbolic Messaging.
Information on mounting and wiring the optional
external power supply.
Information on mounting and wiring the
Micro830 10-point Controllers.
Information on mounting and wiring the
Micro830 16-point Controllers.
Information on mounting and wiring the
Micro830 24-point Controllers.
Rockwell Automation Publication 2080-UM002F-EN-E - December 2013 iii
Preface
Resource Description
Micro830 Programmable Controllers Installation
Instructions 2080-IN005
Micro850 Programmable Controllers Installation
Instructions 2080-IN007
Micro850 Programmable Controllers Installation
Instructions 2080-IN008
Micro800 16-point and 32-point 12/24V Sink/
Source Input Modules Installation Instructions
2085-IN001
Micro800 Bus Terminator Module Installation
Instruction 2085-IN002
Micro800 16-Point Sink and 16-Point Source 12/
24V DC Output Modules Installation Instructions
2085-IN003
Micro800 8-Point and 16-Point AC/DC Relay
Output Modules Installation Instructions
2085-IN004
Micro800 8-Point Input and 8-Point Output AC
Modules Installation Instructions 2085-IN005
Micro800 4-channel and 8-channel Analog
Voltage/current Input and Output Modules
Installation Instructions 2085-IN006
Micro800 4-channel Thermocouple/RTD Input
Module 2085-IN007
Micro800 RS232/485 Isolated Serial Port Plug-in
Module Wiring Diagrams 2080-WD002
Micro800 Non-isolated Unipolar Analog Input
Plug-in Module Wiring Diagrams 2080-WD003
Micro800 Non-isolated Unipolar Analog Output
Plug-in Module Wiring Diagrams 2080-WD004
Micro800 Non-isolated RTD Plug-in Module
Wiring Diagrams 2080-WD005
Micro800 Non-isolated Thermocouple Plug-in
Module Wiring Diagrams 2080-WD006
Micro800 Memory Backup and High Accuracy
RTC Plug-In Module Wiring Diagrams
2080-WD007
Micro800 6-Channel Trimpot Analog Input Plug-In
Module Wiring Diagrams 2080-WD008
Micro800 Digital Relay Output Plug-in Module
Wiring Diagrams 2080-WD010
Micro800 Digital Input, Output, and Combination
Plug-in Modules Wiring Diagrams 2
Industrial Automation Wiring and Grounding
Guidelines, publication 1770-4.1
080-WD011
Information on mounting and wiring the
Micro830 48-point Controllers.
Information on mounting and wiring the
Micro850 24-point Controllers
Information on mounting and wiring the
Micro850 48-point Controllers
Information on mounting and wiring the
expansion I/O modules (2085-IQ16, 2085-IQ32T)
Information on mounting and wiring the
expansion I/O bus terminator (2085-ECR)
Information on mounting and wiring the
expansion I/O modules (2085-OV16, 2085-OB16)
Information on mounting and wiring the
expansion I/O modules (2085-OW8, 2085-OW16)
Information on mounting and wiring the
expansion I/O modules (2085-IA8, 2085-IM8,
2085-OA8)
Information on mounting and wiring the
expansion I/O modules (2085-IF4, 2085-IF8,
2085-OF4)
Information on mounting and wiring the
expansion I/O module (2085-IRT4)
Information on mounting and wiring the
Micro800 RS232/485 Isolated Serial Port Plug-in
Module.
Information on mounting and wiring the
Micro800 Non-isolated Unipolar Analog Input
Plug-in Module.
Information on mounting and wiring the
Micro800 Non-isolated Unipolar Analog Output
Plug-in Module.
Information on mounting and wiring the
Micro800 Non-isolated RTD Plug-in Module.
Information on mounting and wiring the
Micro800 Non-isolated Thermocouple Plug-in
Module.
Information on mounting and wiring the
Micro800 Memory Backup and High Accuracy
RTC Plug-In Module.
Information on mounting and wiring the
Micro800 6-Channel Trimpot Analog Input Plug-In
Module.
Information on mounting and wiring the
Micro800 Digital Relay Output Plug-in Module.
Information on mounting and wiring the
Micro800 Digital Input, Output, and Combination
Plug-in Modules.
Provides general guidelines for installing a
Rockwell Automation industrial system.
iv Rockwell Automation Publication 2080-UM002F-EN-E - December 2013
Preface
Resource Description
Product Certifications website, http://ab.com Provides declarations of conformity, certificates,
Application Considerations for Solid-State
Controls SGI-1.1
National Electrical Code - Published by the
National Fire Protection Association of Boston,
MA.
Allen-Bradley Industrial Automation Glossary
AG-7.1
and other certification details.
A description of important differences between
solid-state programmable controller products
and hard-wired electromechanical devices.
An article on wire sizes and types for grounding
electrical equipment.
A glossary of industrial automation terms and
abbreviations.
You can view or download publications at http://www.rockwellautomation.com/
literature/. To order paper copies of technical documentation, contact your local
Rockwell Automation distributor or sales representative.
You can download the latest version of Connected Components Workbench for
your Micro800 at the URL below.
http://ab.rockwellautomation.com/Programmable-Controllers/ConnectedComponents-Workbench-Software.
Rockwell Automation Publication 2080-UM002F-EN-E - December 2013 v
Preface
Notes:
vi Rockwell Automation Publication 2080-UM002F-EN-E - December 2013
Table of Contents
Preface
Hardware Overview
About Your Controller
Who Should Use this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Purpose of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Chapter 1
Hardware Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Micro830 Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Micro850 Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Programming Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Embedded Serial Port Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Embedded Ethernet Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Chapter 2
Programming Software for Micro800 Controllers. . . . . . . . . . . . . . . . . . . . . 9
Obtain Connected Components Workbench. . . . . . . . . . . . . . . . . . . . . 9
Use Connected Components Workbench . . . . . . . . . . . . . . . . . . . . . . . . 9
Agency Certifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Compliance to European Union Directives. . . . . . . . . . . . . . . . . . . . . . . . . . . 9
EMC Directive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Environment and Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Preventing Electrostatic Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
North American Hazardous Location Approval. . . . . . . . . . . . . . . . . 13
Disconnecting Main Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safety Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Periodic Tests of Master Control Relay Circuit . . . . . . . . . . . . . . . . . 14
Power Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Isolation Transformers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Power Supply Inrush. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Loss of Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Input States on Power Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Other Types of Line Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Preventing Excessive Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Master Control Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Using Emergency-Stop Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Schematic (Using IEC Symbols) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Schematic (Using ANSI/CSA Symbols). . . . . . . . . . . . . . . . . . . . . . . . 20
Chapter 3
Install Your Controller
Rockwell Automation Publication 2080-UM002F-EN-E - December 2013 vii
Controller Mounting Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Mounting Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DIN Rail Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Panel Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Table of Contents
Panel Mounting Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
System Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Chapter 4
Wire Your Controller
Communication Connections
Wiring Requirements and Recommendation . . . . . . . . . . . . . . . . . . . . . . . 29
Use Surge Suppressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Recommended Surge Suppressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Grounding the Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Controller I/O Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Minimize Electrical Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Analog Channel Wiring Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Minimize Electrical Noise on Analog Channels . . . . . . . . . . . . . . . . . 37
Grounding Your Analog Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Embedded Serial Port Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Chapter 5
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Supported Communication Protocols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Modbus RTU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Modbus/TCP Client Server . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
CIP Symbolic Client Server. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
CIP Client Messaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
ASCII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
CIP Communications Pass-thru . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Examples of Supported Architectures. . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Use Modems with Micro800 Controllers. . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Making a DF1 Point-to-Point Connection. . . . . . . . . . . . . . . . . . . . . . 45
Construct Your Own Modem Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Configure Serial Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Configure CIP Serial Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Configure Modbus RTU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Configure ASCII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Configure Ethernet Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Ethernet Host Name. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Configure CIP Serial Driver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Chapter 6
Program Execution in Micro800
viii Rockwell Automation Publication 2080-UM002F-EN-E - December 2013
Overview of Program Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Execution Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Controller Load and Performance Considerations . . . . . . . . . . . . . . . . . . 56
Periodic Execution of Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Power Up and First Scan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Motion Control with PTO and
PWM
Chapter 1
Variable Retention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Memory Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Guidelines and Limitations for Advanced Users . . . . . . . . . . . . . . . . . . . . 58
Chapter 7
Use the Micro800 Motion Control Feature. . . . . . . . . . . . . . . . . . . . . 62
Input and Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Motion Control Function Blocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
General Rules for the Motion Control Function Blocks. . . . . . . . . . 69
Motion Axis and Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Motion Axis State Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Axis States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Motion Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Motion Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Axis Elements and Data Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Axis Error Scenarios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
MC_Engine_Diag Data Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Function Block and Axis Status Error Codes . . . . . . . . . . . . . . . . . . . . . . . 86
Major Fault Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Motion Axis Configuration in Connected Components Workbench . 89
Add New Axis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Edit Axis Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Axis Start/Stop Velocity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Real Data Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
PTO Pulse Accuracy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Motion Axis Parameter Validation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Delete an Axis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Monitor an Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Homing Function Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Conditions for Successful Homing. . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
MC_HOME_ABS_SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
MC_HOME_LIMIT_SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
MC_HOME_REF_WITH_ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
MC_HOME_REF_PULSE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
MC_HOME_DIRECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Use PTO for PWM Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
POU PWM_Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Chapter 8
Use the High-Speed Counter
and Programmable Limit Switch
Rockwell Automation Publication 2080-UM002F-EN-E - December 2013 ix
High-Speed Counter Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Programmable Limit Switch Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
What is High-Speed Counter? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Features and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
HSC Inputs and Wiring Mapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Table of Contents
High Speed Counter (HSC) Data Structures . . . . . . . . . . . . . . . . . . . . . . 117
HSC APP Data Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
PLS Enable (HSCAPP.PLSEnable) . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
HSCID (HSCAPP.HSCID) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
HSC Mode (HSCAPP.HSCMode) . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Accumulator (HSCAPP. Accumulator) . . . . . . . . . . . . . . . . . . . . . . . 124
High Preset (HSCAPP.HPSetting) . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Low Preset (HSCAPP.LPSetting). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Overflow Setting (HSCAPP.OFSetting) . . . . . . . . . . . . . . . . . . . . . . 125
Underflow Setting (HSCAPP.UFSetting) . . . . . . . . . . . . . . . . . . . . . 125
Output Mask Bits (HSCAPP.OutputMask) . . . . . . . . . . . . . . . . . . . 126
High Preset Output (HSCAPP.HPOutput) . . . . . . . . . . . . . . . . . . . 127
Low Preset Output (HSCAPP.LPOutput) . . . . . . . . . . . . . . . . . . . . 127
HSC STS (HSC Status) Data Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Counting Enabled (HSCSTS.CountEnable) . . . . . . . . . . . . . . . . . . . 128
Error Detected (HSCSTS.ErrorDetected) . . . . . . . . . . . . . . . . . . . . . 128
Count Up (HSCSTS.CountUpFlag). . . . . . . . . . . . . . . . . . . . . . . . . . 129
Count Down (HSCSTS.CountDownFlag) . . . . . . . . . . . . . . . . . . . . 129
Mode Done (HSCSTS.Mode1Done) . . . . . . . . . . . . . . . . . . . . . . . . . 129
Overflow (HSCSTS.OVF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Underflow (HSCSTS.UNF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Count Direction (HSCSTS.CountDir) . . . . . . . . . . . . . . . . . . . . . . . 130
High Preset Reached (HSCSTS.HPReached) . . . . . . . . . . . . . . . . . . 130
Low Preset Reached (HSCSTS.LPReached) . . . . . . . . . . . . . . . . . . . 131
Overflow Interrupt (HSCSTS.OFCauseInter) . . . . . . . . . . . . . . . . . 131
Underflow Interrupt (HSCSTS.UFCauseInter). . . . . . . . . . . . . . . . 131
High Preset Interrupt (HSCSTS.HPCauseInter). . . . . . . . . . . . . . . 132
Low Preset Interrupt (HSCSTS.LPCauseInter) . . . . . . . . . . . . . . . . 132
Programmable Limit Switch Position (HSCSTS.PLSPosition) . . 132
Error Code (HSCSTS.ErrorCode) . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Accumulator (HSCSTS.Accumulator) . . . . . . . . . . . . . . . . . . . . . . . . 133
High Preset (HSCSTS.HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Low Preset (HSCSTS.LP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
High Preset Output (HSCSTS.HPOutput) . . . . . . . . . . . . . . . . . . . 134
Low Preset Output (HSCSTS.LPOutput). . . . . . . . . . . . . . . . . . . . . 134
HSC (High Speed Counter) Function Block . . . . . . . . . . . . . . . . . . . . . . 135
HSC Commands (HScCmd). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
HSC_SET_STS Function Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Programmable Limit Switch (PLS) Function . . . . . . . . . . . . . . . . . . . . . . 137
PLS Data structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
PLS Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
PLS Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
HSC Interrupts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
HSC Interrupt Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
HSC Interrupt POU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Auto Start (HSC0.AS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
x Rockwell Automation Publication 2080-UM002F-EN-E - December 2013
Chapter 1
Mask for IV (HSC0.MV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Mask for IN (HSC0.MN). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Mask for IH (HSC0.MH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Mask for IL (HSC0.ML). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
HSC Interrupt Status Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
User Interrupt Enable (HSC0.Enabled) . . . . . . . . . . . . . . . . . . . . . . . 143
User Interrupt Executing (HSC0.EX). . . . . . . . . . . . . . . . . . . . . . . . . 143
User Interrupt Pending (HSC0.PE). . . . . . . . . . . . . . . . . . . . . . . . . . . 144
User Interrupt Lost (HSC0.LS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Use HSC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Chapter 9
Controller Security
Specifications
Exclusive Access. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Password Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Compatibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Work with a Locked Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Upload from a Password-Protected Controller . . . . . . . . . . . . . . . . . 146
Debug a Password-Protected Controller. . . . . . . . . . . . . . . . . . . . . . . 147
Download to a Password-Protected Controller. . . . . . . . . . . . . . . . . 147
Transfer Controller Program and Password-Protect Receiving
Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Back Up a Password-Protected Controller . . . . . . . . . . . . . . . . . . . . . 148
Configure Controller Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Recover from a Lost Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Appendix A
Micro830 Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Micro830 10-Point Controllers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Micro830 16-Point Controllers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Micro830 24-Point Controllers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Micro830 48-Point Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Micro830 and Micro850 Relay Charts . . . . . . . . . . . . . . . . . . . . . . . . 165
Micro850 Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Micro850 24-Point Controllers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Micro850 48-Point Controllers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Micro800 Programmable Controller External AC
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Appendix B
Modbus Mapping for Micro800
Rockwell Automation Publication 2080-UM002F-EN-E - December 2013 xi
Modbus Mapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Endian Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Mapping Address Space and supported Data Types. . . . . . . . . . . . . 175
Example 1, PanelView Component HMI (Master) to Micro800
(Slave) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Table of Contents
Example 2, Micro800 (Master) to PowerFlex 4M Drive (Slave) . . 177
Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Appendix C
Quickstarts
User Interrupts
Flash Upgrade Your Micro800 Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Establish Communications Between RSLinx and a
Micro830/Micro850 Controller through USB. . . . . . . . . . . . . . . . . . . . . 186
Configure Controller Password. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Set Controller Password. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Change Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Clear Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Use the High Speed Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Create the HSC Project and Variables . . . . . . . . . . . . . . . . . . . . . . . . . 198
Assign Values to the HSC Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Assign Variables to the Function Block . . . . . . . . . . . . . . . . . . . . . . . . 204
Run the High Speed Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Use the Programmable Limit Switch (PLS) Function . . . . . . . . . . . 207
Forcing I/Os . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Checking if Forces (locks) are Enabled. . . . . . . . . . . . . . . . . . . . . . . . . 209
I/O Forces After a Power Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Appendix D
Information About Using Interrupts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
What is an Interrupt? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
When Can the Controller Operation be Interrupted? . . . . . . . . . . 212
Priority of User Interrupts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
User Interrupt Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
User Fault Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
User Interrupt Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
STIS - Selectable Timed Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
UID - User Interrupt Disable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
UIE - User Interrupt Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
UIF - User Interrupt Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
UIC – User Interrupt Clear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Using the Selectable Timed Interrupt (STI) Function . . . . . . . . . . . . . . 221
Selectable Time Interrupt (STI) Function Configuration and Status. 221
STI Function Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
STI Function Status Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Using the Event Input Interrupt (EII) Function . . . . . . . . . . . . . . . . . . . 223
Event Input Interrupt (EII) Function Configuration and Status. . . . . 224
EII Function Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
EII Function Status Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
xii Rockwell Automation Publication 2080-UM002F-EN-E - December 2013
Appendix F
Chapter 1
Troubleshooting
IPID Function Block
System Loading
Status Indicators on the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Error Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Controller Error Recovery Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Calling Rockwell Automation for Assistance . . . . . . . . . . . . . . . . . . . . . . 238
Appendix G
How to Autotune . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
How Autotune Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Troubleshooting an Autotune Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
PID Application Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
PID Code Sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Appendix H
Calculate Total Power for Your Micro830/Micro850 Controller 247
Index
Rockwell Automation Publication 2080-UM002F-EN-E - December 2013 xiii
Table of Contents
Notes:
xiv Rockwell Automation Publication 2080-UM002F-EN-E - December 2013
Hardware Overview
Chapter
1
This chapter provides an overview of the Micro830 and Micro850 hardware
features. It has the following topics:
Topic Page
Hardware Features 1
Micro830 Controllers 2
Micro850 Controllers 4
Programming Cables 6
Embedded Serial Port Cables 7
Embedded Ethernet Support 7
Hardware Features
Rockwell Automation Publication 2080-UM002F-EN-E - December 2013 1
Micro830 and Micro850 controllers are economical brick style controllers with
embedded inputs and outputs. Depending on the controller type, it can
accommodate from two to five plug-in modules. The Micro850 controller has
expandable features and can additionally support up to four expansion I/O
modules.
Chapter 1 Hardware Overview
IMPORTANT
14
15
16
17
18
19
20
45031
45030
Micro830 10/16-point controllers and status indicators
Controller
Status indicator
14
15
16
17
18
19
20
45016
45017
Micro830 24-point controllers and status indicators
Controller
Status indicator
For information on supported plug-in modules and expansion I/O, see the
following publications:
• Micro800 Discrete and Analog Expansion I/O User Manual,
publication 2080-UM003
• Micro800 Plug-in Modules User Manual, publication 2080-UM004
The controllers also accommodate any class 2 rated 24V DC output power
supply that meets minimum specifications such as the optional Micro800 power
supply.
See Troubleshooting
on page 227 for descriptions of status indicator operation
for troubleshooting purposes.
Micro830 Controllers
12 3 4 5 6 7 8
79610111213
12 3 4 5 6 7 8
89910111213 6
2 Rockwell Automation Publication 2080-UM002F-EN-E - December 2013
Hardware Overview Chapter 1
14
15
16
17
18
19
20
45036
45037
Micro830 48-point controllers and status indicators
Status indicator
Controller
12
12
11
1013 6 9 8
34 5 6 7 88
Controller Description
Description Description
1 Status indicators 8 Mounting screw hole / mounting foot
2 Optional power supply slot 9 DIN rail mounting latch
3 Plug-in latch 10 Mode switch
4 Plug-in screw hole 11 Type B connector USB port
5 40 pin high speed plug-in connector 12 RS-232/RS-485 non-isolated combo serial port
6 Removable I/O terminal block 13 Optional AC power supply
7 Right-side cover
Status Indicator Description
(1)
Description Description
14 Input status 18 Force status
15 Power status 19 Serial communications status
16 Run status 20 Output status
17 Fault status
(1) For detailed description of the different status LED indicators, see Troubleshooting
on page 227.
Rockwell Automation Publication 2080-UM002F-EN-E - December 2013 3
Chapter 1 Hardware Overview
45909
45910
Status indicators
1
2
3
4
5
6
7
8
8
10
6
11
12
13
14
15
9
10
Micro850 24-point controllers and status indicators
Micro850 Controllers
Controller Description
16
17
18
19
20
21
22
23
24
Description Description
1 Status indicators 9 Expansion I/O slot cover
2 Optional power supply slot 10 DIN rail mounting latch
3 Plug-in latch 11 Mode switch
4 Plug-in screw hole 12 Type B connector USB port
5 40 pin high speed plug-in connector 13 RS232/RS485 non-isolated combo serial port
6 Removable I/O terminal block 14 RJ-45 Ethernet connector (with embedded green and
yellow LED indicators)
7 Right-side cover 15 Optional power supply
8 Mounting screw hole / mounting foot
Status Indicator Description
(1)
Description Description
16 Input status 21 Fault status
17 Module Status 22 Force status
18 Network Status 23 Serial communications status
19 Power status 24 Output status
20 Run status
(1) For detailed descriptions of the different status LED indicators, see Troubleshooting
on page 227.
4 Rockwell Automation Publication 2080-UM002F-EN-E - December 2013
Hardware Overview Chapter 1
16
17
18
19
20
21
22
23
24
45915
45918
Status indicators
1
2
3
4
5
8
6
8
7
9
8
10
6
11
12
13
14
15
Micro850 48-point controllers and status indicators
Controller Description
Description Description
1 Status indicators 9 Expansion I/O slot cover
2 Optional power supply slot 10 DIN rail mounting latch
3 Plug-in latch 11 Mode switch
4 Plug-in screw hole 12 Type B connector USB port
5 40-pin high speed plug-in connector 13 RS232/RS485 non-isolated combo serial port
6 Removable I/O terminal block 14 RJ-45 EtherNet/IP connector (with embedded yellow
and green LED indicators)
7 Right-side cover 15 Optional AC power supply
8 Mounting screw hole / mounting foot
Status Indicator Description
(1)
Description Description
16 Input status 21 Fault status
17 Module status 22 Force status
18 Network status 23 Serial communications status
19 Power status 24 Output status
20 Run status
(1) For detailed descriptions of these LED status indicators, see Troubleshooting
Micro830 Controllers – Number and Type of Inputs/Outputs
Catalog Number Inputs Outputs PTO Support HSC Support
110V AC 24V DC/V AC Relay 24V Sink 24V Source
on page 227.
2080-LC30-10QWB 6 4 2
2080-LC30-10QVB 6 4 1 2
2080-LC30-16AWB 10 6
2080-LC30-16QWB 10 6 2
Rockwell Automation Publication 2080-UM002F-EN-E - December 2013 5
Chapter 1 Hardware Overview
45221
Micro830 Controllers – Number and Type of Inputs/Outputs
Catalog Number Inputs Outputs PTO Support HSC Support
110V AC 24V DC/V AC Relay 24V Sink 24V Source
2080-LC30-16QVB 10 6 1 2
2080-LC30-24QBB 14 10 2 4
2080-LC30-24QVB 14 10 2 4
2080-LC30-24QWB 14 10 4
2080-LC30-48AWB 28 20
2080-LC30-48QBB 28 20 3 6
2080-LC30-48QVB 28 20 3 6
2080-LC30-48QWB 28 20 6
Micro850 Controllers – Number and Types of Inputs and Outputs
Catalog Number Inputs Outputs PTO Support HSC Support
120V AC 24V DC/V AC Relay 24V Sink 24V Source
2080-LC50-24AWB 14 10
2080-LC50-24QBB 14 10 2 4
2080-LC50-24QVB 14 10 2 4
2080-LC50-24QWB 14 10 4
2080-LC50-48AWB 28 20
2080-LC50-48QBB 28 20 3 6
2080-LC50-48QVB 28 20 3 6
2080-LC50-48QWB 28 20 6
Programming Cables
Micro800 controllers have a USB interface, making standard USB cables usable as
programming cables.
Use a standard USB A Male to B Male cable for programming the controller.
6 Rockwell Automation Publication 2080-UM002F-EN-E - December 2013
Hardware Overview Chapter 1
yellow LED
green LED
RJ-45 connector
RJ-45 Ethernet Port Pin Mapping
Contact
Number
Signal Direction Primary Function
1 TX+ OUT Transmit data +
2 TX- OUT Transmit data -
3 RX+ IN Differential Ethernet Receive
Data +
4 Terminated
5 Terminated
6 RX- IN Differential Ethernet Receive
Data -
7 Terminated
8 Terminated
Shield Chassis Ground
45920
The yellow status LED
indicates Link (solid yellow)
or No Link (off).
The green status LED
indicates activity (blinking
green) or no activity (off).
Embedded Serial Port Cables
Embedded serial port cables for communication are listed here. All embedded serial
port cables must be 3 meters in length, or shorter.
Embedded Serial Port Cable Selection Chart
Connectors Length Cat. No. Connectors Length Cat. No.
8-pin Mini DIN to 8-pin Mini DIN 0.5 m (1.5 ft)
8-pin Mini DIN to 8-pin Mini DIN 2 m (6.5 ft)
(1) Series C or later for Class 1 Div 2 applications.
1761-CBL-AM00
1761-CBL-HM02
(1)
(1)
8-pin Mini DIN to 9-pin D Shell 0.5 m (1.5 ft)
8-pin Mini DIN to 9-pin D Shell 2 m (6.5 ft)
8-pin Mini DIN to 6-pin RS-485
terminal block
30 cm (11.8in.) 1763-NC01 series A
1761-CBL-AP00
1761-CBL-PM02
Embedded Ethernet Support
For Micro850 controllers, a 10/100 Base-T Port (with embedded green and
yellow LED indicators) is available for connection to an Ethernet network
through any standard RJ-45 Ethernet cable. The LED indicators serve as
indicators for transmit and receive status.
(1)
(1)
Rockwell Automation Publication 2080-UM002F-EN-E - December 2013 7
Micro850 controllers support Ethernet crossover cables (2711P-CBL-EX04).
Ethernet Status Indication
Micro850 controllers also support two LEDs for EtherNet/IP to indicate the
following:
• Module status
• Network status
See Troubleshooting
indicators.
on page 227 for descriptions of Module and Network status
Chapter 1 Hardware Overview
Notes:
8 Rockwell Automation Publication 2080-UM002F-EN-E - December 2013
About Your Controller
Chapter
2
Programming Software for Micro800 Controllers
Connected Components Workbench is a set of collaborative tools supporting
Micro800 controllers. It is based on Rockwell Automation and Microsoft Visual
Studio technology and offers controller programming, device configuration and
integration with HMI editor. Use this software to program your controllers,
configure your devices and design your operator interface applications.
Connected Components Workbench provides a choice of IEC 61131-3
programming languages (ladder diagram, function block diagram, structured
text) with user defined function block support that optimizes machine control.
Obtain Connected Components Workbench
A free download is available at:
http://ab.rockwellautomation.com/Programmable-Controllers/ConnectedComponents-Workbench-Software
Use Connected Components Workbench
To help you program your controller through the Connected Components
Workbench software, you can refer to the Connected Components Workbench
Online Help (it comes with the software).
Agency Certifications
Compliance to European Union Directives
Rockwell Automation Publication 2080-UM002F-EN-E - December 2013 9
• UL Listed Industrial Control Equipment, certified for US and Canada.
UL Listed for Class I, Division 2 Group A,B,C,D Hazardous Locations,
certified for U.S. and Canada.
• CE marked for all applicable directives
• C-Tick marked for all applicable acts
• KC - Korean Registration of Broadcasting and Communications
Equipment, compliant with: Article 58-2 of Radio Waves Act, Clause 3.
This product has the CE mark and is approved for installation within the
European Union and EEA regions. It has been designed and tested to meet the
following directives.
Chapter 2 About Your Controller
EMC Directive
This product is tested to meet Council Directive 2004/108/EC Electromagnetic
Compatibility (EMC) and the following standards, in whole or in part,
documented in a technical construction file:
• EN 61131-2; Programmable Controllers (Clause 8, Zone A & B)
• EN 61131-2; Programmable Controllers (Clause 11)
• EN 61000-6-4
EMC - Part 6-4: Generic Standards - Emission Standard for Industrial
Environments
• EN 61000-6-2
EMC - Part 6-2: Generic Standards - Immunity for Industrial
Environments
This product is intended for use in an industrial environment.
Installation Considerations
Low Voltage Directive
This product is tested to meet Council Directive 2006/95/ECLow Voltage, by
applying the safety requirements of EN 61131-2 Programmable Controllers, Part
2 - Equipment Requirements and Tests.
For specific information required by EN 61131-2, see the appropriate sections in
this publication, as well as the following Allen-Bradley publications:
• Industrial Automation Wiring and Grounding Guidelines for Noise
Immunity, publication 1770-4.1
• Guidelines for Handling Lithium Batteries, publication AG-5.4
• Automation Systems Catalog, publication B115
Most applications require installation in an industrial enclosure (Pollution
(1)
Degree 2
Category II
) to reduce the effects of electrical interference (Over Voltage
(2)
) and environmental exposure.
Locate your controller as far as possible from power lines, load lines, and other
sources of electrical noise such as hard-contact switches, relays, and AC motor
drives. For more information on proper grounding guidelines, see the Industrial
Automation Wiring and Grounding Guidelines publication 1770-4.1
.
.
(1) Pollution Degree 2 is an environment where normally only non-conductive pollution occurs except that
occasionally temporary conductivity caused by condensation shall be expected.
(2) Overvoltage Category II is the load level section of the electrical distribution system. At this level, transient
voltages are controlled and do not exceed the impulse voltage capability of the products insulation.
10 Rockwell Automation Publication 2080-UM002F-EN-E - December 2013
About Your Controller Chapter 2
WARNING: When used in a Class I, Division 2, hazardous location, this equipment must be mounted in a
suitable enclosure with proper wiring method that complies with the governing electrical codes.
WARNING: If you connect or disconnect the serial cable with power applied to this module or the serial
device on the other end of the cable, an electrical arc can occur. This could cause an explosion in hazardous
location installations. Be sure that power is removed or the area is nonhazardous before proceeding.
WARNING: The local programming terminal port is intended for temporary use only and must not be
connected or disconnected unless the area is assured to be nonhazardous.
WARNING: The USB port is intended for temporary local programming purposes only and not intended for
permanent connection. If you connect or disconnect the USB cable with power applied to this module or
any device on the USB network, an electrical arc can occur. This could cause an explosion in hazardous
location installations. Be sure that power is removed or the area is nonhazardous before proceeding.
The USB port is a nonincendive field wiring connection for Class I, Division2 Groups A, B, C and D.
WARNING: Exposure to some chemicals may degrade the sealing properties of materials used in the
Relays. It is recommended that the User periodically inspect these devices for any degradation of
properties and replace the module if degradation is found.
WARNING: If you insert or remove the plug-in module while backplane power is on, an electrical arc can
occur. This could cause an explosion in hazardous location installations. Be sure that power is removed or
the area is nonhazardous before proceeding.
WARNING: When you connect or disconnect the Removable Terminal Block (RTB) with field side power
applied, an electrical arc can occur. This could cause an explosion in hazardous location installations.
WARNING: Be sure that power is removed or the area is nonhazardous before proceeding.
ATTENTION: To comply with the CE Low Voltage Directive (LVD), this equipment must be powered from a
source compliant with the following: Safety Extra Low Voltage (SELV) or Protected Extra Low Voltage (PELV).
ATTENTION: To comply with UL restrictions, this equipment must be powered from a Class 2 source.
ATTENTION: Be careful when stripping wires. Wire fragments that fall into the controller could cause
damage. Once wiring is complete, make sure the controller is free of all metal fragments.
ATTENTION: Do not remove the protective debris strips until after the controller and all other equipment in
the panel near the module are mounted and wired. Remove strips before operating the controller. Failure to
remove strips before operating can cause overheating.
ATTENTION: Electrostatic discharge can damage semiconductor devices inside the module. Do not touch
the connector pins or other sensitive areas.
ATTENTION: The USB and serial cables are not to exceed 3.0 m (9.84 ft).
ATTENTION: Do not wire more than 2 conductors on any single terminal.
ATTENTION: Do not remove the Removable Terminal Block (RTB) until power is removed.
Rockwell Automation Publication 2080-UM002F-EN-E - December 2013 11
Chapter 2 About Your Controller
Environment and Enclosure
This equipment is intended for use in a Pollution Degree 2 industrial environment, in
overvoltage Category II applications (as defined in IEC 60664-1), at altitudes up to
2000 m (6562 ft) without derating.
This equipment is considered Group 1, Class A industrial equipment according to
IEC/CISPR 11. Without appropriate precautions, there may be difficulties with
electromagnetic compatibility in residential and other environments due to
conducted and radiated disturbances.
This equipment is supplied as open-type equipment. It must be mounted within an
enclosure that is suitably designed for those specific environmental conditions that
will be present and appropriately designed to prevent personal injury resulting from
accessibility to live parts. The enclosure must have suitable flame-retardant
properties to prevent or minimize the spread of flame, complying with a flame
spread rating of 5VA, V2, V1, V0 (or equivalent) if non-metallic. The interior of the
enclosure must be accessible only by the use of a tool. Subsequent sections of this
publication may contain additional information regarding specific enclosure type
ratings that are required to comply with certain product safety certifications.
In addition to this publication, see:
• Industrial Automation Wiring and Grounding Guidelines, Rockwell Automation
publication 1770-4.1
• NEMA Standard 250 and IEC 60529, as applicable, for explanations of the degrees
of protection provided by different types of enclosure.
, for additional installation requirements.
Preventing Electrostatic Discharge
This equipment is sensitive to electrostatic discharge, which can cause
internal damage and affect normal operation. Follow these guidelines when
you handle this equipment:
• Touch a grounded object to discharge potential static.
• Wear an approved grounding wriststrap.
• Do not touch connectors or pins on component boards.
• Do not touch circuit components inside the equipment.
• Use a static-safe workstation, if available.
• Store the equipment in appropriate static-safe packaging when not in use.
Safety Considerations
Safety considerations are an important element of proper system installation.
Actively thinking about the safety of yourself and others, as well as the condition
of your equipment, is of primary importance. We recommend reviewing the
following safety considerations.
12 Rockwell Automation Publication 2080-UM002F-EN-E - December 2013
About Your Controller Chapter 2
North American Hazardous Location Approval
The following information applies when operating this equipment
in hazardous locations:
Products marked "CL I, DIV 2, GP A, B, C, D" are suitable for use in Class I
Division 2 Groups A, B, C, D, Hazardous Locations and nonhazardous
locations only. Each product is supplied with markings on the rating
nameplate indicating the hazardous location temperature code. When
combining products within a system, the most adverse temperature code
(lowest "T" number) may be used to help determine the overall
temperature code of the system. Combinations of equipment in your
system are subject to investigation by the local Authority Having
Jurisdiction at the time of installation.
EXPLOSION HAZARD
• Do not disconnect equipment unless power has been
removed or the area is known to be nonhazardous.
• Do not disconnect connections to this equipment unless
power has been removed or the area is known to be
nonhazardous. Secure any external connections that mate to
this equipment by using screws, sliding latches, threaded
connectors, or other means provided with this product.
• Substitution of any component may impair suitability for
Class I, Division 2.
• If this product contains batteries, they must only be changed
in an area known to be nonhazardous.
Informations sur l’utilisation de cet équipement en environnements
dangereux:
Les produits marqués "CL I, DIV 2, GP A, B, C, D" ne conviennent qu'à une
utilisation en environnements de Classe I Division 2 Groupes A, B, C, D
dangereux et non dangereux. Chaque produit est livré avec des marquages
sur sa plaque d'identification qui indiquent le code de température pour les
environnements dangereux. Lorsque plusieurs produits sont combinés dans
un système, le code de température le plus défavorable (code de
température le plus faible) peut être utilisé pour déterminer le code de
température global du système. Les combinaisons d'équipements dans le
système sont sujettes à inspection par les autorités locales qualifiées au
moment de l'installation.
RISQUE D’EXPLOSION
• Couper le courant ou s'assurer que l'environnement est classé
non dangereux avant de débrancher l'équipement.
• Couper le courant ou s'assurer que l'environnement est classé
non dangereux avant de débrancher les connecteurs. Fixer tous
les connecteurs externes reliés à cet équipement à l'aide de vis,
loquets coulissants, connecteurs filetés ou autres moyens
fournis avec ce produit.
• La substitution de tout composant peut rendre cet équipement
inadapté à une utilisation en environnement de Classe I,
Division 2.
• S'assurer que l'environnement est classé non dangereux avant
de changer les piles.
Disconnecting Main Power
WARNING: Explosion Hazard
Do not replace components, connect equipment, or disconnect equipment
unless power has been switched off.
The main power disconnect switch should be located where operators and
maintenance personnel have quick and easy access to it. In addition to
disconnecting electrical power, all other sources of power (pneumatic and
hydraulic) should be de-energized before working on a machine or process
controlled by a controller.
Rockwell Automation Publication 2080-UM002F-EN-E - December 2013 13
Chapter 2 About Your Controller
Safety Circuits
WARNING: Explosion Hazard
Do not connect or disconnect connectors while circuit is live.
Circuits installed on the machine for safety reasons, like overtravel limit switches,
stop push buttons, and interlocks, should always be hard-wired directly to the
master control relay. These devices must be wired in series so that when any one
device opens, the master control relay is de-energized, thereby removing power to
the machine. Never alter these circuits to defeat their function. Serious injury or
machine damage could result.
Power Distribution
There are some points about power distribution that you should know:
• The master control relay must be able to inhibit all machine motion by
removing power to the machine I/O devices when the relay is deenergized. It is recommended that the controller remain powered even
when the master control relay is de-energized.
• If you are using a DC power supply, interrupt the load side rather than the
AC line power. This avoids the additional delay of power supply turn-off.
The DC power supply should be powered directly from the fused
secondary of the transformer. Power to the DC input and output circuits
should be connected through a set of master control relay contacts.
Periodic Tests of Master Control Relay Circuit
Any part can fail, including the switches in a master control relay circuit. The
failure of one of these switches would most likely cause an open circuit, which
would be a safe power-off failure. However, if one of these switches shorts out, it
no longer provides any safety protection. These switches should be tested
periodically to assure they will stop machine motion when needed.
14 Rockwell Automation Publication 2080-UM002F-EN-E - December 2013
About Your Controller Chapter 2
Power Considerations
The following explains power considerations for the micro controllers.
Isolation Transformers
You may want to use an isolation transformer in the AC line to the controller.
This type of transformer provides isolation from your power distribution system
to reduce the electrical noise that enters the controller and is often used as a stepdown transformer to reduce line voltage. Any transformer used with the
controller must have a sufficient power rating for its load. The power rating is
expressed in volt-amperes (VA).
Power Supply Inrush
During power-up, the Micro800 power supply allows a brief inrush current to
charge internal capacitors. Many power lines and control transformers can supply
inrush current for a brief time. If the power source cannot supply this inrush
current, the source voltage may sag momentarily.
The only effect of limited inrush current and voltage sag on the Micro800 is that
the power supply capacitors charge more slowly. However, the effect of a voltage
sag on other equipment should be considered. For example, a deep voltage sag
may reset a computer connected to the same power source. The following
considerations determine whether the power source must be required to supply
high inrush current:
• The power-up sequence of devices in a system.
• The amount of the power source voltage sag if the inrush current cannot
be supplied.
• The effect of voltage sag on other equipment in the system.
If the entire system is powered-up at the same time, a brief sag in the power source
voltage typically will not affect any equipment.
Loss of Power Source
The optional Micro800 AC power supply is designed to withstand brief power
losses without affecting the operation of the system. The time the system is
operational during power loss is called program scan hold-up time after loss of
power. The duration of the power supply hold-up time depends on power
consumption of controller system, but is typically between 10 milliseconds and
3 seconds.
Rockwell Automation Publication 2080-UM002F-EN-E - December 2013 15
Chapter 2 About Your Controller
TIP
Input States on Power Down
The power supply hold-up time as described above is generally longer than the
turn-on and turn-off times of the inputs. Because of this, the input state change
from “On” to “Off” that occurs when power is removed may be recorded by the
processor before the power supply shuts down the system. Understanding this
concept is important. The user program should be written to take this effect
into account.
Other Types of Line Conditions
Occasionally the power source to the system can be temporarily interrupted. It is
also possible that the voltage level may drop substantially below the normal line
voltage range for a period of time. Both of these conditions are considered to be a
loss of power for the system.
Preventing Excessive Heat
Master Control Relay
For most applications, normal convective cooling keeps the controller within the
specified operating range. Ensure that the specified temperature range is
maintained. Proper spacing of components within an enclosure is usually
sufficient for heat dissipation.
In some applications, a substantial amount of heat is produced by other
equipment inside or outside the enclosure. In this case, place blower fans inside
the enclosure to assist in air circulation and to reduce “hot spots” near the
controller.
Additional cooling provisions might be necessary when high ambient
temperatures are encountered.
Do not bring in unfiltered outside air. Place the controller in an enclosure
to protect it from a corrosive atmosphere. Harmful contaminants or dirt
could cause improper operation or damage to components. In extreme
cases, you may need to use air conditioning to protect against heat buildup within the enclosure.
A hard-wired master control relay (MCR) provides a reliable means for
emergency machine shutdown. Since the master control relay allows the
placement of several emergency-stop switches in different locations, its
installation is important from a safety standpoint. Overtravel limit switches or
mushroom-head push buttons are wired in series so that when any of them opens,
the master control relay is de-energized. This removes power to input and output
16 Rockwell Automation Publication 2080-UM002F-EN-E - December 2013
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