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Programmable Logic Controller 2MLI

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1. Current Current Module Model consump Module Model consump tion mA tion mA 2MLF 420 2MLI Dos AV8A CPU module CPUU AID PME conversion ACBA 420 module 2MLI 2MLF D21A a AD4S 619 2MLl 2MLF D22A 30 DV4A 190 250 2MLl 2MLF D22B 30 DC4A 190 400 DC12 24V input 2MLl 50 EUN ue 2MLF 200 200 module D24A DC4S 200 module 2MLl 2MLF D24B 50 DV8A 147 180 2MLI 2MLF D28A 60 DC8A 243 300 2MLI 2MLF D28B 9 High Speed HO2A 210 Counter AC110V input 2MLl 30 module 2MLF 330 module A12A HD2A Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 3 Hardware Specifications 3 3 Power Module R 200 1 09 Current Current Module Model consump Module Model consump tion mA tion mA AC220V input 2MLI 2MLF module aza 7 poga 400 2MLQ 2MLF RY1A 230 PO2A on Relay output 2MLQ 2MLF 500 340 module RY2A Positioning PO1A dule 2MLQ dox 2MLF RY2B 900 PD3A 990 2MLQ 2MLF TR2A TQ PD2A 139 2MLQ 2MLF TR2B ie PD1A cus 2MLQ 130 Thermocouple 2MLF 610 Transistor output TR4A input module TC4S module 2MLQ 26 TR4B Resistance 2MLQ temperature 2MLF TR8A 230 detector input RD4A ao module 2MLQ YRSB 499 Triac output 2MLQ 300 Profibus DP 2MLL 560 module SS2A module PMEA 2MLL
2. 128 000 vede eh Max I O memory mogues Data Symbolic Memory Variable Area 512 KB Maximum 256 KB retain settable Capacity A NP Occupying 20 No point limit bytes j 9 Timer Time Range 0 001 4 294 967 295 seconds PAA 1 193hours variable area per point Occupying 8 No point limit bytes of Counter symbolic Coefficient Range 32 768 32 767 variable area per point Fixed Area M Variable R Direct Variable Input Image Area Output Image Q Area Ww Flag Variables F System Flag K PID Flag High Speed Link oL Flag N P2P Flag 26 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 2 Specifications 2 3 Performance specifications Specifications Item Related 2MLI CPUU Non redundant Standards Analog Refresh ou Flag as VAR_GLOBAL INIT task 1max Timer Interrupt 35 max tasks Program Type Internal Device Allocation Interrupt tasks 32 max Scan program Balance 256 minus sum of above Total 256 max CPU operation mode RUN STOP DEBUG CPU restart mode Cold or warm restart Self diagnosis Watchdog timer memory error I O error battery error power error communication error etc RS 232C 1CH Modbus slave supported via USB 1CH Q 12MBPS RS 232C port Built in Program port Note Additional program connection
3. to STOP and execute Writing Program Is the RIN STUP switch set STOP Remote Stop Is the Remote DIP switch of the CPU Tum on Remote DIP switch and Module On execute Writing Program Felease the PLC connection off read the error code displayed when it connects Does the Stop LED bl ink and modify it according to the message Programmable Logic Controller 2MLI CPUU CPU User s Guide 159 Honeywell Confidential amp Proprietary 9 Troubleshooting 9 3 Error Codes List 9 3 Error Codes List Error Codes during CPU Operation Eror Causes Measures Restart mode after the measure operation LED status Diagnostic Code status timing Abnormal Data Bus Abnormal Data RAM Abnormal Click IC RTC Abnormal program memory Abnormal backup RAM 11 Abnormal backup 12 Flash Abnormal base 3 information The program of 22 backup flash is defective Abnormal USB IC 160 X Eo octet e He Blink When EE A S service if it still exists after turning it on Fault according to turning it gaim LED orders ON Contact A S service if it still exists after turning it on EE When ath Fault according to turning it gain LED orders ON EDS old When Contact A S service if it still exists after turning it on ERR On turning it again ON serene s PX UE When Contact A S service if it still exists after turning it on Fault ERR On turning it again ON Contact A S service if
4. eeeeeeeeeeeeseseeeee 32 EMG Specifications con eerte po pec e eripe aides eons 32 jui ae 33 e rr M 35 25 Complying with the low voltage directive eese 37 Specifications applicable to MasterLogic 200 Series sseee 37 Selecting a MasterLogic 200 Series PLC ssssssseeee emm eene 37 3 HARDWARE SPECIFICATIONS ceeeseeeeeee 39 31 Parts and f nctions 2 eerie eerie rre 39 MEIST NI EREMO EE 39 ExpanslorniB ase 5i etu on E ED ERES ERE Den decease cee Ed ER aca thavetde ERR Lex EAE 40 xo igiene E 41 3 2 Main and Expansion Base ccsceseeeceeeeeeeeeeeeeneeeeeeeeseeeseaeeeseeeseeeeesneeeeeees 43 Main base specifications iscsi i e E e Aae EEEE E IE a a irn 43 Expansion Base specifications tarnega e e a a enra i e ia nnn 44 Extended Cable specifications c scccses dcetesseasccivnetsebenneehestunetsiensnsnetecueveebteheanecdevesbettebesneds 45 3 9 Power Module s iiccecaiseciccccsscecesisscececctscetesascedscadvcezedisscenecngascedecetzcceactsscecnentszeee 46 Power Module specificatioris 1 1 rei eI ce eterne nde Tee eee ieu 46 Example of Current Consumption Power Calculations eee 50 R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 1 09 Honeywell Confident
5. Ladder Scan Ladder Scan Program Ladder Scan Scan BP Controller ee os Oe tHHHt VO Module Network Module Data Refresh Data exchange e Scantime Scan program process System check and Task process I O data Refresh Network Service SoftMaster Service User Task Program process a Scan program process no of program steps created x 0 028 b System check and Task process 600 1 0 ms parameter depending on the usage of auxiliary functions c SoftMaster Service process time 100 at the max data monitor d Task Program process time Sum of task processing time that occurs within a scan the time calculation by task programs are the same as of scan a program Example 120 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 7 Program Structure and Operation Method 7 1 Program Introduction R 200 1 09 The scan time of a system consisting of a CPU program 16kstep 32 points 6 I O modules 6 analog modules 4 communication modules 200 bytes 8 blocks per module is as follows Scan time ladder execution time system processing time digital module I O processing time analog I O processing time communication module processing time SoftMaster Service processing time 16000 x 0 028 600 20 x 6 75 x 6 185 x 8 x 4 100 7638 7 6 However if the monitor is changed scan time increases tem
6. 1l WDT is the timer used to detect operation delay by user program error The detection time of WDT is set in basic parameter using SoftMaster 2 If WDT detects the excess of setting time during the scan while watching the operation it stops the operation of PLC immediately and switches off all the outputs 3 If the excess of Scan Watchdog Timer is expected during program processing of the specific part while performing the user program FOR NEXT instruction CALL instruction clear the timer by using WDT instruction 4 The WDT instruction initializes the elapsed time of Scan Watchdog Timer and starts the time measurement from 0 again 5 Use the following method to clear the error state of watchdog Power reset operation of manual reset switch Mode conversion to STOP mode R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 69 1 09 Honeywell Confidential amp Proprietary 5 Functions of the CPU Module 5 1 Self diagnostic Function WDT 0123 Count ms WDT Reset Scan END Executing DT Scan END command TIP The range of WDT is between 10 1000ms resolution of 1ms I O Module Check This function is used to check the error state of an I O module during the beginning of an operation or during operation 1 Incase the module installed physically is not as per the module type configured in the software I O parameter settings then it shows an error 2 Incase t
7. 1 09 Honeywell Confidential amp Proprietary 206BContents 210BSymbol Definitions laico 124 3 Operation Mode orn rr HERE xt ee manera te no Seen re ER Ea 134 Overview of the Operation MODE ssssesssee I emememenennnnnnnnnnnnn nnne nnn nnns 134 RUIN Mode Cm 134 STOP MOde rics ie 136 DEBUGIMOGde s ires deo rote ite Mali Gea Nisee tae 136 Changing Operation Mode ccccccceecceceeeeeeeeeceeeeeeeeeeeeeaeeeeeeeeesecaeaeeeeeseseecaeaeeeeeeeeeeeeee 138 TA CRU MGM Ny 140 Overview of CPU memoty 1 remet ette reri Ea aaa Ea Eea A aaaea atad 140 Program Memoty 5 terere rut etr PR e PRECOR ETRE NR PEE e ERR Pr EE RE ERR Eee nece 140 Data oos EE eneier es 141 Data Retain Area Setting cire ceteri pei quede sd dte eee d seda cene ten doces 142 Data initialization by restart mode sssssee eee emen 143 Operation in the data retain area ssssssssssssssseeeseeeeeeenen eene enne 143 Data Initialization CE 144 8 MAINTENANCE ekaa aai apaan aknan 145 8 1 Repairs and Maintenance ccccceceesseeeeeceeeeeeeeeeeeeneeseeeeeseesseaneeeeeeeneees 145 WO Module maintenance sseesseeeeneenm een nemen nneen erre n nene nennen nnns 145 8 2 Routine InspectlOon
8. 2MLI CPUU Non redundant Related Standards Program Execution methods Cyclic scan Time driven interrupts Internal Memory interrupts I O control method Scan synchronous batch processing I O refresh method Direct I O method by program instruction Program language Ladder Diagram Sequential Function Chart Structured Text Instruction List view only Operator 18 Basic functions 136 real number operation function Number of instruction Basic function 43 S block Dedicated Dedicated communication function blocks P2P function block LD 0 028us Step Processin MOV 0 084us Step oe 0 392us S 0 924ys D S Single real 0 392us S 0 us instruction Real number number operation 0 924us S 2 254us D 0 896us S 2 240us D x D Double real number Program memory capacity 1MB approx 128 KSteps Max I O bases 8 main 7 extension Max slots 96 Max base Using 64 6h 65444 64ceh 9 6 slets R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 25 1 09 Honeywell Confidential amp Proprietary 2 Specifications 2 3 Performance specifications Specifications Item Related 2MLI CPUU Non redundant Standards DI DO module 0 Using 32 ch DDO module 9 072 32ch 96 slots Max I O extension distance 15m proprietary cable open standards Network Remote I O
9. A user defined task scan program does not execute when the initialization task program is executing The scan program has a low priority over user defined Task program Whenever a user defined task program occurs the scan program is stopped and the task program execution takes precedence over the scan program If user defined tasks frequently occur during the first scan or intensively and intermittently occur a scan time may increase drastically Pay special attention while setting the conditions of task Protection from task program of a currently running program If program execution continuity is lost by executing a higher priority program you can partially protect the task program from being executed for a problematic part Currently a program can be protected by application function commands of DI task program operation disabled or EI task program operation enabled Insert the DI application function command into the beginning position of a program section to be protected and EI to the program section to cancel it Initialization task is not affected by the application function commands of DI and ET TIP If a task program priority is identical the program execution follows the order in which the task programs were created Processing Method of Fixed Cycle Task Program It describes the processing method when a Task Program is set at the fixed cycle 1 128 Task settings P
10. Error detection by external device error This is to detect an error in an external control device by using the PLC program In case of a fatal error the system stops but in case of non fatal error the system provides an indication about the error state and continues to operate TIP The error codes are saved in special flag F 1026 when a fatal error is detected The error code is saved in 96F 1027 when a non fatal error is detected B REFERENCE INTERNAL For additional information on the Flags see Appendix 1 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 5 Functions of the CPU Module 5 2 Clock Function 5 2 Clock Function The CPU module has an in built real time clock device RTC In a power OFF or instantaneous interruption the RTC continues to function using the battery back up The clock data of the RTC is used to provide the time control for operations or fault logs The current time of the RTC is updated to the clock related F address memory area at every scan period Read from SoftMaster Setting Click Online gt PLC Information on the SoftMaster menu bar The following dialog box is displayed PLC Information NewPLC queen CPU Performance Password PLC RTC State PLC RATC is set Date Time E 30 2007 2 55 21 PM Synchronize PLC with PC clock Send to PLC R 200 Programmable Logic Co
11. e PROC 1 occurrence During a scan program the program is executed as follows R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 131 1 09 Honeywell Confidential amp Proprietary 7 Program Structure and Operation Method 7 2 Program Execution 132 Scan start T stScan Tst scan end tst operation start program end 2 nd scan start P0 Execution Time 0 678 10 12 1 20 22 2425 30 32 34 L Execution without program interruption C Instant stopping during program execution C Delay of program execution Processing by time period Time ms Processing 0 Scan starts and the scan program PO starts operation 0 10 Program PO is executed 10 12 PO stops due to the execution request from P1 and P1 is executed 17 Execution request for P2 12 20 P1 execution is complete and the suspended PO resumes 20 24 PO stops due to the execution request from P1 and P1 is executed 24 25 As P1 execution is complete the suspended PO is completely executed 25 Check the execution request for P2 at the moment when scan program PO is complete and execute P2 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 ms 7 Program Structure and Operation Method 7 2 Program Execution R 200 1 09 25 30 Execute program P2 30 32 P2 stops due to the execution request from P1 and P1 is executed As
12. eni tne tete rte eee rep ierat 147 9 3 Periodic Inspection eire aa a aaa raaa aaar eaa aa iaa aaen 149 9 TROUBLESHOOT ING sasaasssssssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnne 151 9 1 Basic Troubleshooting Procedure eene 151 9 2 Troubleshooting eerte cient derer redeem etin tnra arua ecmnn 152 Action when POWER LED is OFF nennen nennen nennen enne 152 Action when ERR LED is ON 5 inca eet eere cree qi ae d ede ted dus 154 Action when RUN STOP LED is Off nennen nennen nennen enne 156 Action when I O module does not function properly sseee m 156 Action when Writing a Program to the CPU fails seem 159 9 3 Error Codes List erre RE Ree 160 Error Codes during CPU Operation sene ener 160 10 APPEN D ET 164 10 1 Flag AMI E ER 164 The Flags of Operation Mode and State Flags ssssssssseeeeee 164 System Error Flags eain idee encased sie dunes bee ie Ee ene End ep Re tenes d edd dude Dun 166 System Warning Flags iere eter tete eee PEE Lose mee ER exin tune dne 169 14 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 206BContents 210BSymbol Definitions USers Flags eee pert te BEER MEER NR RR ORE 169 Operation result flags 2 1 nne ett eren d eed ped eie Eee dad cede ee 171 T
13. Input Output Internal memory area of CPU module installed to maintain I O states International Electrotechnical Commission Interrupt driven task programs executed on meeting a given condition in addition to regular scan programs It consists of 2 types e Timer interrupt task e Internal flag Interrupt task Kilo Bytes Kilo Steps Least Significant Bit Mega Bytes MasterLogic 200 A standard component with a specific function to configure a system such as the I O board assembled to be inserted into the base motherboard Examples CPU module power module and I O module Most Significant Bit Operating System Point to Point Service in MasterLogic 200 communication modules Process Automation Controller Programmable Logic Controller A system consisting of a PLC CPU modules and peripherals configured to be controlled by a user program Profibus DP Network Random Access Memory As an abbreviation of Real Time Clock it is collectively referred as a universal IC with the function of a clock Programmable Logic Controller 2MLI CPUU CPU User s Guide Honeywell Confidential amp Proprietary 208BAcronyms amp definitions vi RTC Snet SoftMaster STP Symbolic variable TP UTP Warm Restart Watchdog Timer Real Time Clock Serial Link Network Programming tool for creating editing and debugging a program Shielded Twisted Pair Named Variables which are declared with a nam
14. DIREC_IN DIREC OUT function is used to change the I O values This enables the user to read the state of input and output contact points directly during program execution B ATTENTION When DIREC IN DIREC OUT function is used the value is applied immediately and it precedes Forced I O REFERENCE INTERNAL For additional information about the DIREC_IN DIREC_OUT function see the SoftMaster Instruction manual R 200 1 09 Programmable Logic Controller 2MLI CPUU CPU User s Guide 83 Honeywell Confidential amp Proprietary 5 Functions of the CPU Module 5 5 Viewing PLC Error Event Log 5 5 Viewing PLC Error Event Log Overview of operation history There are four types of logs e Error log e Mode change log e Shut down log e System log The PLC saves the time frequency and operation of each event in memory This can be monitored from SoftMaster The operation log is continuously saved in the PLC unless it is deleted using SoftMaster Error Log The PLC saves the errors that occur during operation into an error log It saves the following details of errors e Error code date time and error details e Error history of the errors that occur during operation It saves a maximum of 2 048 messages The saving of error history is automatically diabled in case memory backup fails due to low battery Mode Change Log In the event of a change in operation mode the PLC saves this information wi
15. Function Block HSL This is one of the CPU restart modes which affects the variable parameters of the I O image area when the CPU is restarted With the CPU restart mode set to cold restart all the parameters like the internal register timer and counter initialize to zero Central Processing Unit Digital to Analog Conversion Memory area which can be directly accessed with IEC standard addressing notations with or without any variable name They are l input Q output and M internal flags amp registers variables Address Examples 961X0 0 2 QW1 2 1 and MD1234 DeviceNet Network Fast Ethernet Network Fiber Optic Is an operation unit that immediately outputs the operation results for an input such as four arithmetical operations and comparative operations Is an operation unit that memorizes the operation results within the commands such as timer and counter or results derived from several scans Function blocks are the fundamental element for logic programs function blocks like timer and counter have input and output connections to indicate the flow High Speed Link Service in MasterLogic 200 communication modules Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 208BAcronyms amp definitions V0 I O image area IEC Interrupt Task KB KStep LSB MB ML 200 Module MSB O S P2P PAC PLC PLC System Pnet RAM RTC
16. HSL services are communication threads that runs in CPU configured to perform selected communication functions related to FEnet FDEnet Pnet Dnet modules Each HSL is further divided into 128 blocks of data transfer for modularity Examples where HSL services are applicable e peer to peer communication between PLC A amp PLC B via FENet or FDEnet modules with configurable data areas into manageable blocks e to read write I O values between Profibus DPor DeviceNet master module and Smart I O modules on respective open network 110 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 6 Configuration 6 3 Network system P2P service P2P services are communication threads that runs in CPU configured to perform communication functions related to Snet FEnet or FDEnet module In a MasterLogic 200 CPU a max of 8 P2P services can be configured using SoftMaster Each P2P is further divided into 128 blocks of data transfer For example one HSL can be assigned to transfer configured memory data from PLC A to PLC B via FDEnet modules The following tablelists the communication capacity of the CPU Modules applications 2MLI CPUU Maximum No of high speed link services 12 per CPU Maximum No of P2P services per CPU 8 Maximum No of communication modules 24 per CPU B ATTENTION Point to Point P2P service 1 1 communication Computer Link Snet I F System
17. INTERNAL For additional information on Fault Mast setting see SoftMaster User s Manual For additional information on setting fault mask through a program see Appendix 1 Flags list Releasing Fault Mask The Fault mask can be released in the following ways e Setting release from online menu of SoftMaster e Release by program e Automatic release in case memory backup is lost because of battery voltage falling The fault mask is not released in the following cases 1 Power Off On 2 Operation mode change 3 Program download 4 Reset key released only when it is pressed for 3 seconds and longer 5 Data clear R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 89 1 09 Honeywell Confidential amp Proprietary 5 Functions of the CPU Module 5 7 Fault Mask Function 90 ATTENTION Check the state of the error flag before releasing the Fault Mask flag The system goes to STOP mode if the Fault Mask is released without clearing the Error Flag Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 5 Functions of the CPU Module 5 8 I O Module Skip Function 5 8 I O Module Skip Function I O Module skip operational overview The I O module skip function is used to exclude a designated module from operation while the PLC is in RUN Mode The I O data updation and error diagnosis ceases for the designated module It is used when
18. LG terminal Power input terminal Terminal cover Ground terminal for electric shock prevention Ground terminal of power filter Power input terminal 2MLP ACF1 2MLP ACF2 2MLP AC23 2MLP DC42 Terminal block protection cover Programmable Logic Controller 2MLI CPUU CPU User s Guide Honeywell Confidential amp Proprietary R 200 1 09 3 Hardware Specifications 3 2 Main and Expansion Base 3 2 Main and Expansion Base Main base specifications The Main base consists of the Power module CPU module I O module Special module and the Communication module Item 2MLB M12A 2MLB M08A 2MLB M06A 2MLB M04A No of I O modules installed 12 4 Dimensions mm 426 X 98 X 19 318 X 98 X 19 264 X98 X 19 210 X98 X 19 Hole distance to attach panel 406 X 75 298 X 75 244 X 75 190 X 75 Hole size to attach panel 4 5 using M4 screw Screw size for FG connection PHM 3 X 6 washer 5 Weight kg R 200 1 09 Programmable Logic Controller 2MLI CPUU CPU User s Guide Honeywell Confidential amp Proprietary 43 3 Hardware Specifications 3 2 Main and Expansion Base Expansion Base specifications 44 The expansion base consists of the Power module I O module Special module and the Communication module Item 2MLB E12A 2MLB E08A 2MLB E06A 2MLB E04A No of I O modules 12 8 6 4 Dime
19. Names Description Note DATA CLEAR acts only in STOP operation mode USB connector to connect with SoftMaster PC Supports version USB USB connector 1 1 onwards e A connector to connect with peripherals SoftMaster connection with PLC RS 232C connector Any Modbus equipment connection Modbus slave protocol support TX no 7 Pin RX no 8 Pin GND no 5 Pin Battery built in Back up battery built in cover bottom side Cover R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 31 1 09 Honeywell Confidential amp Proprietary 2 Specifications 2 4 Conformance to EMC Specifications 2 4 Conformance to EMC Specifications EMC Specifications 32 The EMC Directive specifies that products must be so constructed that they do not cause excessive electromagnetic interference emissions and are not unduly affected by electromagnetic interference immunity The applicable products are requested to meet these requirements This section summarizes the precautions for the MasterLogic 200 PLC to ensure conformance to the EMC Directive Details of these precautions are based on the requirements and the applicable standards However Honeywell does not guarantee that the overall system manufactured according to these details conforms to the directives listed in the following table The method of conformance to the EMC directive and the judgment on whether or not the system conforms to the EMC Directive mus
20. condition and if any fault is found replace the CPU module Reset changing to RUN mode STOP Restart after I O parameter is reloaded Replace a battery in case of defective battery After I O parameter is reloaded check the storage condition and if any fault is found replace the CPU module Reset STOP changing to RUN mode Restart after basic parameter is reloaded Replace a battery in case of defective battery After basic parameter is reloaded check the storage condition and if any fault is found replace the CPU module Reset changing to RUN mode STOP Check the wrong slot position in SoftMaster modify a module slot position or configuration and then STOP Changing to restart RUN RUN mode Reference flag Module type inconsist error flag Check any removed added slot position in SoftMaster Modify the installed slot and restart STOP When scan according to the configuration RUN ends Reference flag Module attachment error flag Check the position of a slot of where fuse has blown out in the SoftMaster Replace the fuse and STOP ERR On When scan restart as per the configuration RUN P S On ends Reference flag Fuse disconnection error flag Check the position of a slot with access error in SoftMaster Replace the fuse and restart as per the STOP ERR On When scan configuration RUN P S On ends Reference flag I O Module Write Read error flag Check the position of a
21. 2 means the state to occur the pollution of non electric conductivity generally but the state to occur temporary electric conduction according to the formation of dew Compliance to European Union Directives 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 EMC Directive This apparatus is tested to meet Council Directive 89 336 EEC Electromagnetic Compatibility EMC using a technical construction file and the following standards in whole or in part EN 50081 2 EMC Generic Emission Standard Part 2 Industrial Environment EN 50082 2 EMC Generic Immunity Standard Part 2 Industrial Environment The product described in this document is intended for use in an industrial environment Low Voltage Directive This product is also designed to meet Council Directive 73 23 EEC Low Voltage by applying the safety requirements of EN 61131 2 Programmable Controllers Part 2 Equipment Requirements and Tests Programmable Logic Controller 2MLI CPUU CPU User s Guide 23 1 09 Honeywell Confidential amp Proprietary 2 Specifications 2 2 Battery 2 2 Battery Battery Specifications Item Specifications Battery Type Manganese Dioxide Lithium Battery Nominal Voltage Current DC 3 0 V 1 800 mAh Warranty period Battery Life 5 years at ambient temperature Program data backup RTC operation
22. ATTENTION If a fault is found in a module when releasing the skip function the system may stop Before releasing the skip function ensure the release os the skip with fault mask set and check the operation of a module Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 5 Functions of the CPU Module 5 9 Replacing a Module during Operation 5 9 Replacing a Module during Operation Overview of replacing modules The MasterLogic 200 system enables the user to change modules while the PLC is in RUN mode However special care must be taken while changing the modules as it can lead to abnormalities in the system CAUTION During PLC operation e Do not replace the base and power module e Some communication modules 2MLL PMEA 2MLL DMEA can be connected as long as network is set using Sycon software e When replacing a module align the bottom of the base and the holding part of a module before inserting it Incorrect installation may cause the system to shutdown Replacing Modules Following are the methods to change modules Using the Module Replacement Wizard of SoftMaster B REFERENCE INTERNAL For additional information see SoftMaster User s Manual Using the CPU module switch Step Action 1 Set Module change switch M XCHG in front of CPU module to right ON 2 Remove the module PS LED is ON 3 Setup the new module I
23. Address memory mE Retain setting Feature Retain settable if adding a parameter to the Default O auto parameter area M o Retain settable into internal contact area by gt parameter K X Contact that is kept as contact status in case k of interrupt F X System flag area U X Analog data register retain not settable L X High speed link P2P service status contact of communication Module retained N X P2P service address area of communication 1 module retained R X Exclusive flash memory area retained 142 Programmable Logic Controller 2MLI CPUU CPU User s Guide Honeywell Confidential amp Proprietary R 200 1 09 7 Program Structure and Operation Method 7 4 CPU Memory TIP O indicates available and X indicates not available K VoL N and R address memory area are basically retained K L and N address memory areas can be deleted in the memory deletion window of PLC an online menu of SoftMaster Online Clear PLC gt Clear Memory B REFERENCE INTERNAL For additional information on data retention see the Online section of the SoftMaster User s manual Data initialization by restart mode There are 3 parameters related to the restart mode DEFAULT INITIALIZATION and RETAIN retain parameter The initialization methods of each parameter are as follows in the restart mode de Cold Warm Paramete Default Initializing as 0 Init
24. Confidential amp Proprietary 1 09 7 Program Structure and Operation Method 7 2 Program Execution A longer execution time of a task program may cause a longer scan time or irregularity In addition it may cause task program collision It is recommendedto et the execution time as short as possible especially create a fixed cycle task program so that it could be executed within 10 of the shortest task cycle among several tasks 4 Is the program for the highest priority task protected during the execution of the program Ifa different task breaks into a task program execution it completes the current task and then executes the task with the highest priority among waiting tasks Different tasks breaking into a scan program can be prevented by using DP EP application functional commands It may cause a fault while processing a global parameter process commonly used with other program or a special or communication module Program Configuration and Example of Processing Register task and program as follows e Registering a task T SLOW fixed cycle 10ms Priority 3 PROC 1 internal contact MO Priority 5 e Registering a program Program gt PO scan program Program gt P1 operating by task T SLOW Program gt P2 operating by task PROC 1 e Ifthe program execution time and occurrence of external interrupt signal are same Execution time of each program PO 21ms P1 2ms and P2 7ms
25. DC5V 6A Power module input 2MLP AC23 AC200V 240V Desv 8 5A input 2MLP DC42 DC24V input DC5V 6A Extension cable 2MLC E041 Length 0 4 m Total length must 2MLC E061 Length 0 6 m 100 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 6 Configuration 6 1 System configuration Item Type Description Be omens 2MLC E121 Length 1 2m 2MLC E301 Length 3 0 m 2MLC E501 Length 5 0 m 2MLC E102 Length 10 m 2MLC E152 Length 15 m Terminating 2MLT TERA Necessary when extension base is resistance connected Dummy module 2MLT DMMA Dust protection module for an unused slot Voltage input 8 channels 2MLF AV8A DC 1 5V 0 5V 0 10V 10 10V A D Current input 8 channels pr 2MLF AC8A TIS DC 4 20mA 0 20mA 2MLF AD4S Voltage Current input 4 channels inter channel isolation Voltage output 4 channels 2MLF DV4A DC 1 5V 0 5V 0 10V 10 10V Current output 4 channels 2MLF DC4A DC 4 20mA 0 20mA DIA C t output 4 ch Is inter ch I GORVBISIOH 2MLF DC4S Current output 4 channels inter channe mod le isolation Voltage output 8 channels 2 2MLF DV8A 2 DC 1 5V 0 5V 0 10V 10 10V Es Current output 8 channels D 2MLF DC8A a DC 4 20mA 0 20mA R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 1 09 Honeywell Confidential amp Proprietary 101 6 Configu
26. Mode and State Flags FDO Flags Name _SYS_STATE DWORD _RUN _STOP FX1 _ERROR FX2 _DEBUG FX3 FX4 BOOL 9oFX6 9oFX8 LOCAL CON REMOTE CON RUN EDIT ST BOOL RUN EDIT CHK BOOL BOOL BOOL RUN EDIT DON FX10 FX11 _RUN_EDIT_NG R 200 1 09 Honeywell Confidential amp Programmable Logic Controller 2MLI CPUU CPU User s Guide Contents Description Indicates PLC mode and operation state of the system PLC Mode and operation state Run Run state Stop Stop state Error Error state Debug Debug state Indicates operation mode changeable state only by the Mode key and SoftMaster Local control The Remote control mode Remote Mode On Editing program download during Run Editing during Run Internal edit processing during Run Edit is done during Run Edit ends abnormally during Run 164 Proprietary 10 Appendix 1 10 1 Flag List Flags Name _CMOD_KEY _CMOD_LPADT _CMOD_RPADT _CMOD_RLINK _USTOP_ON _ESTOP_ON _INIT_RUN R 200 1 09 Type BOOL BOOL BOOL BOOL BOOL BOOL Contents Description FX12 FX13 FX14 FX15 FX16 FX17 0 Bis Input Output Skip FX19 FX20 FX21 FX22 FX24 Operation mode change Forced Input Forced Output Fault mask Monitor on execution Stopped by STOP function Stopped by ESTOP function Initialization task on execution Programmable L
27. P1 execution is completed at 32 the suspended P2 is executed until 32 34 34 34 Start a new scan P2 execution starts Programmable Logic Controller 2MLI CPUU CPU User s Guide Honeywell Confidential amp Proprietary 133 7 Program Structure and Operation Method 7 3 Operation Mode 7 3 Operation Mode Overview of the Operation MODE The 2MLI CPUU has three operation modes Each mode describes the operation process at each operation mode e RUN mode e STOP mode e DEBUG mode RUN Mode The CPU executes a program operation normally WARNING Changing the operation mode can energise the field and may cause serious threat to human life 134 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 7 Program Structure and Operation Method 7 3 Operation Mode Start the first scan at RUN mode Initialize data area Determine whether to process by verifying the effectiveness of program Execute input refresh Execute scan pwogram and interrupt Dnocrarm Inspect the operation and detachment of modules installed Execute output refresh Process communication service and others d FUN Mode ange Operation Mode Maintaini Changing to other mode Operate atthe changed operation mode 1 Processing when a mode is changed R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 135 1 09 Honeywell Confidential am
28. amp Proprietary 6 Configuration 6 3 Network system 6 3 Network system Inter System Network MasterLogic 200 series supports various open networks through several communication modules for easy system configuration e High speed Ethernet FEnet module for communication with Experion PKS or other HMI systems in both TP CATS or multi mode fiber optic media This module can be also be used for peer to peer communication between MasterLogic 200 PLCs e High speed Dedicated Ethernet FDEnet module for high performance peer to peer communication between MasterLogic 200 PLCs on both TP CATS and fibre optic media e Serial Communication Snet module for communication between PLC and serial devices e g RS232 RS422 485 on proprietary or open MODBUS protocols e Profibus DP master module Pnet for communication with Profibus DP devices including our Smart I O modules e DeviceNet master module Dnet for communication with Dnet devices including our Smart I O Local Network A maximum of 24 communication modules can be installed on a MasterLogic 200 PLC They can be installed on either a main base or an expansion base It is recommended that the communication modules having high communication capacity should be installed on the main base The constraints per CPU module are shown in the below table High Speed Link Service In the MasterLogic 200 CPU a max of 12 High Speed Link HSL services can be configured using SoftMaster
29. basic parameters and I O parameters cannot be modified during operation To modify these parameters it is necessary to stop operation Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 6 Configuration 6 1 System configuration 6 Configuration 6 1 System configuration 2MLI CPUU System Configuration The system configuration of the 2MLI CPUU is as follows R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 1 09 Honeywell Confidential amp Proprietary 97 6 Configuration 6 1 System configuration a RS 232C SoftMaster CD or USB memory USB Cable Power module Main base 24 8 MonA reppin 0 E MN T E VO module jl TIETETETITITI eis 290 0000 Extension base 2t 5 EnnA Special module 2MLF can Terminating resistance MLDP TERA p Communication module auma Honeywell Confidential amp Proprietary 1 09 6 Configuration 6 1 System configuration Components List 2MLI CPUU system consists of the following components Item Type Description CPU module 2MLI CPUU CPU module Maximum I O points 6 144 Program capacity 1MByte 2MLI D21A DC 24V input 8 points current source sink input 2MLI D22A DC 24V input 16 points current source sink input 2MLI D24A DC 24V input 32 points current source sink input 2MLI D28A DC 24V
30. block Area device PnBx Device 2 to save Saves area device 2 to save P2P i structu P2P xwD2 parameter n xx block re parameter n xx block Area size 2 _PnBx Word to save P2P Saves area size 2 to save P2P xWS2 parameter n parameter n xx block xx block Area device PnBx Device 3 to save Saves area device 3 to save P2P structu P2P xWD3 parameter n xx block re parameter n xx block Area size 3 _PnBx Word to save P2P Saves area size 3 to save P2P xWS3 parameter n parameter n xx block xx block R 200 1 09 Programmable Logic Controller 2MLI CPUU CPU User s Guide Honeywell Confidential amp Proprietary 179 10 Appendix 1 10 3 Appendix Communication Flags P2P List 180 Area device PnBx Device 4 to save Saves area device 4 to save P2P structu P2P xWD4 parameter n xx block re parameter n xx block Area size 4 _PnBx WOR to save P2P Saves area size 4 to save P2P xWS4 D parameter n parameter n xx block xx block ATTENTION N area is set automatically while setting P2P parameter by using SoftMaster NM It can be modified while in RUN mode by using P2P dedicated command N area has a different address classified according to P2P parameter setting no block index The area not used by P2P service as address is divided can be used by internal device Programmable Logic Controller 2MLI CPUU CPU User s Guide Honeywell Confidential amp Proprietary R 200
31. dangerous Peak voltages can be higher than 42 4V for the AC 110 220V rated I O voltages Therefore the CE mark compliant models are internally enhanced in isolation between the primary and secondary The I O modules of DC 24V or of less rating are out of the low voltage directive application range 3 CPU Module Base Unit These modules use DC 5V and 3 3V circuits so they are out of the low voltage directive application range R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 37 1 09 Honeywell Confidential amp Proprietary 2 Specifications 2 5 Complying with the low voltage directive 4 Special Module Communication Module The special module and communication modules use DC 24V or less rated voltage therefore they are out of the low voltage directive application range 38 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 3 Hardware Specifications 3 1 Parts and functions 3 Hardware Specifications 3 1 Parts and functions Main Base 5 6 Index Part Function 1 Base attached guide hole It is used to attach the main base to the panel in control panel 2 Power module connector For installation of Power Supply module 3 For installation of I O special amp other Module built in connector r communiucation modules 4 FG terminal Ground terminal connected to the shielded pattern of PCB board 5 Extended cable connector Connects
32. following precautions while handling or installing modules e Do not drop the PLC module or apply excessive force on it e Avoid touching the PCB inside the module with bare hands as this can lead to failure of the PLC Modules e Ensure that foreign materials such as wiring fragments do not enter the upper part of modules casing Even if such materials accidentally enter the module casing remove them immediately Precautions for installing handling I O module 54 Note the following points about handling or installing I O module 1 Recheck I O module specifications Check the input voltage for input modules For output modules check if the voltage applied exceeds the maximum Open Close capacity Over voltage may lead to failure damage or sparking 2 Cable selection Select the appropriate cable after considering its capacity to withstand temperature and intensity of current flowing through it The minimum specification of cable must be AWG22 0 3mm 3 Environment When wiring an I O module ensure that it is not too close to a heat emitting equipment In addition avoid the wires from coming in direct contact with oil as it may cause a short circuit breakage or can cause abnormal errors during operation 4 Polarity The polarity of the module terminals and that of the field signal must be the same 5 Wiring e The I O must be wired using high voltage cables or power cables Lower voltage wires can cause inductive distu
33. in Applications case of power failure Dimensions 17 0 X 33 5 mm Cautions for usage Heating up the battery or welding the electrode may reduce battery CAUTION life e Attempting to measure the voltage of the battery with a tester it may cause a short circuit and fire e Do not disassemble the battery Battery Life e The durability of the battery normally depends on power time out ambient temperature and so on However the 2MLI CPUU batteries are designed for use for over 5 years in any environment If the voltage of a battery is lowered CPU module shows a Battery Voltage Drop Warning It is possible to check this from the CPU module LED and flag or error message in SoftMaster and Experion System Alarm e The battery works for a limited amount of time even after Battery Voltage Drop Warning occurs you can take an action after warning in the system of daily checking In general the battery generates a warning 5 years after purchase CAUTION You may get an early warning in case of excessive discharge because of defects or leakage in the battery If you get a warning shortly after replacing the battery contact after sales service 24 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 2 Specifications 2 3 Performance specifications 2 3 Performance specifications 2MLI CPUU performance specifications Item Specifications
34. in case REMOTE switch is OFF e Red ON Error has occurred and CPU cannot operate normally Q c ERR LED e OFF Normal operation e Red ON o User assigned flag is ON PS LED o Operating in the error state by operation proceeding in the D d Programmable error setting Status o Module is detached or new module is installed in the state where M XCHG switch is ON e OFF Normal operation ON Red Battery voltage is low Q e BAT LED OFF Normal operation e Red ON Setting is different from standard setting its is possible to add delete clear by parameter Module change switch is set as Module change Operating in DEBUG mode Ot CHK LED Forced ON setting state Fault mask SKIP flag is set Warning occurs during operation Extended base power error e Red Blink Arithmetic Operation Error during RUN e OFF Normal operation a Bost Norswitches Used to download new O S or upgrade of CPU firmwares before releasing the product R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 29 1 09 Honeywell Confidential amp Proprietary 2 Specifications 2 3 Performance specifications No Names Description e ON right For normal CPU operation mode e OFF left Used for download of new O S It is reserved for use by Honeywell factory authorized personnel Switching to this position by user is strictly prohibited Note Both Boot Nor swi
35. moderate injury It may also be used to alert against unsafe practices CAUTION symbol on the equipment refers the user to the product manual for additional information The symbol appears next to required information in the manual WARNING Indicates a potentially hazardous situation which if not avoided could result in serious injury or death WARNING symbol on the equipment refers the user to the product manual for additional information The symbol appears next to required information in the manual WARNING Risk of electrical shock Potential shock hazard where HAZARDOUS LIVE voltages greater than 30 Vrms 42 4 Vpeak or 60 VDC may be accessible Programmable Logic Controller 2MLI CPUU CPU User s Guide ix Honeywell Confidential amp Proprietary 210BSymbol Definitions noise immunity improvement Symbol Definition A ESD HAZARD Danger of an electro static discharge to which kad equipment may be sensitive Observe precautions for handling electrostatic sensitive devices r Protective Earth PE terminal Provided for connection of the ty protective earth green or green yellow supply system conductor FN Functional earth terminal Used for non safety purposes such as NOTE This connection shall be bonded to Protective Earth at the source of supply in accordance with the national local electrical code requirements Earth Ground Functional earth connection NOTE This connection shall be bonded to P
36. slot with access error in SoftMaster Replace the module and restart as per STOP ERR On When scan configuration RUN P S On ends Reference flag Special Link Module interface error Programmable Logic Controller 2MLI CPUU CPU User s Guide 161 Honeywell Confidential amp Proprietary 9 Troubleshooting 9 3 Error Codes List Error Operation Diagnostic Measures Restart mode after the measure LED status CPU is suddenly System is suddenly abnormal due to noise or abnormal hardware RUN On 39 ahora 1 Contact A S service if it still exists after turning it STOP ERR On Always ON again 2 Develop methods to prevent noise The scan time of a program excedente Check the scan delay watchdog time designated by When scan delay watchdog RUN On 40 parameter modify parameter or program and STOP i program is time designated by ERR On restart executed parameter during operation To eliminate an operation error reload the program and restart Operation error while When 41 executing user If STOP Check the details of operation error by the STOP ERR On program is program SoftMaster and modify the program RUN CHK blink executed If RUN Refer to the error steps in F address memory area Exceeding the RUN On When 42 specified stack range Restart STOP E program is ERR On during program executed Use of Timer Index STOP RUN On When scan 44 eror Modify the timer index program reload a
37. the extended cable by send receive connector with extended base R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 39 1 09 Honeywell Confidential amp Proprietary 3 Hardware Specifications 3 1 Parts and functions 6 CPU module connector For installation of CPU module Expansion Base Index Part Function 1 Base attached guide hole Itis used to attach the main base to the panel in control panel 2 Power module connector I O module built in connector 3 Module built in connector I O module built in connector 4 FG terminal Ground terminal connected to the shielded pattern of PCB board 5 Extended cable connector Connects the extended cable by send receive connector with extended base 40 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 3 Hardware Specifications 3 1 Parts and functions Power Module Index Part Function 1 Power LED DC5V power indication LED Power supply to the module required for DC24V in 2 DC24V 24G terminal Output module 2MLP ACF2 2MLP ACF3 does not print out DC24V 3 Indicates RUN state of system RUN terminal OFF when CPU STOP error occurs OFF when CPU mode is changed to STOP mode R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 41 1 09 Honeywell Confidential amp Proprietary Qo cg o e 3 Hardware Specifications 3 1 Parts and functions 42 FG terminal
38. to operate it temporarily excluding the fault Setting and Processing I O Data The SoftMaster is used to configure the skip setting on the I O module REFERENCE INTERNAL For additional information about skip setting see SoftMaster User s Manual e Input I image area suspends input refresh and maintains the value set before the skip setting At this time it is possible to operate the image by forced ON OFF e The actual output of the output module is set to OFF when setting the skip function But output image changes depending on a user program s operation irrespective of the skip setting After the skip setting the output value of the output module cannot be controlled by forced ON OFF e The skip function executed similarly as described above even while using I O function Releasing Skip Function The I O module skip function is released by the following methods e Using the online menu of SoftMaster e Releasing by overall reset e Automatically release in case of memory backup failure because of low battery level Note that the fault mask is not released in the following cases e Power Off On e Operation mode change e Program download e Reset key Released only when it is pressed for 3 seconds and longer R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 91 1 09 Honeywell Confidential amp Proprietary 5 Functions of the CPU Module 5 8 I O Module Skip Function 92 Data clear B
39. 0 Honeywell Confidential amp Proprietary 1 09 5 Functions of the CPU Module 5 10 I O Address 5 10 I O Address Allocating I O address I O address allocation refers to assigning the address to the I O terminal of each module This enables reading data from an input module and transmitting the data to an output module The I O number allocation is related with base number slot position and module type The number is allocated by the fixed method in the 2MLI CPUU The base has its base number as 0 and the extension base has a switch to set the base number The following table provides the guidance for base number setting Base Number Setting 0 m om gt C b a x a es REFERENCE INTERNAL To see examples of I O number allocation see section on Basic System Configuration R 200 1 09 Programmable Logic Controller 2MLI CPUU CPU User s Guide 95 Honeywell Confidential amp Proprietary 5 Functions of the CPU Module 5 11 Program Modification 5 11 Program Modification Program Modification during Operation 96 During PLC operation a program and some parameters can be modified without interruption to the control E REFERENCE INTERNAL For additional information on Program modification during operation refer SoftMaster User s Manual The items modifiable during operations are as follows e Program e Communication parameters B ATTENTION The
40. 1 09 10 Appendix 1 10 4 Appendix 1 4 Reserved Words 10 4 Appendix 1 4 Reserved Words The following is a list of predefined words to be used in the system These words must not be used as an identifier R 200 1 09 l 2 SOP QO cp oO pe oo 9 11 12 13 14 15 16 17 18 19 20 21 22 ACTION END ACTION ARRAY OF AT CASE OF ELSE END CASE CONFIGURATION END CONFIGURATION Name of Data Type DATEZ D DATE AND TIMEZ DT EXIT FOR TO BY DO END FOR FUNCTION END FUNCTION FUNCTION BLOCK END FUNCTION BLOCK Names of Function Block IF THEN ELSIF ELSE END IF OK Operator IL Language Operator ST Language PROGRAM PROGRAM END PROGRAM REPEAT UNTIL END REPEAT RESOURCE END RESOURCE RETAIN Programmable Logic Controller 2MLI CPUU CPU User s Guide 181 Honeywell Confidential amp Proprietary 10 Appendix 1 10 4 Appendix 1 4 Reserved Words 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 182 RETURN STEP END STEP STRUCTURE END STRUCTURE T TASK WITH TIME OF DAY TOD TRANSITION FROM TO END TRANSITION TYPE END_TYPE VAR END VAR VAR INPUT END VAR VAR OUTPUT END VAR VAR IN OUT END VAR VAR EXTERNAL END VAR VAR ACCESS END VAR VAR GLOBAL END VAR WHILE DO END WHILE WITH Programmable Logic Controller 2MLI CP
41. 2MLL 650 330 FEnet module EFMF C22A opticalelectrical 5 2MLL EFMT 420 Snet module C42A 300 FDEnet 2MLL 2MLL module Master EDMF 990 CH2A 940 Programmable Logic Controller 2MLI CPUU CPU User s Guide 47 Honeywell Confidential amp Proprietary 3 Hardware Specifications 3 3 Power Module CPU CommuiComm OutputInput Specia nication nication lay see Power AC power 100v 240V Constant voltage transformer DC5v lo4v 100V 240V lev current consumption of each module DC5V circuit internal current consumption la average current consumption of DC24V for output module The following table lists the specifications of the Power Module Items 2MLP ACF1 2MLP ACF2 2MLP AC23 2MLP DC42 Rated input voltage AC 100V AC 240V AC 200V AC 240V DC 24V Input voltage Ac 85V AC 264V AC170V AC264V range Input frequency 50 60 Hz 47 63 Hz Input Inrush current 20 APeak or less 80APesk or less Efficiency 65 or more 60 or more Input fuse Built in user no change UL standard Slow Blow Type Allowable momentary Within 20ms shutdown Output voltage DC 5V 296 DC5V 296 Output current 3 0A 6 0A 8 5A 6 0A Output1 i Over current 3 2A or more 6 6A or more 9 0A or more 6 6A or more protect Over voltage 3 protect 5 5V 6 5V 48 Programmable Logic Controller 2MLI CPUU
42. 8 2 Routine Inspection The following items must be routinely inspected Checklist Check point Judgment basis Actions Attachment of the base Check any loose screw Screws must be firmly tightened Tighten ing Attachment of I O module e Check the screws are firmly tightened e Check any separation of module cover Must be firmly tightened Tighten ing Attachment of terminal strip and extension cable Loose screw Not loose Tighten ing Proximity with clamped terminal Proper spacing Rearra ngeme nt Connector of extension cable Connector must be tightened Rearra ngeme nt Power LED Check whether it is LED ON LED On off is error RUN LED Check whether it is LED ON in RUN state LED On off or blinking is error STOP LED Check whether it is LED Off in RUN state Blinking is error section Input LED Check whether LED On or Off LED On with input ON and LED Off with input off on Perfor mance specific ations Output LED R 200 1 09 Check whether LED On or Off LED On with output ON and LED Off with output off Programmable Logic Controller 2MLI CPUU CPU User s Guide Honeywell Confidential amp Proprietary 147 8 Maintenance 8 2 Routine Inspection 148 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 8 Main
43. Array n k block 7 general state HS1STATEk HS1MODk amp _ HS1TR X k amp _HSnERRk High speed Indicates operation mode of HSn MO link station set in k data block of Dk Bit parameter the parameter n k block k 000 12 Array station RUN 7 operation mode Normal Indicates if communication HSn TR communicati state of k data of parameter Xk Bit on with High is communicated smoothly speed link according to the setting k 000 12 Array parameter 7 n k block station Indicates if errors occur in the communication state of k data block of parameter _HSn_ER Bit High speed Rk link Array parameter 7 Programmable Logic ControlleriaMLI CPUU CPU User s Guide Honeywell Confidential amp Proprietary 175 10 Appendix 1 10 2 Appendix Link Flags L List No Keyword Type Contents Description operation error mode High speed Indicates whether or not to HSn SE pit link set k data block of TBLOCKk parameter parameter Array n k block setting Communication Flag List according to P2P Service Setting P2P parameter no n 1 8 P2P block xx 0 63 No Keyword Type Address Contents Description LX1000 P2P parameter 0 n XX LX5905 Indicates P2P parameter _P2Pn_NDRxx Bit 6 Block service n xx Block service normal normal end end LX1000 P2P parameter 1 LX5 n XX Indicates P2P parameter P2Pn ERRxx Bit 9057 n xx Block servic
44. BUG operation when DIP switch of the CPU module is in REMOTE position and RUN STOP switch is in STOP position e tis convenient to check the execution state of a program or the contents of each data from Debugging function using REMOTE DEBUG Mode Remote Reset e Remote Reset function is used to reset a CPU module by running a remote operation when an error occurs and it is not possible to operate a CPU module e This supports Reset and Overall Reset like an operation by switch R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 77 1 09 Honeywell Confidential amp Proprietary 5 Functions of the CPU Module 5 3 Remote Functions 3 REFERENCE INTERNAL For the further information about remote functions refer to the Online section in the SoftMaster User s Manual Flash Memory Operation Mode In the Flash memory operation mode the system operates from the program in flash memory in case the program in the RAM is corrupted When Flash Memory Operation Mode is enabled the program is saved into flash memory The flash memory operation starts when the operation mode is changed to RUN mode from any other mode or while CPU restart e Flash Memory Operation Mode Setting Check the operation mode setting by using Online Set Flash Memory Enable flash memory run mode and click OK When Enable flash memory run mode selection is accepted a dialog box appears stating Saving flash memory pro
45. C 1300 300 4822 Pacific toll free within Australia 61 8 9362 9559 outside Australia India Honeywell Global TAC 91 20 2682 2458 India Korea Honeywell Global TAC 82 2 799 6317 Korea People s Honeywell Global TAC 86 10 8458 3280 ext 361 Republic of China China Singapore Honeywell Global TAC 65 6580 3500 South East Asia Taiwan Honeywell Global TAC 886 7 323 5900 Taiwan Japan Honeywell Global TAC 81 3 5440 1303 Japan Elsewhere Call your nearest Honeywell office viii Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 210BSymbol Definitions Symbol Definitions The following table lists the symbols used in this document to denote certain conditions R 200 1 09 Symbol Definition 5 9 0 g CAUTION gt A A ATTENTION Identifies information that requires special consideration TIP Identifies advice or hints for the user often in terms of performing a task REFERENCE EXTERNAL Identifies an additional source of information outside of the bookset REFERENCE INTERNAL Identifies an additional source of information within the bookset Indicates a situation which if not avoided may result in equipment or work data on the system being corrupted or lost or may result in the inability to properly operate the process CAUTION Indicates a potentially hazardous situation which if not avoided may result in minor or
46. C ST This document lists the specifications and the procedures for installing handling configuring and programming the CPU module Features 1 Compact size The 2MLI CPUU has all the functionality packed in a compact size thus enabling installation in small spaces In addition it reduces storage amp freight costs 2 High Speed processing a MasterLogic s high performance microprocessor technology provides a record execution speed of Sequence command 0 028us step MOV instructions time 0 084ps step b Real number operation Improved operational speed of single double preciseness Item x Single 0 602 0 602 1 106 1 134 real Double 1 078 1 078 2 394 2 66 real c Improved Data transmission speed 16 point I O module data process 0 20 us 0 80 us module R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 17 1 09 Honeywell Confidential amp Proprietary 1 Introduction 1 1 Functional Overview Analog Channel data process 0 20 us 0 80 us channel 1 KB communication module data process 12 8 us Parallel processing of I O image refresh during program operations 3 Easy Use of Analog I O Modules It guarantees precision in data collection stability and convenience by using e Dedicated U address memory area for data amp status collection e Setting Parameters without using memory maps for special modules like Analog Input Analog Outpu
47. CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 3 Hardware Specifications 3 3 Power Module Output voltage DC 24V 10 Output current 0 6A Output2 Over current DA or more protect Over voltage Nana protect Application RUN contact Refer to the section 8 3 Rated switching DC 24V 0 5A voltage current Relay Minimum DC 5V 1 Output switching load Response time OFF ON ON OFF 10 orless 12 or less Life Mechanical More than 20 000 000 times Electrical More than 100 000 times at rated switching voltage current RUN signal output Relay output Rating DC24V 0 5A Voltage indicator Output voltage normal LED ON Cable specification 0 75 2mm Compressed terminal RAV 1 25 3 5 RAV 2 3 5 Weight 0 4kg keeps Allowable Momentary Power Failure Time The time that input voltage normal output voltage normal operation in the state that AC110 220V voltage is lower than the rated value AC85 170V 2 Over current protection If the current is more than the standard and flows i n DC5V DC24V circuit the over current protection device R 200 1 09 shutsdown the circuit to stop the system Remove the causes such as lack of current capacity or short circuits that leads to over current and then restart the system 3 Over voltage protec
48. Controller 2MLI CPUU CPU User s Guide 75 1 09 Honeywell Confidential amp Proprietary 5 Functions of the CPU Module 5 3 Remote Functions 5 3 Remote Functions Overview of Remote functions The key switch installed on the local CPU is used to operate a remote CPU connected to it To operate the CPU remotely set REM switch no 2 dip switch of 4 pin dip switch of the CPU module ON and move RUN STOP switch to STOP position Types of Remote Operation e By connecting the SoftMaster through the USB or RS 232 port available in CPU module e By using SoftMaster to connect to another PLC on the same network as illustrated in the following figures View Connection Settings Connect to the remote 1 PLC aa Ethernet IP 10 1 18 194 i 76 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 5 Functions of the CPU Module 5 3 Remote Functions View Connection Settings Connect to the remote 2 PLC w aa Ethernet IP 10 1 18 194 St 0 g Rnet BaseD Slot Remote RUN STOP e Remote RUN STOP function performs RUN STOP when the DIP switch of the CPU module is in REMOTE position and RUN STOP switch is in STOP position e When the CPU module is installed in an inaccessible location and is difficult to operate it is convenient to control it using Remote RUN STOP Remote DEBUG e Remote DEBUG is a function that performs DE
49. Honeywell Honeywell Process Solutions Programmable Logic Controller 2MLI CPUU CPU User s Guide 2MLI CPUU R 200 1 09 Release 200 Honeywell Confidential amp Proprietary This work contains valuable confidential and proprietary information Disclosure use or reproduction outside of Honeywell Inc is prohibited except as authorized in writing This unpublished work is protected by the laws of the United States and other countries Notices and Trademarks Copyright 2008 by Honeywell International Inc Release 200 Jan 2009 While this information is presented in good faith and believed to be accurate Honeywell disclaims the implied warranties of merchantability and fitness for a particular purpose and makes no express warranties except as may be stated in its written agreement with and for its customers In no event is Honeywell liable to anyone for any indirect special or consequential damages The information and specifications in this document are subject to change without notice Honeywell PlantScape Experion PKS and TotalPlant are registered trademarks of Honeywell International Inc Other brand or product names are trademarks of their respective owners Honeywell International Process Solutions 2500 West Union Hills Phoenix AZ 85027 1 800 343 0228 ii Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 About This Document This document describes
50. Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 7 Program Structure and Operation Method 7 3 Operation Mode Operation process e Execute I O refresh e Debug the operation depending on the settings e After debugging the operation until the end of the program it executes output refresh e Inspect the operation and detachment of the modules installed e Process the communication service and other internal operations e Debug operation conditions There are four conditions in Debug operation and in case it reaches break point it is possible to set other type of break point Operation condition Description Execute by one operation unit With operation instruction it executes only one operation unit and stops step over Execute according to If break point is assigned in the Program it stops at the Break Point assigned break point Execute according to If the contact area desired to be watched and the desired the state of contact stop state Read Write Value are assigned it stops when point the assigned operation occurs at the assigned contact point Execute according to If scan time to operate is assigned it operates as per the scan times assigned scan times and stops Operation method a Set the debug operation conditions at SoftMaster and execute the operation b Interrupt Program mode can be set to Enable or Disable state Enab
51. RR flag is used and for non fatal error ANC WAR flag is used Handling a fatal error in an external device 1 Inauser program if a fatal error of external device is detected the error type can be set by a user program For this the user needs to write the value except 0 in the system flag ANC ERR While checking Scan Program completion time if any error occurs it is indicated in the system representative error flag ANNUM ER of CNF ER PLC then shuts off all output modules and gives an error 2 Ifcase of an error a user can find the cause by using SoftMaster or by monitoring the ANC ERR flag 3 The ERR LED P S LED and CHK LEDs are turned ON by the fatal fault error flag of an external device The LEDs can be turned OFF by resetting the PLC Turn the PLC OFF and then ON to turn off the LEDs 34 _ANC_ERR R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 87 1 09 Honeywell Confidential amp Proprietary 5 Functions of the CPU Module 5 6 Diagnosing Faults of an External Device Handling a non fatal error in an external device l Example 88 When a Non fatal Error warning in an external device occurs select the flag of the corresponding position as ON ANC WB according to user identification from system flag At the end of the scan program if a warning is detected when checking from ANC WB 0 it is indicated by the system representative error flag ANNUN
52. Snet I F system is designed to exchange data between computers peripherals and CPU modules by using the RS 232C or RS 422 or RS 485 ports of the Snet module B REFERENCE INTERNAL For additional information on the Snet module refer to the user s manual of Snet module The Snet module allows you to install a maximum of 24 modules including other communication modules regardless of the Main base and Expanded base Snet does not provide high speed link and it supports up to 8 modules for P2P service Smart I Os Modules Remote I O R 200 1 09 Smart I O modules are intelligent I O modules digital and analog which can be located remotely and communicates with the host on open international standard protocols e g Profibus DP DeviceNet Snet MODBUS They can be connected to either MasterLogic 200 PLC system or other PLCs controllers from different manufacturers Programmable Logic Controller 2MLI CPUU CPU User s Guide 111 Honeywell Confidential amp Proprietary 6 Configuration 6 3 Network system The Smart I O modules are classified as follows Network Master Class Network type Module 1 Profibus DP 2MLL PMEA 2 DeviceNet 2MLL DMEA 2MLL CH2A 3 Modbus Snet 2MLL C42A System Configuration Pnet Dnet Snet Master Module en MM l iT 5 v HfldO2 WTNC 1nd FII Smart 1 O Maximum number of installations and modules per service are same as the local ne
53. UU CPU User s Guide Honeywell Confidential amp Proprietary R 200 1 09 11 Appendix 2 Dimensions Unit mm 10 4 Appendix 1 4 Reserved Words 11 Appendix 2 Dimensions Unit mm CPU Module 2MLI CPUU I O Module R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 183 1 09 Honeywell Confidential amp Proprietary 11 Appendix 2 Dimensions Unit mm 10 4 Appendix 1 4 Reserved Words I O Module Terminal Block type EA E n TEM I O Module connector type Power Module 184 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 11 Appendix 2 Dimensions Unit mm 10 4 Appendix 1 4 Reserved Words Power Module DUUM DUO Main Expansion Base R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 185 1 09 Honeywell Confidential amp Proprietary 11 Appendix 2 Dimensions Unit mm 10 4 Appendix 1 4 Reserved Words Expansion Base 186 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 11 Appendix 2 Dimensions Unit mm 10 4 Appendix 1 4 Reserved Words 2MLB MO6A 2MLB E06A 264 2MLB M12A 2MLB E12A 426 R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 187 1 09 Honeywell Confidential amp Proprietary
54. WR of CNF WAR The number of non fatal error of external device is recorded in the order of occurrence from ANC WAR 0 to ANC WAR 7 If any error occurs a user can find the cause of that error using SoftMaster or the cause of warning by monitoring ANC WAR and ANC WPB flags directly If the non fatal error of external device is released from ANC WB nJ after performing the user program it is automatically removed from the ANC WAR nJ flag and if all are released ANNUN WR system flag CNF WAR is re set low rw det CHK ANC 20 _ANC_WAR Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 5 Functions of the CPU Module 5 7 Fault Mask Function 5 7 Fault Mask Function Fault Mask Operational overview Fault mask enables uninterrupted program execution even in the case of an error in the module e Ifthe error occurs in the module where the Fault Mask is set the corresponding module stops operation However the rest of the system continues to operate e Ifthe module error occurs when the PLC is in RUN mode the CPU module sets the error flag and the front PS LED turns ON You can see the error state through SoftMaster Setting Fault Mask The Fault mask can be set from the online menu of SoftMaster Fault mask can be also set by a program It is achieved by setting fault mask flag with a program B REFERENCE
55. a device 1 to read P2P structu P2P xRD1 parameter n xx block re parameter n xx block Area size 1 _PnBx to read P2P Saves area size 1 to read P2P Word xRS1 parameter n parameter n xx block xx block Area device _PnBx Device 2 to read Saves area device 2 to read P2P structu P2P xRD2 parameter n xx block re parameter n xx block Area size 2 _PnBx w to read P2P Saves area size 2 to read P2P ord xRS2 parameter n parameter n xx block xx block Area device _PnBx Device 3 to read Saves area device 3 to read P2P structu P2P xRD3 parameter n xx block re parameter n xx block 178 Programmable Logic Controller 2MLI CPUU CPU User s Guide Honeywell Confidential amp Proprietary R 200 1 09 10 Appendix 1 10 3 Appendix Communication Flags P2P List Area size 3 PnBx to read P2P Saves area size 3 to read P2P AM Word xRS3 parameter n parameter n xx block xx block Area device PnBx Device 4 to read Saves area device 4 to read P2P structu P2P xRD4 parameter n xx block re parameter n xx block Area size 4 PnBx to read P2P Saves area size 4 to read P2P TE Word xRS4 parameter n parameter n xx block xx block Area device PnBx Device Tto save Saves area device 1 to save P2P structu P2P xwD1 parameter n xx block re parameter n xx block Area size 1 PnBx to save P2P Saves area size 1 to save P2P Word xWS1 parameter n parameter n xx block xx
56. and secure the stability e Installation and modification of network connections during operation e Use of trend monitoring function e User event function e Data trace function 7 Improved User experience Improved user experience with various functions supported e Module Changing Wizard It is used for changing the module online when PLC is in RUN mode e System Diagnosis e Skip I O e Fault Mask e Various Operation History Programmable Logic Controller 2MLI CPUU CPU User s Guide 19 Honeywell Confidential amp Proprietary 2 Specifications 2 1 General specifications 2 Specifications 2 4 General specifications TT Related Item Specifications Standards Ambient 5 Temp rae Storage 3 Temp 25 70 C Ambient ORS humidity 5 95 RH Non condensing Storage 5 95 RH Non condensing humidity Occasional vibration Frequency Acceleration du es 10 f 57Hz 0 075mm 57 lt f lt 150Hz 9 8m s7 1G z Vibration 10 ti Continuous vibration each IEC611312 direction Frequency Acceleration Noe X Y and Z 10 lt f lt 57Hz 0 035mm 57 lt f lt 150Hz 4 9m s 0 5G e Peak acceleration 147m s 15G Shocks Duration sims IEC61131 2 e Pulse wave type Half sine 3 times in each of X Y and X directions R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 21 1 09 Honeywell Confidential amp Proprietary 2 Specifications 2 1 Ge
57. conductor elements Hence the life of a PLC is subject to the health of its semiconductor parts Regular checks must be carried out as errors in the elements may occur due to the effect of the surrounding environment Refer to the following table for the items to be checked once or twice every 6 months Checklist Judgment basis Actions Power supply Within the power variance range Between 15 to 10 Adjust the power within the allowable voltage variance range I O specifications of Adjust the power within the allowable O power each module voltage variance range Tempera 0 55 ture Adjust the temperature and humidity conditions properly Environ ment Humidity DE N Use vibration preventive rubber or c one Vibration other measures Shakes of modules Must not have shake Every module must be protected from shaking Loose terminal screw No looseness Tighten any loose screw R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 145 Honeywell Confidential amp Proprietary 1 09 8 Maintenance 8 1 Repairs and Maintenance Check whether the amount and Replenish insufficient parts and Spare parts n e conditions of spare improve the storage condition parts are proper 146 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 8 Maintenance 8 2 Routine Inspection
58. ct module type is mounted on the base Maximum Configuration of the Base System System Configuration example e 2MLI CPUU e 12 slot base if 64 point module is installed 106 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 6 Configuration 6 2 Basic system configuration Main base Power CPU Extension cable 9 gt Extension Base no Setting SAV1 Installation i point of terminating resistance R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 107 1 09 Honeywell Confidential amp Proprietary 6 Configuration 6 2 Basic system configuration Connecting the Terminating Resistance If a system requires the main base and the extension base to be connected the terminating resistance must be attached to the extension connector OUT of the last extension base If only the main base is used the terminating resistance need not be installed 7 Structure 8 Installation Position 108 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 6 Configuration 6 2 Basic system configuration Main base Base no 0 Base no 1 Installation point of terminating resistance 1 R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 109 1 09 Honeywell Confidential
59. ction 1 Click Online gt Force I O on the SoftMaster menu bar 2 Forced I O Setup Forced input O Enable Disable Apoy Forced output O Enable Disable x w0 0 0 zw 0 0 1 Tw0 0 2 Iw0 0 3 273 EE EE Hu E DNO 2 EE JU 271 E D 16 16 32 48 48 17 17 33 49 49 18 18 34 50 50 18 us 35 51 51 20 20 36 52 52 21 21 37 53 53 22 22 38 54 54 23 23 39 55 55 24 24 40 56 56 25 25 41 57 57 26 26 42 58 58 27 27 43 59 59 28 28 44 60 60 23 23 45 61 61 30 30 46 62 62 31 31 47 63 63 Q Fg dd voa oupa 3 Select appropriate flag and select appropriate data check box of P device to set Forced I O 4 To set the value 1 select corresponding bit data and flag R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 81 1 09 Honeywell Confidential amp Proprietary 5 Functions of the CPU Module 5 4 Forced ON OFF of I O Step Action 5 To set the value 0 select only the flag 6 The setting is applied when forced input or output is enabled B ATTENTION e Forced I O setting is applicable only on DI DO modules It is not applicable to special modules e Forced I O setting is available only in local I O modules It cannot be set in remote I O module smart I O module When forced I O is set CHK LED is ON e The forced I O setting is maintained even after a new program is downloaded T WARNING Forcing can energise the I O and may cause serious malfunction in the
60. d as an integer in the occurrence order R 200 1 09 Programmable Logic Controller 2MLI CPUU CPU User s Guide Honeywell Confidential amp Proprietary 169 10 Appendix 1 10 1 Flag List Flag Name Contents Description FX144 Clock signal used in a user program reverses On Off per a half cycle Use the clock signal longer than PLC scan time Clock signal starts from Off condition when initialization program starts or when scan 20ms cycle clock program starts _T100ms clock example 50ms 50ms BE FX153 Always On state flag used _ON BOOL Ordinary time On while writing the user program FX154 Always Off state flag used Ordinary time Off while writing the user program 9 3 Bool PIS ast scan On e One 170 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 10 Appendix 1 10 1 Flag List Flag Name Contents Description FX156 Only 1 st scan Off after _10OFF BOOL 1 st scan Off operation start For all further scans it is ON FX157 On Off reversed flag per every scan when user program is working On state for first scan Reversal every scan Operation result flags Flags Name Contents Description Operation error flag on the basis of Operation FX176 Function FN or Function Operation error flag Block FB is renewed every time the operation works FX181 Operation error latch flag on
61. e Block service abnormal end abnormal end LW626 P2P parameter pop LW36 n XX Indicates error code in P2Pn STATU Word 92 case of P2P parameter n Sxx Block service xx Block service abnormal abnormal end end error Code LW627 P2P parameter LW36 n Xx P2Pn SVCCN Doubl 93 Indicates P2P parameter Txx e Block service n xx Block service normal word normal count count Doubl 96LW629 Indicates P2P parameter SPEED CERRON e LW36 P2P parameter n xx Block service Txx n XX word 95 abnormal count 176 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 10 Appendix 1 10 2 Appendix Link Flags L List No Keyword Type Address Contents Description Block service abnormal count R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 177 1 09 Honeywell Confidential amp Proprietary 10 Appendix 1 10 3 Appendix Communication Flags P2P List 10 3 Appendix Communication Flags P2P List Link Register List according to P2P No P2P Parameter No n 1 8 P2P Block xx 0 63 Flags Type Contents Description Saves another station no of P2P P2P parameter 1 00 block PnB parameter n may Word xx block In case of using another station no at X another SoftMaster NM it is possible to edit station no while in RUN mode by using P2PSN command Area device PnBx Device 1 to read Saves are
62. e type but address is automatically allocated in symbolic memory area A by the CPU For instance named variables declared as Valve1 Pump2 or Speed3 with any IEC standard data type Twisted Pair cables typically CAT5 cables with RJ45 connectors for Ethernet communication Unshield Twisted Pair This is one of the CPU restart modes which affects the variable parameters of the I O image area when the CPU is restarted With the CPU restart mode is set to warm restart all the parameters like the internal register timer and counter retain the previous values A timer to monitor pre determined execution time of a program and to generate a warning when it is not complete within the time Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 209BContacts Contacts World Wide Web For more information visit the following Honeywell websites Honeywell Organization WWW Address URL Corporate http www honeywell com Process Solutions http www honeywell com ps R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide vii 1 09 Honeywell Confidential amp Proprietary 209BContacts Telephone Contact us by telephone at the numbers listed Location Organization Phone United States Honeywell IAC Solution 1 800 822 7673 and Canada Support Center Europe Honeywell TAC EMEA 32 2 728 2704 Pacific Honeywell Global TA
63. e more than 2mm2 cables for grounding Place the earth point near the PLC as much as possible to limit the length of earth cable Separate LG Line Ground of power module and FG Frame Ground of base board for earth Power Power Power LG FG 2 A FG LG rG A Exclusive grounding best B common grounding good C common grounding defective If any malfunction on grounding is detected separate the FG of the base from the grounding Specifications of Wiring Cable The specifications of cable used for wiring are as follows HG DT Cable specification mm connection Lower limit Upper limit Digital input 0 18 AWG24 1 5 AWG16 Digital output 0 18 AWG24 2 0 AWG14 Analog I O 0 18 AWG24 1 5 AWG16 Communication 0 18 AWG24 1 5 AWG16 Main power 1 5 AWG16 2 5 AWG12 Protective grounding 1 5 AWG16 2 5 AWG12 68 Programmable Logic Controller 2MLI CPUU CPU Users Guide R200 Honeywell Confidential amp Proprietary 1 09 5 Functions of the CPU Module 5 1 Self diagnostic Function 5 Functions of the CPU Module 5 1 Self diagnostic Function The CPU module can perform a self diagnosis to locate any errors in the PLC system It can also prevent abnormal operations resulting from the error Scan Watchdog Timer WDT Watchdog Timer is a function run by the CPU module that detects program congestion through hardware and software errors of PLC
64. ed ON or the key switch of the CPU module is in RUN The program processes an operation according to the following configuration 122 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 7 Program Structure and Operation Method 7 2 Program Execution Operation starts Subroutine program l lt It is executed only when De conditions are met Scan program d Fixed cycle program END Scan Program Function e This program sequentially executes all operations from step 0 to the last step and is repeated regularly for every scan e Incase interrupt program is running while executing Scan Program it stops the program being executed and executes the related interrupt service program Interrupt Task Program This program stops the execution of the Scan Program and then executes the interrupt service program The interrupt can be triggered by periodic non periodic internal device signals The following are the two types of Task program Time driven interrupt task program Executes according to the fixed time internals Internal device interrupt task program Executes when condition of internal device occurs The device start condition is detected after the Scan Program R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 123 1 09 Honeywell Confidential amp Proprietary 7 Pr
65. eparate input and output cable for wiring I O signal cable must be separated by a distance of atleast 100mm from the main circuit cable of high voltage high current If it is not possible to separate the main circuit cable and power cable use the shielded cable in all cases and ground the PLC Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 4 Installation and Wiring 4 3 Wiring Type 3 Grounding Type 3 Grounding 5 Incase of pipe wiring check the pipe for grounding properly 6 Separate output cable of DC 24V from AC 110V cable or AC 220V cable B ATTENTION Current leakage may take place for wiring distances longer than 200m caused by the capacitance between the cables Grounding 1 Sufficient measures against noise are taken in the PLC making it possible to be used without grounding When there is lot of noise its better to ground the PLC as shown in the following figure 2 Use dedicated grounding for the wires as far as possible 3 Incase the grounding is functional use class 3 grounding grounding resistance must be 100 2 or less 4 lfitis not possible to use dedicated grounding use common grounding as depicted in the following figure Type 3 Grounding Type 3 Grounding R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 67 1 09 Honeywell Confidential amp Proprietary 4 Installation and Wiring 4 3 Wiring Us
66. erial communication RS 232C 2 channels 2MLL C42A Serial communication RS 422 485 2 channels 2MLL CH2A Serial communication RS 232C 1 ch RS 422 485 1 ch FDEnet I F module Master 2MLL EDMF Exclusive ethernet optical Master Deterministic communication supported 100 10 Mbps supported Optical does not support 10Mbps 2MLL EDMT Exclusive ethernet electrical Master Deterministic communication supported 100 10 Mbps supported Changed to dedicated communication Profibus DP I F module 2MLL PMEA Profibus DP Master module DeviceNet I F module 2MLL DMEA DeviceNet Master module R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 1 09 Honeywell Confidential amp Proprietary 103 6 Configuration 6 1 System configuration BH ATTENTION For further information on the above modules please refer to the respective user s manual For further information on Smart I O block type remote I O module refer to the respective communication network manual for FEnet Snet Pnet 104 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 6 Configuration 6 2 Basic system configuration 6 2 Basic system configuration Configuring the Basic System The basic system consisting of the main base and the extension base has the follow
67. ery despite no voltage drop display display To be replaced regularly because element may Fuse Visual e No fuse blown have inspection condition deteriorated due inrush current 150 Programmable Logic Controller 2MLI CPUU CPU User s Guide Honeywell Confidential amp Proprietary R 200 1 09 9 Troubleshooting 9 1 Basic Troubleshooting Procedure 9 1 R 200 1 09 9 Troubleshooting The chapter describes types of potential errors that occur while operating the system causes of errors how to detect them and corrective measures Basic Troubleshooting Procedure To improve the reliability of a system it is important to take corrective measures promptly when a trouble fault occurs To recover the system from the fault immediately it is most important to quickly detect the potential causes of a fault and take corrective measures To troubleshoot the system correctly ensure the following cautions and procedures 1 Check the following manually a Operation status Stop and Run b Power On Off status c TO device status d Wiring status I O wiring extension and communication cable e The status of each display POWER LED RUN STOP LED I O LED and any other status display connect to peripherals and check the operation condition and program 2 Check for any abnormality Observe how a fault changes by executing the followings a Move the key switch to STOP and turn it On Off 3 Restr
68. f steps to be taken if RUN STOP LED is OFF RUN STOP LED is Off Power module Off On Is still RUN STOP LED off Contact the dealer Action when I O module does not function properly The following points describe the procedure to be followed when I O Module does not function normally during operation as shown in the following program example 156 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 9 Troubleshooting 9 2 Troubleshooting SWITCHI SWITCH2 SOLI i q SOLI pl If IO module does not function normally SOLI Output LEDis Or Separate the external wiring and check the power connection of the module output Check the status of output deviegSOL1 Replace the output module R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 157 1 09 Honeywell Confidential amp Proprietary 9 Troubleshooting 9 2 Troubleshooting Is the LED of SMTCHI 2 on Measure the terminal voRage of Switch 12 by a tester Replace the input modde 158 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 9 Troubleshooting 9 2 Troubleshooting Action when Writing a Program to the CPU fails R 200 1 09 Use the following sequence of steps when writing a program to the CPU Module fails Can not write a program No Turn the ALN STOP switch
69. figuration Operation error during user program processing Error detection by external device failure Mode of Operation on detecting a fault When error occurs the PLC records the error comments flags it and stops all operations or continues to operate in Error Mode R 200 1 09 PLC hardware error In case of a fatal hardware error the CPU module and power module of the PLC is disabled and the system stops However if the error is non fatal such as a battery error then the system continues operating in Error Mode Error in system configuration This error occurs when hardware configuration of the PLC is not in line with the software configuration This causes the system to stop Operation Error during User Program Processing This error occurs while user program is being executed and also in case of numeric operation error The error is recorded flagged and the system continues to operate However if the operation time exceeds the scan watchdog time or the built in I O module is unable to function normally the system stops Programmable Logic Controller 2MLI CPUU CPU User s Guide 71 Honeywell Confidential amp Proprietary 5 Functions of the CPU Module 5 1 Self diagnostic Function 72 TIP The operation process is determined by selecting Basic Parameters Error Operation Setup Continue running when an arithmetic error occurs The default is set to Continue running when an arithmetic error occurs
70. following table Operation Retain M area retain R area retain Reset Maintaining the previous value Maintaining the previous value Maintaining the previous value Over all reset Initializing as 0 Initializing as 0 Maintaining the previous value D CLR Initializing as 0 Initializing as 0 Maintaining the previous value D CLR 3sec Initializing as 0 Initializing as 0 Initializing as 0 STOP RUN Maintaining the previous value Maintaining the previous value Maintaining the previous value TIP Default variable A variable not set to maintain the initial previous value Initialization INIT variable A variable set to maintain the initial value e Retain variable A variable set to maintain the previous value Data Initialization Every device memory is cleared up as 0 when memory deletion occurs The data value may be assigned initially depending on a system and the initialization task required must be used 144 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 8 Maintenance 8 1 Repairs and Maintenance 8 Maintenance 8 1 Repairs and Maintenance The following routine and periodic inspections are recommended to maintain the PLC in good condition I O Module maintenance The I O module mainly consists of semi
71. for successful execution of the task Processing Method of Internal Device Task Program The Internal Device Task program describes the processing method of an internal device task program of which the task operation condition execution range is extended from contact to device Task settings Set the conditions Select the CPU in the Project window and go to Project gt Add Item Task in SoftMaster and priority of a device which is the operation condition of a task program to execute Check the task number to manage tasks 2 Internal device task processing R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 129 1 09 Honeywell Confidential amp Proprietary 7 Program Structure and Operation Method 7 2 Program Execution After a scan program is executed in the CPU module the task is processed if the conditions of devices that are the operation conditions of internal device task program are met according to the priority 3 Cautions for using internal device task program Internal device task program is executed after a scan program is completely executed Therefore although a scan program or task program fixed cycle external contact generates the execution conditions of internal device task program it is not immediately executed The execution request of internal device task program checks the conditions of execution when a scan program is completely executed Therefore if the execution condi
72. from the axis of the lower part by pressing the hook 4 By lifting the module upward remove the fixed projection of the module from the fixing hole 62 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 4 Installation and Wiring 4 2 Inserting Removing Modules Hook for module installation While detaching the module press the hook and remove the module CAUTION from the base only then remove the fixed projection of the module from the fixed hole of module In this case if module is detached forcefully a hook or the fixed projection of the module can break R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 63 1 09 Honeywell Confidential amp Proprietary 4 Installation and Wiring 4 3 Wiring 4 3 Wiring Power Wiring 1 Connect a voltage regulated transformer if the power variance is higher than the specified range 2 Incase of excessive interference noise use an Isolation transformer 3 The following figure illustrates the distributions of 220V AC for PLC Power Supply I O Modules and other Mains Circuit Equipment power power onstant Voltag Transformer 5 p Main circuit device 64 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 4 Installation and Wiring 4 3 Wiring 4 While using Power Module of DC 24V output a Do not c
73. gram and copies the program from user program area to flash memory Flash Memory Run Mode Setup mig State Type Internal 16MB flash memory Disable flash memory operation mode Select Enable flash memory run mode Disable flash memory run mode Info Always copies backup the program to PLC flash memory after program download or online editing Also copies the program to flash memory when this dialog is closed 78 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 5 Functions of the CPU Module 5 3 Remote Functions Saving flash memory program Saving flash memory program a err Enables flash memory operation mode F f flash operation mode is disabled program will not be copied to flash memory B ATTENTION The default option is Flash Memory Operation Mode not selected Flash Memory Operation Mode can be changed irrespective of RUN STOP mode Flash Memory Operation Mode can be set from the online menu of SoftMaster If the flash memory operation setting is modified to flash memory operation mode during RUN and the program is successfully written in the flash memory the changed program shall be applied only when it restarts Note that if the PLC restarts before a program is saved into flash memory the previous program that was saved earlier operates instead of the changed program If flash memory operation mode is changed f
74. gram Structure and Operation Method 7 4 CPU Memory Program storage area Scan program backup area Task program area Upload area User defined function Function block area Parameter initialization data area Preserved parameter designation data area Reserved area Data Memory The total data memory area is 2MB The storage capacity and data area type of the data memory are as follows Item area Capacity System area O data table Forced I O table Reserved area System flag Analog image flag Flag area PID flag High speed link flag P2P flag Input image area l Output image area 96Q R area R R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 141 1 09 Honeywell Confidential amp Proprietary 7 Program Structure and Operation Method 7 4 CPU Memory Direct parameter area M 256KB W area W 128 KB Symbolic parameter area Maximum 512KB Stack area 256KB Total Data Retain Area Setting 2046KB The default auto parameter RETAIN is used to save the data necessary for operation or to save the data collected during operation even when the PLC stops and resumes operation Alternatively a part of the M area device may be used as the retain area by the parameter setting The following table summarizes the features of retain settable device
75. guration eese nnne 105 Configuring the Basic System sssssssssesee eene een nene en nnne 105 Maximum Configuration of the Base System ssssssssssssssseeeeeeeere nnn 106 Connecting the Terminating Resistance sssseeeem enne 108 6 3 Network system oen iRREIEEEERUPECI HERI 110 Inter System Network cccceccccecce cece eeeceeaeee cnet cece eaaeeeceeeeeesaaaaeaeceseseeeeeaeaeseeeeeseeceaneeeeeeess 110 Local N tWOTK eee 110 High Speed Link Service 2 0 2 2 eccceccecceceeeeeeneeeeceeeee cece aeaeceeeeesaaaeaeeeceeesaecneaeaeeeeeeeeennaeaeeeeeess 110 P2P setvice 7 un ene ee i hd Meee ee a e eee ts 111 Smart I Os Modules Remote l O essen enne 111 I O allocation method and I O address assignment seen 113 7 PROGRAM STRUCTURE AND OPERATION METHOD 115 7 1 Program introduc tOn socaning A N 115 Program Operation Methods cccccccecsecceceeeeeeeeceeceeeeeeeeecaeaeeeeeeeesescaaeeeeeeeseseenaeaeeeeeees 115 Operation of Instantaneous Interruption ssseee eem 118 SIME 119 7 2 Program Execution eese enne nennen nennen nnn nnne nn 122 Program Configuration einser renee meer o ea piden rere m Fein aii 122 Program Execution 2 iei tesi c der ios dne dete en lean cae e Feed ode Edo dede De n duce 122 R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 13
76. he I O module is removed or error occurs during operation the error is detected and indicated by the warning lamp ERR and the CPU module ceases to operate Battery Voltage Check The CPU module is capable of detecting a battery voltage drop below the memory backup voltage On detecting a low battery level and the low battery warning lamp BAT located on front of CPU module is turned on Error Logs The CPU module has a function that records error history and analyzes the cause of these errors This enables the user to take appropriate corrective action when the error occurs subsequently This function saves each error code in a special flag F0006 All results of self diagnosis are recorded in the F address memory area 70 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 5 Functions of the CPU Module 5 1 Self diagnostic Function B REFERENCE INTERNAL For additional information on self diagnostic and troubleshooting errors see section on Error Codes during CPU Operation Troubleshooting errors Classification of Errors An error is classified as a Fatal Error and Non Fatal Error A fatal error stops operation for system safety and Non Fatal Error warns the user about the error and continues to operate The PLC system normally encounters the following types of errors L 3 3 4 PLC hardware error Error in system con
77. he flags of the information of the system operation state sssssssssussss 172 10 2 Appendix Link Flags L List eee 174 Communication Flag List according to High speed link no sssssessssees 174 Communication Flag List according to P2P Service Setting 176 10 3 Appendix Communication Flags P2P List ess 178 Link Register List according to P2P No sssseeneene emm enne enne 178 10 4 Appendix 1 4 Reserved Words seen 181 11 APPENDIX 2 DIMENSIONS UNIT MM 183 CPUJModule s toit eee eT etu te ee E x Weed ODER UE e toam te E E 183 I O Mod le atu Er ette et ae eevee i eio debe bien Ico Pont te etta 183 WO Module connector type sssssseeene enn ene eee ennemi enne ener 184 Power Module n ret Vr peer Wy R E e E epe Fd a egeo 184 Main Expansion Base 5 2 etico nd petere red epi dd iced Coe e td deed Tn edu r edes 185 ExparislohiBase s ute racine nde d e MINE N Leti eie st tossed tee Soret sah t Malte 186 R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 1 09 Honeywell Confidential amp Proprietary 15 1 Introduction 1 1 Functional Overview 1 Introduction 1 4 Functional Overview Overview of 2MLI CPUU The 2MLI CPUU is a MasterLogic 200 PLC CPU using IEC 61131 3 standard programming languages i e LD SF
78. he method used for calculating the current consumption of PLC system necessary for heat protection design Power CPL Commi aaa Special ls nication nication DCSV AC Power Power consumption of each part 1 Current Consumption of Power Module The current conversion efficiency of the power module is around 70 Radiation consumes 30 and current consumption is 3 7 of the output power The calculation is as follows Wow 3 7 15V X 5 IDAV X 24 W I 5V Current consumption of DC 5V circuit of each module internal current consumption 24V Average current consumption of DC 24V of output module current consumption of simultaneous ON point 52 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 4 Installation and Wiring 4 1 Installing the PLC R 200 1 09 If DC24V is externally supplied or a power module without DC24V is used it is not applicable 2 Sum of DC 5V circuit current consumption The DC 5V output circuit current of the power supply module is the sum of current consumption of each module W 5V I5V X5 W 3 DC 24V Average current consumption current consumption of simultaneous ON point DC 24V output circuit average current of power module is the sum of current consumption of each module W 24V 124V X 24 W 4 Average current consumption by output voltage drop of output module current co
79. ial amp Proprietary 206BContents 210BSymbol Definitions 4 INSTALLATION AND WIRING eene 51 44 Installing the PLO inerte eenen 51 Installation Environment a r a e a r a aa a aE aa eara raa ns 51 Precautions for installing handling the PLC modules seem 54 42 Inserting Removing MOdulles ccccceceeeeeseeeceeeeeeeeeeessaneeeeeeseseesseeneeeees 60 4 3 Wiring oen ceasscte cede tenecssavact dE annee acts sauet ENA 64 Power Wirlngiz e ntur eerste Sect en ERR VIA E eed bbe alge lataltes E E T 64 l O Device Wiring 2 toe e e e oos rerit edad Hote e dedo foe 66 Cie eoe 67 Specifications of Wiring Cable ssssseeeeeeneenen meme nnen nme 68 5 FUNCTIONS OF THE CPU MODULE 69 5 1 Self diagnostic Function eeeeeeeeeeeeenenenenenen nennen nnn 69 Scan Watchdog Titre iiec teer 28s DELE te eget Re RR no eC agave shoe EE eR RR toate 69 VO Module CHECK quM 70 Battery Voltage Check rite pen e er sede coves terrere ree inen 70 Error OOS epe D EE 70 Troubleshooting errors tire ette nc tres tt gti gd ce apania r aahei niea pe 71 5 2 Glock Furictlion 0 uec eene Iren carie aeaa Irure Sine Deer eua sts 73 Read from SoftMaster Setting 2 0 0 eccccessceeseeeeeeenneeeeeeeeeessaeeeeseenaeeeeeeeeeessieeeesenaeeeeneaeees 73 C
80. ial amp Proprietary 1 09 206BContents 210BSymbol Definitions Fault Mask Operational overview sesssssseeeen eene enne nnne nnns 89 Setting Fault Mask 4 rne eU uei riore ce aae de e et eee e nett 89 Releasing Fault Mask 5 cipi ei a edere se des eb d nde cud tne ed dude ed cbe 89 5 8 WO Module Skip Function eeueeseeseeseeesseeeeeeeeeer ennt 91 I O Module skip operational overview cccccceccecneceeeeeeeceeaeeeeeeeeeeeneaeeeeeeesesencueaeeeeeeeeees 91 Setting and Processing I O Data sssssseee eee eem ene enen nnne 91 Releasing Skip Function eret retener terrere id nter tret Rin 91 5 9 Replacing a Module during Operation eene 93 Overview of replacing modules sssseseeneene enm eene eene enn 93 Replacing Modules einer teer ther en E ERR ene rre Ee NER T 93 5 10 joy GNI CDD Em 95 Allocating I O address 1 iiim e eee gu T ES 95 5 11 Program Modification eeeeeeeeeeeeeeeneneneennn nnne nnn 96 Program Modification during Operation seen mme 96 6 CONFIGURATION irent re apii rec sn rEE eH ERES 97 6 1 System configuration eeeeeeeeeeeeenen eene nennen nnn nnn 97 2MLI CPUU System Configuration sese 97 Components Liste sanss e etii E cr tee e tee et eode etse 99 6 2 Basic system confi
81. ializing as 0 Retain Initializing as 0 Maintaining the previous value Cc Initializing as a user Initializing as a user defined Initialization defined value value Retain and Initializing as a user C e i Maintaining the previous value initialization defined value Operation in the data retain area Retain data can be deleted by using the following methods e D CLR switch of the CPU module e RESET switch of the CPU module 3 seconds and longer Overall Reset e RESET by SoftMaster Overall Reset R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 143 1 09 Honeywell Confidential amp Proprietary 7 Program Structure and Operation Method 7 4 CPU Memory e Deleting memory at STOP mode by SoftMaster e Configuring by a initialization task In the project tree right click on offline CPU and select Add Item gt Task Select the Execution condition as Initialization e Writing 0 FILL and so on at SoftMaster monitor mode D CLR clear does not function in RUN mode To use the D CLR switch change it to STOP mode In addition the default area is initialized when clearing by D CLR switch When instantaneously operating D CLR only the retain area is deleted If maintaining D CLR for 3 seconds 6 LEDs blink and during that time if the switch returns even R area data is deleted For the maintenance or reset clear of the retain area data according to the PLC operation refer to the
82. icting Range Estimate by which factor a fault occurs by the following methods a Is it from the PLC or external factor b I O module or others c PLC program Programmable Logic Controller 2MLI CPUU CPU User s Guide 151 Honeywell Confidential amp Proprietary 9 Troubleshooting 9 2 Troubleshooting 9 2 Troubleshooting The following section illustrates how to troubleshoot a fault in the PLC This section describes the troubleshooting scenarios common faults and error codes associated with the PLC Trouble If Power LED is ot Measures taken when Power LED is Off If Err LED is Qn If Run Stop LED is Off If VO module does not work property If writing a program is not possible Measures taken when Error LED is On Measures taken when Run Stop LED is Off GOUOUUU Measures taken when VO module does notwork property Measures taken when writing programis not possible Action when POWER LED is OFF 152 This section describes the sequence of steps to be taken if the POWER LED is Off Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 9 Troubleshooting 9 2 Troubleshooting POWER LED is Off isthe power being supplied hh aye Yes No Yes Ethe POWER LED On Adjust the supplying power within the range No Isthe POWERLED On Has a fuse bumt out Yes Repbcea fuse with new ore Yes Isthe POWERLED On No li N
83. information Indicates CPU version number Indicates OS version number Indicates OS distribution date Indicates maximum scan time during operation Unit 0 1ms Indicates minimum scan time during operation Unit 0 1ms Indicates current scan time during operation Unit 0 1ms Indicated on the basis of 1 Jan 1984 Indicates a day of the week 0 Mon 1 Tue 2 Wed 3 Thu 4 Fri 5 Sat 6 Sun Indicates active block no R 200 1 09 10 Appendix 1 10 1 Flag List Flags Name Contents Description _BUF_FULL_C UINT Full count of CPU Increases when CPU NT internal buffer internal buffer is full UINT 9oFW13 Indicates the instant Indicates momentary power off count during the shutdown times RUN mode operation FALS NUM UINT FW14 FALS no Indicates the number of False No _AC_F_CNT R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 173 1 09 Honeywell Confidential amp Proprietary 10 Appendix 1 10 2 Appendix Link Flags L List 10 2 Appendix Link Flags L List This Appendix describes the data link communication Flags L Communication Flag List according to High speed link no Typical address ranges from LX0 to LX9471 For additionla information see SoftMaster Global variables address High speed link no 1 12 No Keyword Type Contents Description High High speed link Spee HSn RLI Bit parameter d NK n
84. ing features Item 2MLI CPUU Maximum extension bases Maximum number of I O module including the extension mounted Maximum I O point including extension mounted Maximum extension length Allocation of I O 7 bases 96 modules 16 points module 1 536 points 32 points module 3 072 points 64 points module 6 144 points 15m Each slot of the base is allocated 64 points fixed irrespective of the type of module mounted Special modules can be mounted in any position Unlike digital I O modules a special module is not allocated any I O address A special module is controlled by a dedicated function block and the address is automatically allocated to the memory For instance the I O number of 12 slot base is allocated as follows Address St 0 1 2 3 4 5 6 7 8 9 10 11 12 slot base Ben C NE cir tr rir olojojotirioio w p 1 1 3 6 1 3 3 6 3 1i3 R ulele 2 4 6 2 2 4i2i632 p PL P P PJ PJ JPJ PIDIDID Pj prm 96 QX 0 10 0 31 96QX 0 80 15 IX 0 8 0 31 Baseno 1 R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 105 1 09 Honeywell Confidential amp Proprietary 6 Configuration 6 2 Basic system configuration B ATTENTION e The base has its base number as 0 and the extension base has a switch to set the base number e The module starts operating once the the module type and I O parameter are set using SoftMaster and the corre
85. input 64 points current source sink input Digital input module 3 2MLI D22B DC 24V input 16 points current source input 2MLI D24B DC 24V input 32 points current source input 2MLI D28B DC 24V input 64 points current source input 2MLI A12A AC 110V input 16 points 2MLI A21A AC 220V input 8 points Digital output T Relay output 8 points 2A independent module 2MLQRYIA COM 2MLQ RY2A Relay output 16 points 2A 2MLQ RY2B Relay output 16 points 2A built in Varistor 2MLQ TR2A Transistor output 16 points 0 5A sink output 2MLQ TR4A Transistor output 32 points 0 1A sink output R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 1 09 Honeywell Confidential amp Proprietary 99 6 Configuration 6 1 System configuration Item Type Description 2MLQ TR8A Transistor output 64 points 0 1A sink output 2MLQ TR2B Transistor output 16 points 0 5A source output 2MLQ TR4B Transistor output 32 points 0 1A source output 2MLQ TR8B Transistor output 64 points 0 1A source output 2MLQ SS2A Triac output 16 points 0 6A 2MLB M04A For 4 modules 2MLB M06A For 6 modules Main base 2MLB M08A For 8 modules 2MLB M12A For 12 modules 2MLB E04A For 4 modules 2MLB E06A For 6 modules Extension base 2MLB E08A For 8 modules 2MLB E12A For 12 modules 2MLP ACF1 oo DC5V 3A DC24V 0 6A 2MLP ACF2 AGI A ean
86. is flag is set by user s initial program it starts the execution of scan program after initial program completion Indicates current state of local key Handles error flags about non operation fault error as per the following errors 166 Programmable Logic Controller 2MLI CPUU CPU User s Guide Honeywell Confidential amp Proprietary R 200 1 09 10 Appendix 1 10 1 Flag List Flags Name Contents Description FX33 Representative flag displayed when l O configuration parameter for each slot is not matched E hen Modul with actual module lO TYER BOOL ra memana configuration or a specific module is applied in the wrong location Refer to IO TYER N IlO TYER n FX34 Representative flag displayed when the module Module detach t configuration for each slot is lO DEER BOOL kii se E changed while running Refer to lO DEER N lO DEER n FX35 Representative flag displayed when the fuse of _FUSE_ER BOOL Fuse cutoff error module blows out Refer to _FUSE_ER_N FUSE ER n 9cFW90 When I O configuration for a slot does not match with the Slot number of inserted module module in JlO TYER N UINT mismatched module the wrong position this flag type is displayed as the lowest slot number after detecting the mismatch error 9oFW91 When the slot module configuration is changed Slot number of module while PLC is running this JEP EE REN UIN detached flag is displayed as the lowest slo
87. it still exists after turning it on Fault ERR On turning it again ON Par chee ie a When Contact A S service if it still exists after turning it on Fault ERR On turning it again ON ERR On ERR On RR On When When turning it ON Contact A S service if it still exists after turning it on Fault When again changing to turning it ON Contact A S service if it still exists after turning it on STOP again RUN mode Reset Fault E changing to RUN mode R 200 1 09 Restart after modifying the program of the backup flash Programmable Logic Controller 2MLI CPUU CPU User s Guide Honeywell Confidential amp Proprietary Error Code wo N N N o o1 A 99 Co Q2 N 9 Troubleshooting 9 3 Error Codes List Measures Restart mode after the measure The program to execute is not normal Abnormal I O parameter Abnormal basic parameter The module set in configuration and the installed module do not match Module removal or module addition during operation Fuse of a module blown during operation 10 module data cannot be successfully accessed during operation Special link module data cannot be successfully accessed during operation R 200 1 09 Operation status Diagnostic timing LED status ERR On ERR On ERR On Operate after the program is reloaded Replace a battery in case of abnormal battery After a program is reloaded check the storage
88. le Disable by each Interrupt unit B REFERENCE INTERNAL For additional information on operation see section on Debugging of the SoftMaster User s Manual R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 137 1 09 Honeywell Confidential amp Proprietary 7 Program Structure and Operation Method 7 3 Operation Mode Changing Operation Mode An operation mode can be changed by the following methods e Using the mode key of the CPU module e Using the programming tool SoftMaster e Using SoftMaster to change the operation mode of a remote CPU module networked with the main CPU e Using SoftMaster HMI and the computer link module which are networked e Using the STOP command while a program is operating WARNING Changing the operation mode can energise the field and may cause serious threat to human life Setting operation mode The operation mode can be set as follows Operation mode Remote SoftMaster switch switch command Operation mode RUN X Run Run Remote Run Stop Remote Stop Debug Debug Run Transfer changed Mode change operation mode RUN STOP Stop e Remote mode can be changed with Remote On and Mode switch Stop e To change the remote RUN mode to Stop by switch move the switch STOP gt RUN gt STOP B ATTENTION While changing the remote RUN mode to RUN mode using the switch
89. lock Reading by Flag EE E A E E EE 74 5 3 Remote F nctlons eer en E a aea aAa testet aeaa aN Eaa 76 Overview of Remote functions ssssssssssssssssseses eene enne nr nne nnns 76 Types of Remote Operation coii eeieseieecee needed ene dedere ede dore dre ebd eee no dede 76 Flash Memory Operation Mode ssseseeeeeemene emnes 78 5 4 Forced ON OFF of W O triti terat enitn ti aeia Aandi Enida ioni teni Riia 81 Forced I O Setting D 81 Forced On Off Processing iter eret sas tp besnaeee sash cteki nen piantan eana iiini 82 Direct O Operation 5 5 ean er the ne mete ree RR Ee ede 83 5 5 Viewing PLC Error Event LOG 2 cccccccesseeseeeceeeeeeeeeeeeeeeseeeeeseeeeesneaneeseeeens 84 Overview of operation history essen emen mee rennen enne nnns 84 Error E6g iuro ERE iie euibumiseue eii 84 ee dedo area Woo EE 84 Power shut down L09 Eee In eee Lo SPI et Donee ea Raid Ee Ra niue Ere es 84 SAEIA oro ERE NAE DI PII MEE 84 5 6 Diagnosing Faults of an External Device eere 87 Detection and classification of external device fault ssssssssssssssssssse 87 Example iro ttr e e teta it te mb mi eiu tiic 88 5 4 FaultMask F nctlon roD a aeaa aeaa saa REPE DERE PEE ea xx ES 89 12 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confident
90. methods and notices for assigning a Task Program 1 2 Features of a Task program A Task program does not reiteratively process like a scan program It executes only when the execution conditions occur Consider this aspect when creating a task program For instance if a task program with 10 seconds of fixed cycle is used with a timer and a counter the timer may have a maximum error of 10 seconds while the counter checks every 10 seconds Any counter input changed within 10 seconds is not taken into account Execution priority If several tasks are in queue to be executed it processes from the highest priority task program If there are several tasks of same priority they are processed by the order in which they occur The task priority is applied only to a task Set the priority of task program considering the program features importance level and urgency in execution Programmable Logic Controller 2MLI CPUU CPU User s Guide 127 Honeywell Confidential amp Proprietary 7 Program Structure and Operation Method 7 2 Program Execution 3 4 5 Process delay time the delay of task program processing occurs due to the following factors Consider this aspect when setting a task or creating a program Task detection delay Refer to details of each task Program execution delay due to the execution of the preceding task program Correlation between scan program and task program in the initialization
91. mmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 2 Specifications 2 4 Conformance to EMC Specifications 2 The function of LG Line Ground and FG Frame Ground terminals is to pass the noise generated in the PLC system to the ground to ensure an impedance as low as possible 3 To prevent the grounding wire from acting as an antenna and generating noise keep the wire as short and thick as possible Cables Extension cable connection The extension cables contain high frequency noise Therefore attach a ferrite core to the extension cable as shown in the following figure to meet the CE conformance standards R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 35 1 09 Honeywell Confidential amp Proprietary 2 Specifications 2 4 Conformance to EMC Specifications Femte core Model Manufacturer CU1330D E TECH ELECTRONICS ZCAT3035 1330 TDK Fixing a cable in the panel 36 When connecting an extension to the metal panel maintain a space of at least 1cm from the panel The metal board of the control panel has a shielding effect that blocks noise If a metal panel is in in contact with a cable it could serve as an antenna and thereby be a source of noise Programmable Logic Controller 2MLI CPUU CPU User s Guide Honeywell Confidential amp Proprietary 2 Specifications 2 5 Complying with the low voltage di
92. n case of normal module setup PS LED is OFF 4 Check if module operates normally 5 Set Module change switch M XCHG to left OFF Using fault mask and skip function of SoftMaster Step Action R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 93 1 09 Honeywell Confidential amp Proprietary 5 Functions of the CPU Module 5 9 Replacing a Module during Operation Step Action 1 O oa WO N Set fault mask to a slot to replace a module using SoftMaster Set skip to a slot to replace a module using SoftMaster Replace a module Release the skip setting of a part from SoftMaster Check the operation for any errors Refer to Appendix 1 Flag List Even while replacing a module again because of a fault of replaced module it must be repeated from 1 Release the fault mask and restore to normal operation ATTENTION During the procedure the I O module operating on the same base may provide incorrect data instantaneously Because of a fault in the replaced module a fault of another module may be detected It is safe to set fault mask for the entire base While replacing a module isolate the load power for safety While replacing an input module check the input image status by using forced On Off WARNING Incorrect installation of a module may cause malfunction of another module on the same base 94 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 20
93. nd start RUN ERR On ends F rrorduedo extemal Repair a fault device by referring to error detection device is detected by P ory 9 STOP ERR On When scan 50 flag of external device and restart according to a user program RUN P S On ends parameter during operation A When E STOP function Eliminate the causes of error operating E STOP RUN On 60 ND t STOP program is execution function in the program and turn it on again ERR On executed Data memory backup Turn it on again if battery is normal It changesto 509 is not possible STOP mode in Remote Mode STOF ERR EOD Revel 501 Abnormal clock data Reset the time by SoftMaster if battery is normal CHK On Always 162 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 9 Troubleshooting 9 3 Error Codes List Error Operation Diagnostic Measures Restart mode after the measure LED status 502 Low battery voltage Replace a battery when the power ON BAT On Always B ATTENTION e Error No 2 through 13 from Error Codes during CPU Operation can be checked at the A S Service Center e The other errors from 22 and above can be checked by using the error log of SoftMaster R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 163 1 09 Honeywell Confidential amp Proprietary 10 Appendix 1 10 1 Flag List 10 Appendix 1 10 1 Flag List The Flags of Operation
94. neral specifications are Related Item Specifications Standards Square wave Internal impulse noise 1 500V Test Spec IEC61131 2 Electrostatic discharge Voltage 4kV Contact discharge IEC61000 4 2 IEC61131 Noise Radiated 2 immunity electromagneti 27 500MHz 10V m c field noise IEC61000 4 3 Digital Analog Classification Power Input Output IEC61131 2 Fast transient supply Communicatio Burst noise n Interface IEC61000 4 4 Voltage 2kV 1kV Atmosphere Free from corrosive gases and excessive dust Altitude Less than 2 000m Pollution loss hamo degree Cooling method Air cooling Agency Certification UL 508 Industrial Control Equipment S 89 336 EEC EMC Directive EN 50081 2 Emissions Industrial EN 50082 2 Immunity Industrial B ATTENTION IEC International Electrotechnical Commission An international civil community that promotes international cooperation for standardization of electric electro technology publishes international standard and operates suitability assessment system related to the above Pollution Degree An index to indicate the pollution degree of used 22 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 2 Specifications 2 1 General specifications R 200 environment that determines the isolation performance of the device For example pollution degree
95. nfidential amp Proprietary 59 4 Installation and Wiring 4 2 Inserting Removing Modules 4 2 Inserting Removing Modules Inserting a module Use the following procedure to attach a module Step Action 1 Insert the projection on the lower part of the module into the Module fixing hole of the PLC base as shown in the following figure 2 Slide the upper part of module to fix into the base Use the screws in the upper part of the module to hold the module firmly to the base TIP To check if the module is properly installed in the base slowly pull the upper part of module 60 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 4 Installation and Wiring 4 2 Inserting Removing Modules TIP When installing modules insert the fixed projection of the module into the module fixing hole and then press it The module may break if the module is forced onto the base in an incorrect position R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 61 1 09 Honeywell Confidential amp Proprietary 4 Installation and Wiring 4 2 Inserting Removing Modules Detaching modules To detach modules perform the following steps Step Action 1 From the base loosen the fixed screws on the upper part of the module 2 Hold the module using both hands and thoroughly press the fixed hook of the module 3 Pull the upper part of the module
96. ng duct When installing the wiring duct on the upper part of the PLC ensure that its distance is more than 50mm to enable adequate ventilation Maintain sufficient distance from the upper part of the PLC so that the module can be removed easily When installing the wiring duct on the lower part of the PLC take into account the connection of the optical cable or coaxial cable and the minimum cable radius without breaking the cable 4 Install PLC in the direction as shown in the following figure This helps in protecting the PLC from radiation Do not install the PLC in the direction as in the following figure 56 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 4 Installation and Wiring 4 1 Installing the PLC NN NONAS To avoid any effect of radiating noise or heat install the PLC and other devices relay and electronic contact with a spacing secured as indicated in the following figure R 200 1 09 Programmable Logic Controller 2MLI CPUU CPU Honeywell Confidential amp Proprietary User s Guide 57 4 Installation and Wiring 4 1 Installing the PLC 100mm or more 58 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 4 Installation and Wiring 4 1 Installing the PLC R 200 1 09 Programmable Logic Controller 2MLI CPUU CPU User s Guide Honeywell Co
97. normal operation of Link all station Indicates the normal operation of all the stations according to the parameter set in High speed link and the bit is ON in the following conditions 1 All stations set in parameter are in RUN mode and there is no error 2 All data blocks set in parameter are communicated normally 3 The parameter set in each station is communicated normally Once RUN_LINK is ON it continues to be ON unless stopped by LINK_DISABLE H8n LTR Bit Abnormal BL state after H8n RLIN K ON If HSmRLINK flag is ON and if the communication state of the station set in the parameter and data block is as follows this flag is also ON 1 The station set in the parameter is not in RUN mode 2 There is an error in the 174 Programmable Logic Controller 2MLI CPUU CPU User s Guide Honeywell Confidential amp Proprietary R 200 1 09 10 Appendix 1 10 2 Appendix Link Flags L List R 200 1 09 No Keyword Type Contents Description station set in the parameter 3 The communication state of data block set in the parameter is not good LINK TROUBLE is ON when the above three conditions are met Once the the condition returns to normal state it turns OFF again Indicates the general state of communication information for each data block of setting HSn ST High speed parameter ATEk Bit link parameter k 000 12
98. nsions mm 481 X 98 X 19 318 X 98 X 19 264 X 98 X 19 210 X 98 X 19 Distance of hole for panel attachment 461 X 75 298 X 75 244 X 75 190 X 75 Specification of hole for panel attachment 9 4 5 M4 screw used Specification of screw for FG connection PHM 3 X 6 washer 5 Weight kg Programmable Logic Controller 2MLI CPUU CPU User s Guide Honeywell Confidential amp Proprietary R 200 1 09 3 Hardware Specifications 3 2 Main and Expansion Base Extended Cable specifications Length m Weight kg B ATTENTION Do not exceed the length of 15m in case of a combination of extended cables R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 45 1 09 Honeywell Confidential amp Proprietary 3 Hardware Specifications 3 3 Power Module 3 3 Power Module Power Module specifications 46 The selection of a power module is determined by the current and voltage needed by the system The voltage requirement of a system is calculated as a sum of the current consumption by the digital I O modules special modules CPU module power module and the communication module installed on the same base as the power module The system does not operate normally if the rated output capacity of the power module exceeds the predefined limit The following table lists the current consumption per module DC 5V
99. nsumption of simultaneous ON point i Wout Iout X V drop X output point X simultaneous ON rate W ii Iout Output current current in actual use A iii V drop Voltage drop of each output module V 5 Input average current consumption of input module current consumption of simultaneous ON point i Win lin X E X input point X simultaneous ON rate W ii lin Input current actual value in case of AC A iii E Input voltage voltage in actual use V 6 Current consumption of Special module power assembly WS 15V X5 124V X 24 00V X 100 W The sum of the current consumption calculated for each block is the total current consumption of PLC system W WPW WSV W24V Wout Win Ws W Calculate the amount of radiation according to this total current consumption W and review the temperature rising in the control panel Use the following formula for the calculation of the temperature rise in control panel T 2W UA C Where W power consumption of the entire PLC system the calculated value A surface area of control panel m U if equalizing the temperature of the control panel by using a fan and others 6 Programmable Logic Controller 2MLI CPUU CPU User s Guide 53 Honeywell Confidential amp Proprietary 4 Installation and Wiring 4 1 Installing the PLC If the air inside the panel is not ventilated 4 Precautions for installing handling the PLC modules Take the
100. ntroller 2MLI CPUU CPU User s Guide 73 1 09 Honeywell Confidential amp Proprietary 5 Functions of the CPU Module 5 2 Clock Function The RTC displays the time set in the PLC You can adjust the time on the RTC by setting the time to be directly transmitted to the PLC or select Synchronize with PC clock to transmit the PC time connected to the PLC Clock Reading by Flag It can be monitored by flags as detailed in the following table Flags to read the clock Address Sample Value Description MON YEAR DT FW 1034 h0599 May xx99 TIME DAY DT FW1035 h1512 3 P M 12 SEC MIN DT FW 1036 h4142 42 minutes 41 seconds HUND WK DT 96FW1037 h2001 20xx Monday The time data of TIME DAY DT is displayed on 24 hrs basis RTC Data Modification through Program You can set the RTC value using the SoftMaster program This function is used when the time is manually set using the external digital switch or by designing a system that periodically calibrates the clock time on the network Set DATEWR to ON and insert the setting value in the F address memory area and enter the time in RTC at scan END Clock Writing Flag Description Range MON YEAR DT Month Year Jan Dec 1984 2163 TIME DAY DT Hour Date 0 23 hrs 1 31 SEC MIN DT Second Minute 0599 Seconds sog minutes Hundred years day of the 00 99 0 6 HUND_WK_DT ht week Enter the time data in the format prescribed in
101. o Ethe powermodue fied Fixthe powermodule firrhy Yes No Vie Isthe POWERLED On ithe overcurrent protectia Yes 1 Check the cumert capacty and reduce any overcurrent 2 Tum off rput power and tum t on working property agan No No Yes Isthe POWERLED On Prepare a troubleshooting questionnaire and contactthe deder Jiu R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 153 1 09 Honeywell Confidential amp Proprietary 9 Troubleshooting 9 2 Troubleshooting Action when ERR LED is ON This section describes the sequence of steps to be taken if the ERR LED is ON 154 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 9 Troubleshooting 9 2 Troubleshooting Err LED is Off Check the error code message by accessing SoftMaster Please refer to the flags in Appendix 1 and remove the causes Is it a waming CONF WRP ERR LED still blink Prepare a troubleshooting questionnaire and contact the dealer R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 155 Honeywell Confidential amp Proprietary 9 Troubleshooting 9 2 Troubleshooting B ATTENTION If warning error occurs the PLC system does not stop but it is necessary to check the warning message and take a corrective action Or it may cause an error Action when RUN STOP LED is Off This section describes the sequence o
102. ogic Controller 2MLI CPUU CPU User s Guide Honeywell Confidential amp Proprietary Operation mode changed by key Operation mode changed by local PADT Operation mode changed by Remote PADT Operation mode changed by Remote communication module Forced On Off state of input contact Forced On Off state of output contact I O Skip on execution Fault mask on execution Monitor on execution Stopped after scan completion by STOP function while RUN mode operation Instantly stopped by ESTOP function during RUN mode operation User defined Initialization program on execution 165 10 Appendix 1 10 1 Flag List Type BOOL Flags Name _PB1 BOOL BOOL BOOL _CHK_ANC_ERR _CHK_ANC_WAR _INIT_DONE System Error Flags FD1 _CNF_ER DWORD error Address FX28 FX29 Contents Program Code 1 Program Code 2 FX16384 RTC data writing FX16385 FX16386 FX16387 FX16400 FD43 System error fatal fault Scan value initialization Request of the external fatal fault Request of the external non fatal fault Initialization task execution completion Current key state Description Selected program code 1 Selected program code 2 RTC data writing Initialize the scan value Request of fatal fault detection from the external device Request of non fatal fault detection from the external device If th
103. ogram Structure and Operation Method 7 2 Program Execution Interrupt The following flowchart illustrates the execution of interrupt programs during execution of regular scan program It depicts how interrupt tasks are configured in SoftMaster programming software for MasterLogic 200 B ATTENTION For additional information on the SoftMaster see SoftMaster User s Manual 124 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 7 Program Structure and Operation Method 7 2 Program Execution Scan Program Interrupt 1 pues Interrupt 2 Program 2 Interrupt 3 Interrupt 3 occurs Interrupt 2 Program 2 Interrupt 4 TIP When the power is switched ON all Interrupts are in the Disable state R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 125 1 09 Honeywell Confidential amp Proprietary 7 Program Structure and Operation Method 7 2 Program Execution Configuring an Interrupt Task program Create a task in the project window of SoftMaster as shown in the following figure and add a program to be performed by each task S82MITEST PROGRAM 9 NewPLCemei cpuu Offline Global Direct Variables CY Parameter Tg Basic Parameters T3 1 0 Parameters S Scan Program NewProgram Q Fixed cycle 0 Cycle Time 10ms Prio Fixed Program j e Internal device 54 Intemal Device Internal device program U
104. ompleted it prints out the contents saved in output image area to the output module END The program re executes all the steps and returns to the first step after CPU module completes one scan processing The program processing performed is as below e Update the current value of timer and counter etc e User event data trace service e Self diagnosis e High speed link P2P e Service e Check the state of key switch for mode setting Interrupt Operation Time driven Internal Device e In this method if an interrupt occurs the program being executed on the PLC is temporarily stopped The Interrupt Operation carries out a process corresponding to the interrupt subroutine and then returns to the main program being executed e The signal that informs the urgent interruption to the CPU module is called Interrupt Signal It can be configured to trigger at pre defined time intervals R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 117 1 09 Honeywell Confidential amp Proprietary 7 Program Structure and Operation Method 7 1 Program Introduction e Interrupt program can also be triggered by change in the state of internal devices assigned for that purpose Constant Scan Fixed Period e In this method all the programs being executed are scanned after a specific time interval Scanning stops after all the programs are scanned e The features that differentiate it with the other programs are
105. on Methods Cyclic Operation Scan This is a basic method of executing a program on a PLC It repeatedly performs the same operations as per the program starting from the first step to the last step and is called Scan program The processing is divided per stage The process and its description are given below The following figure depicts the Scan program process R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 115 1 09 Honeywell Confidential amp Proprietary 7 Program Structure and Operation Method 7 1 Program Introduction 3 Program operaton processing Program start Program last step 5 116 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 7 Program Structure and Operation Method 7 1 Program Introduction Stage Processing Description Initialization processing At this stage the scan processing is started It is executed every time when power is applied or when Reset command is executed It involves the following e 1 O module reset e Self diagnosis execution e Data clear Address allocation of I O module and type register Input image area refresh The CPU reads the state of input module and saves it in input image area before executing the program Program operation processing The CPU then executes the program as per the identified steps Output image area refresh If the program operation is c
106. onnect the module in parallel with the output of several power modules b If DC 24V output capacity of a power module is not sufficient for the PLC I O modules supply the external DC 24V power as shown in the following figure R 200 1 09 ACI110V AC220V DC24V cables must be properly twisted and connected in the shortest distance ACI10V AC220V cable must be as thick as possible 2mm to reduce voltage drop ACI10V DC24V cables must not be installed close to main circuit cable high voltage high current and I O signal cable They must be 100mm away from such cables Use a surge absorber as a protection against lightning as shown in the following figure Programmable Logic Controller 2MLI CPUU CPU User s Guide 65 Honeywell Confidential amp Proprietary 4 Installation and Wiring 4 3 Wiring PLC I O device Surge absorber to prevent lighting Separate PLC earth E2 from earth E1 of surge absorber against lightning 2 In case of an increase in voltage the surge absorber ensures that it does not increase more than the predefined maximum limit 3 Use a shielded Isolation transformer or noise filter in areas where higher noise levels are expected 4 tis advisable to use twisted cable for input power Ensure that the shielded transformer or noise filter wiring does not pass the duct I O Device Wiring l 2 3 66 The cable used for I O wiring must be 0 3 2 0mm Use a s
107. p Proprietary 7 Program Structure and Operation Method 7 3 Operation Mode At the beginning the data area is initialized and it determines whether to execute it by verifying the effectiveness of the program 2 Operation process Execute I O refresh and program operation Execute the interrupt program by detecting the operation conditions of the interrupt program Inspect the operation and detachment of modules installed Process communication service and other internal operations STOP Mode The CPU stops when there is no program to run Program can be controlled from SoftMaster if the following switches on the CPU module are set e Remote switch on the CPU module is ON e RUN STOP switch on the CPU module is in STOP 1 Processing when a mode is changed Remove the output image area and execute refresh All output data is changed to off state 2 Operation process a Perform an I O refresh b Inspect the operation and detachment of modules installed c Process communication service and other internal operations DEBUG Mode The Debug mode is used to find errors from a program or trace an operation procedure The DEBUG mode can be changed only from the STOP mode In the DEBUG mode a user can verify a program while checking the program execution and data Processing when a mode is changed e When the mode is changed initialize the data area e Clear the output image area and execute input refresh 136
108. porarily If connected by Max USB Writing it is 6ms if connected by Normal USB Writing it is 1 6ms e Scan time monitor Scan time is saved into the following flag F address memory areas J SCAN MAX Maximum value of scan time resolution of 0 1ms SCAN MIN Minimum value of scan time resolution of 0 1ms SCAN CUR Current value of scan time resolution of 0 1ms Programmable Logic Controller 2MLI CPUU CPU User s Guide 121 Honeywell Confidential amp Proprietary 7 Program Structure and Operation Method 7 2 Program Execution 7 2 Program Execution Program Configuration A Program consists of all functional elements necessary for executing a control saved in the RAM of the CPU module or flash memory The functional elements can be categorized as Functional Elements Operation Description Scan program Process a signal that repeats uniformly per scan Program is executed at a fixed interval if time conditional process is required as follows e lf a faster processing is required than the average Fixed cycle processing time of a scan interrupt program If requiring longer time interval than the average processing time of a scan e Ifa process is to be executed at a fixed interval Subroutine Executed only when a specific condition is met if the input program condition of CALL command is On Program Execution It describes the program execution when the power is turn
109. process or threat to human life B REFERENCE INTERNAL For additional information on Forced I O setting see SoftMaster User s Manual Forced On Off Processing Forced input The input forces the data of the contact point Digital Input selected and set as forced ON OFF At the time of input refresh the forced data is updated to the input image area Therefore the user program operates with actual input data while the forced setting area operates with forced setting data Forced output The Output replaces data of contact point Digital Output selected and set as forced ON OFF from the data of output image area This is achieved during output refresh on completion of the user program operation execution with the forced setting data It makes changes in the output module In case of output the data of output image area does not change by forced ON OFF setting 82 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 5 Functions of the CPU Module 5 4 Forced ON OFF of I O Cautions for using forced I O For Forcing the point the Force Flag needs to be set It is possible to set the forced input even if the actual I O module not installed The data set in the CPU is retained till it is cleared Forced I O data is not cleared even CPU is in Stop mode Click Delete all to clear all settings and set forced value again Direct I O Operation The
110. ration 6 1 System configuration 102 100 10 Mbps supported Item Type Description Thermocoupl Temperature T C input 4 channels inter e input 2MLF TC4S parare p channel isolation module Resistance 2MLF RD4A Temperature RTD input 4 channels temperature detector input 2MLF RD4S Temperature RTD input 4 channels inter module channel isolation type Voltage input type Open Collector type f 2MLF HO2A High Speed 200kpps 2 channels Counter module Differential input Line Driver type 2MLF HD2A 500kpps 2 channels 2MLF PO3A Pulse output Open Collector type 3 axes 2MLF PO2A Pulse output Open Collector type 2 axes APM module 2MLF PO1A Pulse output Open Collector type 1 axis Advanced eis 2MLF PD3A Pulse output Line Driver type 3 axes 2MLF PD2A Pulse output Line Driver type 2 axes 2MLF PD1A Pulse output Line Driver type 1 axis Motion control 2MLF M16M Motion dedicated net Mechatrolink type module 16 axes Fast Ethernet optical Master WP 3 2MLL EFMF Ns n not 8 FEnetl F 100 10 Mbps suppo ps module supported Q E Optical Electr Fast Ethernet T ic electrical Master z 2MLL EFMT E o O Programmable Logic Controller 2MLI CPUU CPU User s Guide Honeywell Confidential amp Proprietary R 200 1 09 6 Configuration 6 1 System configuration Item Type Description Snet I F module 2MLL C22A S
111. rbance that may result in abnormalities or failure of PLC operation Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 4 Installation and Wiring 4 1 Installing the PLC e Ensure that the cables do not pass in front of the I O operation indicator LED as it may obstruct the indicator e When inductive load is connected to output module connect a surge absorber or diode in parallel to the load e Terminal Block Wiring Inductive load Output module Output module WARNING Do not apply apply excessive pressure on the I O module or separate the PCB board from the case Honeywell does not bear any responsibility if the user removes the PCB board from the case Precautions for installing the base The following precautions must be taken while installing a PLC on the control panel 1 Ensure sufficient ventilation for the modules especially the upper part of the modules This also helps in changing the modules if required 2 Ifthe PLC is installed near a Contactor Breaker it is recommended to use a Contactor Breaker Large Size in a different panel R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 55 1 09 Honeywell Confidential amp Proprietary 4 Installation and Wiring 4 1 Installing the PLC 3 If necessary install wiring duct for routing the cables Make note of the following points when installing a wiri
112. rective Keep all high speed signal transmission cables at a safe distance from CAUTION the metal board 2 5 Complying with the low voltage directive The low voltage directive requires each device that operates with power supply ranging from 50V to 1000V AC and 75V to 1500VDC to satisfy the safety requirements This section describes the precautions to ensure the installation and wiring of the MasterLogic 200 series conform to the low voltage directive WARNING The contents of this section are based on the requirements and the applicable standards control However Honeywell does not guarantee that the overall product manufactured according to these details conforms to the low voltage regulation Specifications applicable to MasterLogic 200 Series e The MasterLogic 200 series follows EN6100 1 safety of devices used in measurement rooms control rooms or laboratories e The MasterLogic 200 series modules that operate at the rated voltage of AC 50V DC 75V or above are also developed to conform to the low voltage standards Selecting a MasterLogic 200 Series PLC 1 Power Module The voltages inside the power supply modules are extremely dangerous Peak voltage can be higher than 42 4V for the AC 110 220V rated I O voltages Therefore the CE mark compliant models are internally enhanced in isolation between the primary and secondary 2 Digital I O Module The voltages inside the Digital I O modules are extremely
113. reliability and stability Environmental Conditions Dos e Install the PLC in a control panel which is waterproof and can withstand vibration e Install the PLC away from areas with high vibration e Ensure an ambient temperature of 0 55 C e sure incremental Humidity 5 95 Don ts e Do not expose the PLC to direct sun light e Avoid exposing the PLC to sudden changes in the temperature e Do not expose the PLC to corrosive or inflammable gases Installation Conditions e While drilling holes fixing screws or wiring do not let wire or any other metallic part enter the PLC e Do not install the PLC on a panel that has a high voltage device e Maintain a distance of atleast 50mm from the wiring duct or surrounding modules e Ensure the grounding at a place where surrounding noise is minimal R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 51 1 09 Honeywell Confidential amp Proprietary 4 Installation and Wiring 4 1 Installing the PLC Heat Protection Design of Control Panel e Incase the PLC is installed in an airtight control panel the heat protection design must be esnured considering the radiation of other equipment and heat from the PLC When air circulation is provided using a vent or a general fan the flow of dust particles or gas can hamper the functioning of the PLC system e Installing a filter or use of an airtight heat exchanger is recommended The following figure illustrates t
114. rogrammable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 7 Program Structure and Operation Method 7 2 Program Execution Sets the execution cycle and priority of a task which is the operation condition of a task program Check the task number to manage tasks 2 Fixed cycle task processing Executes a fixed cycle task program at a pre defined interval Cautions for using a fixed cycle task program Ifa same task program is to be executed when a fixed cycle task program is in operation or waiting for execution the new task is ignored During the operation mode in RUN a timer executing a fixed cycle program is counted Any interruption time is ignored Note that several fixed cycle task programs are simultaneously executed in certain conditions This happens when the execution cycle of a fixed cycle task program is set as in the following example If using 4 fixed cycle task programs of which cycle is 2 4 10 and 20 seconds respectively it may have simultaneous execution of 4 programs every 20 seconds This may result in a longer scan time A short fixed cycle is not executed if the total duration in which the fixed cycle programs are simultaneously executed is greater than the time specified for the simultaneous execution of several fixed cycle tasks CAUTION Ensure that the cycle time of the fixed cycle task is greater than the scan cycle time of the task
115. rom disable to enable the flash memory operation mode is applied until the flash memory writing is complete In case the PLC restarts before completing program writing Flash memory operation mode is released Flash memory operation method Depending on the Flash Memory operation mode setting the PLC operates as indicated in the following table when the PLC is restarted or its operating mode is ON Flash memory operation mode Description setting R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 79 1 09 Honeywell Confidential amp Proprietary 5 Functions of the CPU Module 5 3 Remote Functions 80 Flash memory operation mode setting Description On If program memory data is corrupted because flash memory and program memory are different or battery voltage is low it downloads the program saved in the flash memory to the program memory Off CPU detects that the flash memory does not have any program and operates by the program saved in the RAM Programmable Logic Controller 2MLI CPUU CPU User s Guide Honeywell Confidential amp Proprietary R 200 1 09 5 Functions of the CPU Module 5 4 Forced ON OFF of I O 5 4 Forced ON OFF of I O Forced I O Setting The forced I O setting function is used to forcibly turn ON or OFF I O channels irrespective of the program execution results To force I O ON OFF perform the following steps Step A
116. rotective Earth at the source of supply in accordance with national and local electrical code requirements Chassis Ground Identifies a connection to the chassis or frame of the equipment shall be bonded to Protective Earth at the source of supply in accordance with national and local electrical code requirements X Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 Contents T INTRODUCTION cei cteo oisi pe hee ERE o Cea Ea ce Pe REFS C ELE PEE ED ies EyE TH Per aidui ei 17 1 4 Functional Overview eeeeeeeeeeeeneeeenen nnne nnne nn nnne nnn nn nennen 17 Overview of 2MLI CP UW ier a ea fot dee eer eapite et dile teen initia cnet 17 dcc 320550550 EE 17 2 COSPECIFICATIONS 55 aiit estt tenete Inset Ma MTM 21 24 General specifications eerte DeL eet tect cietedtaesnesedens 21 2 2 Battery ttes csstccucrsssctctessvoaens essen 24 Battery Specifications poer pce opened etn eren ep IR Nirta o idat shade Saa De pene PL dake 24 Cautions for sage duit NM icc ER oe a befreit aeuo ue rap DE etse 24 Baltery Life nee ter ERES FE REB E wens APR ERR ER AER Re ELE re EEE 24 2 3 Performance specifications eeeeeeesesseesseeeeeneeeenr ennt 25 2MLI CPUU performance specifications esssssssssssseeeneeeeeneren enne 25 Part Names and FUNCTIONS 2 oto ee etu M eS med 28 2 4 Conformance to EMC Specifications
117. s via Ethernet amp serial communication module locate or remote Dale storage meia at Retain area configuration via Basic parameters power off Internal consumption current 960mA Weight 0 12kg Switchover Time NA Flash area 16MB R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 27 1 09 Honeywell Confidential amp Proprietary 2 Specifications 2 3 Performance specifications Part Names and Functions No Names Description Specifies the operation state of CPU module e Green ON CPU operation is in RUN mode state either by RUN STOP switch in CPU set to RUN mode or REMOTE RUN operation through SoftMaster even when the local switch is at STOP mode a RUN STOP LED e Green Blink Warning or error during RUN operation e Red ON CPU operation is in STOP mode state either by RUN STOP switch in CPU set to STOP mode or REMOTE STOP operation through SoftMaster even when the local switch is at RUN mode e Red Blink 28 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 2 Specifications 2 3 Performance specifications No Names Description Warning or error during STOP operation if an error occurs stop the ongoing operation e Yellow ON Remote enabled in case REMOTE switch is ON O b REM LED e OFF Remote disabled
118. ser Function Function Block User Data Type I I I r B REFERENCE INTERNAL For additional information on creating an interrupt program see SoftMaster User s Manual Task Types The various task parameters that can be configured using SoftMaster and their functions are as follows Fixed cycle task parameters that can be configured using SoftMaster and their Internal contact task Spec functions are as follows single task interval task 126 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 7 Program Structure and Operation Method 7 2 Program Execution Number 32 32 Fixed cycle settable up to Operation 4 294 967 295 seconds at the Conditions of internal device condition designation unit of 1ms Detection exec Cyclically execute at the pre Execute by conditional search ution defined interval after completing scan program Detection delay time Delayed as long as a maximum of 0 2ms Delayed as long as the maximum scan time Execution priority Setting 2 7 levels level 2 is the highest priority 2 7 level setting 2 level is highest priority Task number Assigning it between 0 31 so that it is not duplicate Assigning it between 64 95 so that it is not duplicated Processing an Interrupt Task Program R 200 1 09 The following points describe the common processing
119. stalling the PLC on a control panel Control Panel The PLC is a device susceptible to noise To protect it from noise it must be installed on a control panel This also prevents chances of electric shock and reduces PLC generated noise Installing the PLC on a metallic panel reduces PLC generated EMI Electro magnetic interference Control Panel specifications The Masterlogic 200 PLC must be installed on a metallic panel to restrict EMI emitted from the product The specifications of the metallic panel are as follows 1 Use SPCC Cold Rolled Mild Steel for the control panel 2 The thickness of the steel plate must be atleast 1 6mm 3 Use isolating transformers to protect power supply from external surge voltage 4 The control panel must have a structure that prevents radio waves from entering For example make the door as a box structure so that the panel body and the door overlap each other This structure reduces the surge voltage generated by PLC R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 33 1 09 Honeywell Confidential amp Proprietary 2 Specifications 2 4 Conformance to EMC Specifications Panel Main frarne Door Visor Power Cable and Grounding specifications Grounding and power supply wires for the PLC system must be connected as follows 1 Ground the control panel with a thick wire so that a low impedance connection to ground can be ensured even at high frequencies 34 Progra
120. t and so on 4 System Configuration The system is effectively configured keeping in mind the user s needs e Filter Value of the input modules can be adjusted e Output can be kept on hold clear during emergency e Varistor is built in with a durable relay output module e The racks main base and expansion base can be extended up to 15m e Provides system RUN status contact in power supply module e Reduction of installation commissioning and maintenance costs by the reinforced self diagnostic function 5 Communication systems The communication module enables the user to communicate with the CPU using different Protocols It is also used by the CPU for communication with I O s and Special Modules e Anetwork communication can be established without ladder programming e The exclusive tool SoftMaster NM monitors the operations and applies the network settings e Open networks are supported with various international standards e Provides a dedicated network to improve communication e Peer to Peer network compatible with other MasterLogic CPUs 18 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 1 Introduction 1 1 Functional Overview R 200 1 09 6 Online Editing SoftMaster enables the users to modify programs online while CPU is in operation It enables e Program reinforced by symbolic variables e Ability to modify the program during operation
121. t be finally determined by the manufacturer of the system The standards applicable to the EMC Directive are as follows Specification Test items Test details Standard value EN55011 Measure the wave 30 230 QP 50 Radiated emitted from a product Im 1 noise 2 230 1000 QP 57 m EN50081 2 EN55011 Measure the noise that 150 500 QP 79 conducted a product emits to the power line Mean 66 noise 500 230 QP 73 Mean 60 EN61000 4 Immunity test allowing 15 Air discharge Electrostatic static electricity to the EN61131 2 y immunity case of a device 8 Contact discharge EN61000 4 4 Immunity test allowing a Power line 2 fast noise to power af burst noise Analog I O signal lines 1 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 2 Specifications 2 4 Conformance to EMC Specifications Specification Test items Test details Standard value EN61000 4 3 Immunity test injecting 10Vm 26 1000 electric field to a Radiated field product 80 AM AM modulation modulation 1 EN61000 4 12 Immunity test allowing Power line 1 attenuation vibration Damped wave to power cable Digital VO 24V and oscillatory wave higher 1 immunity QP Quasi Peak Mean average value A PLC is an open type device device installed on another base and must be installed on a control panel The system tests are performed after in
122. t number after detecting the detach error R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 167 1 09 Honeywell Confidential amp Proprietary 10 Appendix 1 10 1 Flag List Flags Name Contents Description FW92 When a fuse equipped to Fuse of the slot module blows out this flag is _FUSE_ER_N UINT displayed as the lowest slot number blown out number after detecting the error Representative flag displayed when the fatal _ANNUM_ER BOOL Fatal fault detection fault error detected by the error in external device user program is recorded in ANC ERR n BPRM ER BOOL FX40 Basic parameter error Basic parameter error _IOPRM_ER BOOL FX41 I O parameter error I O parameter error SPPRM ER BOOL FX42 Special module Special module parameter parameter error error FX43 Communication CPPRM ER BOOL module parameter error Communication module parameter error 9oFX44 Indicates that there is a PGM ER BOOL Program error problem with user made program checksum FX45 Indicates that while user _CODE_ER BOOL Program code error program is running the program code cannot be interpreted FX46 Displayed when the saved program is corrupted by an abnormal end of CPU or the program cannot function _BASE_POWE BOOL FX4A7 POWEPFOHOE Indicates that base power is R ER abnormal FX48 Indicates that the scan _WDT_ER BOOL Scan watchdog error program time exceeds the scan watchdog
123. tches must always be set to ON right side Setting it to OFF left side may cause abnormal operation REMOTE enable switch Used to enable the PLC to operate remotely ON right All functions enabled for remote control OFF left Limited remote functions c M XCHG Module exchange switch Used while changing any module online during CPU operation hot swapping ON right Before changing the module put the switch in ON position OFF left After the module is changed put the switch back to OFF position RUN STOP mode Switch Sets the operation mode of CPU module e STOP RUN executes the program e RUN STOP stops the program e The above commands operates irrespective of the REMOTE switch setting Reset D Clear Switch If this switch is moved to left and returned to center executes RESET action left and held for more than 3s then returned to center executes Overall RESET action If this switch is moved to Right and pressed it executes DATA CLEAR action right and returned to center clear Latch 1 area data and general data area right held for more than 3s and then returned to center it clears Latch 2 area data and general data area 30 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 2 Specifications 2 3 Performance specifications No
124. tenance 8 3 Periodic Inspection 8 3 Periodic Inspection Check the following items once or twice every six months and take necessary actions Checklist Check method Judgment basis Actions Temperature Measure by 0 55 C Adjusting thermometer hy according to the Enviro Humidity grometer 5 95 RH general spec nment environmentment Measure al condition in the Contaminati corrosive gas ias of corrosive panel on level 9 Try to carefully M e Too Mio Must be firmly Tightening movement of attached PLC each module status Builtin Visual No built in dust impuriti E M inspection dust impurities Loose Tightening with No loosened i Tightening connector a screwdriver screws Conne Proximity of Visual F ctor clamped f Proper spacing Rearrangement inspection status terminal Loosened Visual Tightening No looseness connector inspection connector screws eee AC100 240V AC voltage of input Change the Check power voltage terminal by 85 264V 9 power supply EU DC24V DC19 2 multimeter 28 8V R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 149 1 09 Honeywell Confidential amp Proprietary 8 Maintenance 8 3 Periodic Inspection e Check the total interruption time A battery must be Check the battery and warranty replaced if the Battery replacement period warranty period timing and has expired voltage drop e No batt
125. th a time stamp e Saves the date time and mode change information e Saves up to 1 024 mode change events Power shut down Log The PLC saves power ON OFF data with its time stamp It saves On Off information date and time It saves a maximum of 1 024 power ON OFF events System Log The PLC saves operation history of the system during operation e Saves the date time and operation changes 84 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 5 Functions of the CPU Module 5 5 Viewing PLC Error Event Log R 200 1 09 Saves the SoftMaster operation data key switch change information Saves instantaneous interruption data and network operation Saves a maximum of 2 048 operation history events PLC history NewPLC Eror Log Mode Log Shut down Log Sytstem Log 2005 08 18 2005 08 18 2005 08 18 2005 08 18 2005 08 18 2005 08 18 2005 08 18 2005 08 18 2005 08 18 2005 08 19 2005 08 19 2005 08 19 2005 08 19 2005 08 19 18 41 33 001 18 43 32 865 18 46 09 001 18 57 16 181 18 57 19 876 18 57 23 541 18 57 57 919 18 58 20 921 18 58 23 903 18 59 04 786 09 41 54 001 09 41 55 526 09 42 04 001 09 42 05 112 11 18 27 001 11 18 32 405 Data trace Use Momently shut down Data trace Use USB OK Connect USB OK Disconnect USB OK Connect USB OK Connect USB OK Disconnect USB OK Disconnect Momently shut down Data trace Use Momentl
126. the 138 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 7 Program Structure and Operation Method 7 3 Operation Mode PLC operates continuously without suspension Editing during RUN is possible in the RUN mode by switch but the mode change is restricted by SoftMaster Change the mode only when the mode change is not remotely allowed R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 139 1 09 Honeywell Confidential amp Proprietary 7 Program Structure and Operation Method 7 4 CPU Memory 7 4 CPU Memory Overview of CPU memory The CPU module contains two types of memory that can be used by a user e Program memory to save a user program created to construct a system e Data memory to provide a address memory area and save the data during operation Program Memory The total program memory area is 10 MB The storage capacity and data area type of the program memory are as follows Item area Capacity System area e System program area e Backup area Parameter area e Basic parameter area I O parameter area High speed link parameter area P2P parameter area Interrupt setting data area e Reserved area Execution program area e Scan program area e Task program area 140 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 7 Pro
127. the basis of Program Block PB The error indication which occurs while program block is running continuously until the end of the program It is possible to delete the same in the program Operation error latch flag Error flag displayed when exceeding the setting array numbers o _ARY_IDX_ER eFX28864 Overflow error flag R array index range FX28896 Error latch flag displayed when exceeding the setting array numbers 9 ALL OFF Boo FX179 Al output Off ye on rh wena Overflow error latch ARY IDX LER BOOL E e STIS flag array index range R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 171 1 09 Honeywell Confidential amp Proprietary 10 Appendix 1 10 1 Flag List The flags of the information of the system operation state Contents Description Flags Name CPU_TYPE CPU_VER OS_VER OS_DATE SCAN_MAX SCAN_MIN SCAN_CUR RTC_DATE RTC_WEEK RBANK_NUM 172 FW44 UINT UINT DWORD DWORD UINT 9oFW45 FD23 FD24 FW5O UINT UINT UINT UINT FW136 FW137 UINT 9oFW158 Programmable Logic Controller 2MLI CPUU CPU User s Guide CPU Type Information CPU version OS version OS date Maximum scan time Minimum scan time Current scan time Current date of RTC Current a day of the week of RTC Active block no Honeywell Confidential amp Proprietary Indicates the operation mode and operation State
128. the specifications performances and operations of CPU module Model 2MLI CPUU of MasterLogic 200 PLC System B ATTENTION This document does not describe the I O modules amp other special communication module and programming For the functions refer to the related user s manual 2MLI CPUU is one of the CPUs of MasterLogic 200 PLC system and the other types of CPU for MasterLogic 200 PLC system are as follows e 2MLK CPUH and 2MLK CPUS Non redundant CPU using only ladder language e 2MLI CPUU Non redundant CPU using IEC standard languages LD SFC ST e 2MLR CPUxxxx Redundant CPU using IEC standard languages LD SFC ST Release Information Document Name Document Release Publication ID Number Date 2MLI CPUU CPU User s Guide 2MLI 200 1 09 CPUU References The following list identifies all the documents that may be sources of reference for material discussed in this publication Document Title R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide iii 1 09 Honeywell Confidential amp Proprietary 208BAcronyms amp definitions Acronyms amp definitions Acronym Term Definition A D Analog to Digital Conversion Base Base is the back plane of the PLC on which the power supply communication and other modules gets installed Examples Main base expansion base BCD Binary Coded Decimal Cold Restart CPU D A Direct variable Dnet FEnet FO Function
129. the table Monitor the RTC read device to check if the RTC data is modified correctly 74 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 5 Functions of the CPU Module 5 2 Clock Function The Weekday expression method is used to represent the weekday in a Ladder Program For example 3 represents a Wednesday wherever we need to specify a date as indicated in the following table Number 0 1 2 3 4 5 6 Day Sund Monday Tuesda Wedne Thursd Friday Saturda ay y sday ay y Time tolerance The RTC tolerance depends on the ambient temperature Time tolerance according to temperature per day is indicated in the following table Operating Maximum error sec date Ordinary sec date Temperature 0 C 4 67 1 38 1 46 25 C 1 64 2 42 0 43 55 C 5 79 0 78 2 29 B ATTENTION e Initially the RTC may not have any clock data e Set the clock data correctly before beginning to use the CPU module e In case the data is out of range of the clock data written in the RTC it may not function normally Example 14Month 32Day 25Hour e RTC may stop or give an error because of battery error If new clock data is written in the RTC the error is cleared B REFERENCE INTERNAL For additional information on modifying the clock data see MasterLogic 200 Instructions User Guide R 200 Programmable Logic
130. the update of input output and to perform in synchronization e In constant scan operation the scan time indicates the net program processing time where the standby time is deducted In case that scan time is bigger than constant CONSTANT ER F0005C flag will be switched ON Operation of Instantaneous Interruption The CPU module detects momentary power failure when the input power voltage supplied to the power module is lower than the normal voltage If the CPU module detects the momentary power failure it carries out the operation as follows 1 Incase of instantaneous interruption less than 20ms Input power Instantaneous interruption within 20ms e CPU stops the operation and holds the output in the state when momentary power failure occurred e If momentary normal power resumes the operation continues e Output voltage of power module keeps the value within the standard range e Even if the operation stops momentary timer measurement and interrupt timer measurement shall be executed normally e Momentary power failure exceeding 20ms 118 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 7 Program Structure and Operation Method 7 1 Program Introduction Input power Instantaneous interruption over 20ms Processing will be restarted at the power supply input What is instantaneous interruption Momentary power failure means the state that the
131. time specified by a parameter _SWDT_ER BOOL CPU abnormal ends 168 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 10 Appendix 1 10 1 Flag List System Warning Flags 0 DWORD pape System warning FX64 Flag Name _CNF_WAR _RTC_ER BOOL RTC error 0 TASK ER BOOL TOL Task collision BAT ER BOOL 9oFX69 ANNUM WA BOOL FX7O R _BASE_INFO_ BOOL FX49 ER Battery error External device fault Base information error High speed link parameter error HS_WARn BooL FX928 _P2P_WARn BOOL FXI44 ei BOOL FX92 FW1026 ANC ERR UINT FW1027 _ANC_WAR UINT User s Flags P2P parameter error Fixed cycle fault Fatal fault information of external device Non fatal fault information of external device Description Representative flag displayed as the system warning Indicates that RTC data is abnormal If two or more tasks collide during execution Error in the battery state The non fatal fault in the external device is detected Base information error High speed link parameter error P2P parameter error Fixed cycle fault Fatal fault of external device is detected by the user program and that error is saved at this zone as numbers which can identify 16 error types Non fatal fault in external device is detected by the user program and the bit position of the occurred error is displaye
132. tion The over voltage protection device shuts down the circuit to stop the system if the voltage is greater than the standard and is applied to the DC5V circuit Programmable Logic Controller 2MLI CPUU CPU User s Guide 49 Honeywell Confidential amp Proprietary 3 Hardware Specifications 3 3 Power Module Example of Current Consumption Power Calculations 50 This section describes which power supply module must be used in coordination to the corresponding modules for MasterLogic 200 Voltage Type Model No 5V 24V CPU module 2MLI 0 96A CPUU 12 Slot basic 2MLB base M12A Input module 2MLI D24A 0 2A Output module 2MLQ 2 0A RY2A FDEnet module 2MLL 1 3A EDMF Profibus DP 2MLL 1 12A PMEA Current Calculation 0 96 0 2 2 1 34 1 12 consumption Result 5 58A Power Calculation 5 58x5V consumption Result 27 9W As the value of 5V current consumption is 5 58A use 2MLP ACF2 5V 6A or 2MLP AC23 5V 8 5A The system does not operate if 2MLP ACF1 5V 3A is used Programmable Logic Controller 2MLI CPUU CPU User s Guide Honeywell Confidential amp Proprietary R 200 1 09 4 Installation and Wiring 4 1 Installing the PLC 4 Installation and Wiring 4 1 Installing the PLC Installation Environment The PLC system is designed to withstand extreme climatic conditions However care must be taken for the following items to ensure
133. tions of internal device task occur and disappear by a scan program or task program fixed cycle external contact during the first scan a task Is not executed because it is not detected when the execution conditions are checked Task Processing in Instantaneous Interruption On resuming operation after a long instantaneous interruption waiting tasks and tasks that occur during the interruption are 1gnored On resuming operation tasks after the interruption are processed If an interruption is 20ms or less a waiting task 1s executed once the interruption is over Any fixed cycle interrupt task that is duplicated during the interruption is ignored Verification of Task Program 130 After creating a task program use the following checklist to verify it 1 Is the task set properly Ifa task occurs excessively or several tasks occur simultaneously in a scan period it may cause longer scan time or irregularity If a task setting cannot be changed check the maximum scan time 2 Is the task priority well arranged Alow priority task program may not be processed in a specified time due to a delay in a higher priority task program When a new task 1s preceded by a delayed task it may cause a task collision The priority must be set in consideration of the urgency of task execution time and so on 3 Is the task program created as short as possible Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell
134. twork 112 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 6 Configuration 6 3 Network system B ATTENTION The specifications may vary with respect to the performance For accurate and latest information refer to the manual of the respective network system l O allocation method and I O address assignment Variables can be allocated to the Remote I O by the high speed link parameters of SoftMaster NM I O variables or internal variables can be designated as I O Itis recommended to use and Q areas to use forced On Off function and the initialization reset function The maximum number of I O points available is 32 765 B ATTENTION e While assigning remote station number and areas the station numbers of sending receiving areas must not be duplicated e Forced On Off I O service is provided only when assigning the I O points by I O variables YIW 96QW e Pay special attention when assigning I O using internal variables B REFERENCE INTERNAL For details on setting fast link parameters for the modules refer to the respective network manual R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 113 1 09 Honeywell Confidential amp Proprietary 7 Program Structure and Operation Method 7 1 Program Introduction 7 Program Structure and Operation Method 7 1 Program Introduction Program Operati
135. voltage of supply power at power condition designated by PLC is lowered as it exceeds the allowable variable range and the short time usually in ms interruption is called momentary power failure Scan Time The processing time from program step 0 to the next step 0 is called Scan Time 1 Operation and performance of 2MLI CPUU The Program execution time I O data process time and communication service time are important factors affecting the scan time e The 2MLI CPUU reduces scan time through improved data reception performance through ladder program execution and backplane ladder program execution by MPU and parallel execution of I O data scan and so on R 200 Programmable Logic Controller 2MLI CPUU CPU User s Guide 119 1 09 Honeywell Confidential amp Proprietary 7 Program Structure and Operation Method 7 1 Program Introduction MPU processing time BP Controller processing time Digital I O Analog Communication Type Ladder module module module execution E ede Tere een basic extension 32kstep points ch 1module 1module 200 byte 1 block 2MLI CPUU 0 896 ms 0 6 ms 20 us 75 us 185 us 2 Calculation of Scan Time The CPU module executes the scan program in the following sequence A user can estimate the scan time performance of a system from the following calculation VO data Refresh System check amp Task process 6 SoftMaster Service
136. y shut down Data trace Use Momently shut down Data trace Use USB OK Connect ATTENTION The saved information is not deleted until you select the delete menu from SoftMaster In case there are more than 100 events the Read All button is enabled Click Read All to check the history Programmable Logic Controller 2MLI CPUU CPU User s Guide Honeywell Confidential amp Proprietary 85 5 Functions of the CPU Module 5 5 Viewing PLC Error Event Log 86 Programmable Logic Controller 2MLI CPUU CPU User s Guide R 200 Honeywell Confidential amp Proprietary 1 09 5 Functions of the CPU Module 5 6 Diagnosing Faults of an External Device 5 6 Diagnosing Faults of an External Device All the Errors in an external device devices wired to I O modules are detected by CPU and is available in a Flag as a real time value This flag enables the indication of an external device error without preparing a complicated program Detection and classification of external device fault The errors in an external device can be detected by the user program They are classified as the following types e Non Fatal Error warning When this type of error occurs the PLC continues to operate in RUN mode It only gives an indication about the device state according to the contents of detected warning e Fatal Error this type of error occurs the PLC stops operation and goes to STOP mode Fatal error ANC E

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