Allen-Bradley Mini-PLC-2/15 Assembly And Installation Manual Download

Page: 77 / 96

Maintenance and Troubleshooting

Chapter 5

IS
POWER SUPPLY
FUSE BLOWN
?

IS
CORRECT
LINE–VOLTAGE AT
SUPPLY INPUTS
?

CYCLE LINE POWER
TO SYSTEM POWER SUPPLY

IS
DC ON
INDICATOR
ON
?

CHECK POSITION OF JUMPERS
ON POWER SUPPLY TERMINAL
STRIP

REPLACE FUSE RESTART
CONTROLLER AND VERIFY
PROPER OPERATION

CORRECT LINE–VOLTAGE
PROBLEM

RESTART CONTROLLER
VERIFY PROPER OPERATION

HAS THE
POWER SUPPLY
LOAD EXCEEDED
6.5 AMPS
?

REMOVE SYSTEM POWER
REPLACE SYSTEM
POWER SUPPLY

REDUCE POWER SUPPLY
LOAD TO 6.5 AMPS
OR LESS

RESTART CONTROLLER
VERIFY PROPER OPERATION

RESTART CONTROLLER. RELOAD
PROGRAM IF NECESSARY
VERIFY PROPER OPRATION

WARNING:
REMOVE
SYSTEM
POWER
BEFORE
CHECKING
FUSE

Yes

10139–I

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Summary of Contents for Mini-PLC-2/15

Page 1: ...rutilized and idle equipment along with credit for buybacks and trade ins Custom engineering so your equipment works exactly as you specify Critical and expedited services Leasing Rentals Demos In sto...

Page 2: ...Bulletin 1772 Mini PLC 2 15 Programmable Controller Assembly and Installation Manual Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com...

Page 3: ...11 I O Chassis and Power Supply Mounting 3 17 I O Chassis Assembly 3 18 Wiring Cabling Installation 3 25 Incoming AC Wiring Guidelines 3 33 Industrial Terminal Installation 3 37 System Start Up 4 1 S...

Page 4: ...i Specifications 6 1 General 6 1 Mini PLC 2 15 Processor 6 1 System Power Supply 6 2 I O Equipment 6 3 Industrial Terminal 6 3 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE...

Page 5: ...ic control device used for industries as diverse as petrochemical food processing pulp and paper mining steel and metals and cement to name a few As the term programmable implies PC memory can be read...

Page 6: ...ities loading storing verifying the program using magnetic tape generating a hard copy printout of the ladder diagram program or total memory generating various types of reports in a user programmed f...

Page 7: ...and their associated cables must be specified by the user when ordering the Mini PLC 2 15 Programmable Controller This section will identify and describe the hardware associated with each of these Mi...

Page 8: ...I O I O Module Field Wiring Arm I O Power Cable Cat No 1771 CL or CM Battery Pack Cat No 1771 BB System Power Supply Mini PLC 2 15 Processor Cat No 1772 LV I O Chassis Assembly Cat No 1771 A1 A2 A4 Ca...

Page 9: ...ts for available modules are listed in Table 1 A The System Power Supply is protected against undervoltage overvoltage and overcurrent conditions it constantly monitors the incoming AC voltage for pro...

Page 10: ...this memory backup power when the Processor is seated in the left most slot of the I O chassis An external Battery Pack can also maintain memory content when the Processor is removed from the I O Chas...

Page 11: ...A WA WE Red Blue Blue Blue Blue Pink Thermocouple Input Expander AC 120V Output DC 12 24 Output DC 48V Output Isolated AC 120V Output Analog 12 bit Output 1771 IY 1771 OA 1771 OB 1771 OC 1771 OD 1771...

Page 12: ...ure 2 3 External Battery Backup Battery Pack Cat No 1771 BB Mini PLC 2 15 Processor Cat No 1772 LV Mini PLC 2 15 Processor Transport Cable Cat No 1772 CD 10105 I In some brownout situations it is poss...

Page 13: ...ed to Field Wiring Arms which can be removed from the smaller Chassis and snapped onto the corresponding positions of the larger Chassis Also when Field Wiring Arms and I o modules are placed in corre...

Page 14: ...has three diagnostic indicators a Mode Select Switch an INTERFACE port and an EPROM access door In addition the Processor has a memory write protect feature that is active when a programmed EPROM is...

Page 15: ...ly completed without error this indicator will stay OFF If an error in EPROM programming occurs this indicator will come ON and stay ON This indicator will also flash if EPROM transfer at power up is...

Page 16: ...mitted in this switch position When a programmed EPROM is already in place this mode is limited by the Memory Write Protect feature See section titled Interface Socket for details When the keyswitch i...

Page 17: ...t be altered by programming The I O Modules Figure 2 6 contain the necessary circuitry to interface the user s I O devices to the Mini PLC 2 15 Processor Each I O circuit has optical isolation to guar...

Page 18: ...ure 2 7 without disturbing filed wiring This aids in start up and troubleshooting by shortening the time needed to replace I O modules thus decreasing down time Cat No 1771 WA Field Wiring Arms are sh...

Page 19: ...o the Rack Number always 1 for the Mini PLC 2 15 System The third digit refers to the Module Group Number 0 7 A Module Group consists of two adjacent I O Module slots in the I O Chassis starting at th...

Page 20: ...1012 Output 0 Input 1 Rack Number Always 1 for Mini PLC 2 15 Module Group Number 0 7 Terminal Number 00 07 10 17 10107 I In addition to Mini PLC 2 15 Controller components the user can supply other eq...

Page 21: ...Figure 2 9 Module Groups 10108 I 32 I O 0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7 64 I IO 128 I O Figure 2 10 Industrial Terminal Cat No 1770 T3 10296 I Artisan Technology Group Quality Instrumentation Guarant...

Page 22: ...entire Manual before installing or operating the Mini PLC 2 15 Controller There are general recommendations to consider for layout of the Controller system These recommendations are the result of both...

Page 23: ...uctive loads such as relays solenoids motors and motor starters when they are operated by hard contacts such as pushbuttons and selector switches in the case of reversing motor starters hard contacts...

Page 24: ...al Purpose Cat No 599 K04 Bulletin 509 Starters Cat No 700 N5 N9 N24 700 N Relays Cat No N10 Bulletin 709 Starters 0 5 220 f 1 Figure 3 2 Typical Suppression for 3 Phase Inductive Load 240 480V AC 101...

Page 25: ...120V AC CR4 Figure 3 4 Typical Suppression for Small DC Inductive Load 10112 I V DC PIV Peak Inverse Voltage rating of diode must be at least twice the applied DC voltage All possible sources of noise...

Page 26: ...etermine the System Power Supply power requirement from the nameplate or product specifications The power requirement for the 1771 P1 Power Supply is 75 VA 2 Determine total power requirement of input...

Page 27: ...for print pockets mounted on the door and stand off measurements when calculating the working depth of an enclosure Component Spacing Considerations Mini PLC 2 15 Controller components must be spaced...

Page 28: ...he same horizontal plane allow at least 6 horizontal inches between them Rule 3 Allow at least 2 inches between the Controller and the wiring duct or terminal strips Rule 4 When the Power supply is mo...

Page 29: ...th ground is defined as the central ground for all electrical equipment and AC power within any facility All ground connections must be permanent and continuous to provide a low impedance path to eart...

Page 30: ...strated in Figure 3 7 Bare metal contact is required to ensure that good electrical contract has been established between Controller components the enclosure back panel and the enclosure Paint or othe...

Page 31: ...be connected to earth ground Figure 3 10 Grounding paths to earth ground must be permanent and continuous and must be able to conduct electromagnetic noise currents and possible ground fault currents...

Page 32: ...the System Power Supply should be mounted to the Chassis before the Chassis is mounted to the enclosure back panel Figure 3 8 Ground Bus Connection Details Ground bus Tapped hole Ground lug Bolt Star...

Page 33: ...auses the operation to shut down The two switch settings indicate the following Figure 3 12 ON Outputs are left in their last state either energized or de energized when a fault is detected OFF Output...

Page 34: ...down in case the batteries leak An optional lithium battery Cat No 177 XO can be installed in the Battery Pack in place of two alkaline batteries Refer to Publication 1770 950 for lithium battery info...

Page 35: ...tery Pack When the batteries are installed slide the Battery Pack onto the tracks and tighten the thumbscrew Figure 3 12 Switch Group Settings 1 2 3 4 5 6 7 8 O N O F F No Significance ON Outputs rema...

Page 36: ...699 I Brackets installed by user Battery Pack slides on tracks Figure 3 14 Alkaline Battery Installation 10120a I 10680 I Orientation Alkaline Battery Alkaline Battery Battery Contacts Artisan Technol...

Page 37: ...e top backplane sockets of the I O Chassis Figure 3 16 they are used to ensure that the correct I O Modules are installed in the correct Module slots They are also used to key the Module slot for the...

Page 38: ...connecting the equipment grounding conductor CAUTION Care must be taken not to allow the I O Chassis to warp when mounted This may occur if the back panel is slightly curved Chassis distortion can cau...

Page 39: ...pe paint and use star washer Tapped Hole Bolt Use a wire brush to Back Wall of Enclosure Welded Stud Scrape paint and use star washer Stud Mounting of this Back Panel to the Back Wall of the Bolt Moun...

Page 40: ...Power Supply mounting configuration 1 ft 30 5 cm Cat No 1771 CL 5 ft 1 5 m Cat No 1771 CM The I O Power Cable Figure 3 21 has three plugs one 3 pin plug and two 9 pin plugs that are labeled for proper...

Page 41: ...a complete description of the EPROM To install the EPROM perform the following steps Figure 3 22 1 Grip the EPROM at the edges and check all EPROM pins to ensure they are not bent or dirty 2 Loosen t...

Page 42: ...1 25 4cm 10 0 3 93cm 1 55 10125 I 32 54cm 17 71 44 98cm 27 71 70 38cm 32 I O 64 I O 128 I O 7 16 18 2cm 8 51 21 62cm Note For ease of assembly Power Supply and I O Chassis should be a unit before moun...

Page 43: ...2cm 7 16 4 56 28 5cm 11 25 25 4cm 10 0 5 0cm 2 0 10126 I 11 6cm Figure 3 21 I O Power Cable 3 Pin Socket 9 Pin Socket I O Power Cable Cat No 1771 CL or CM I O Chassis Socket Thumbscrew 10127 I Artisa...

Page 44: ...Mini PLC 2 15 Processor Field Wiring Arms Field Wiring Arms Cat No 1771 WA for each I O Module slot are shipped with the I O Chassis If a different Field Wiring Arm is required for a certain Module i...

Page 45: ...assis is snapped down to secure the I O Module Figure 3 15 The Field Wiring Arm is then pivoted up and snapped onto the wiring arm locking tab Figure 3 23 Installing Processor Module 4 slot I O Proces...

Page 46: ...ignals DC I O signal wires may be blue in color and AC I O signal wires may be red Local electrical codes may specify insulation colors for various types of signals It is strongly recommended that the...

Page 47: ...ata Highway Cables Serial Communication carry data transmissions between Processors and or Computers Low Level DC I O lines carry low voltage low per signals and their input circuits have short time c...

Page 48: ...de the enclosure Use 14 AWG stranded wire or smaller as permitted by local codes to connect to the Field Wiring Arms All AC I O lines and High Level DC I O lines can be routed with machine power lines...

Page 49: ...M ADDRESSING Publication 5039 September 1980 PAGE OF DATE DESIGNER PROJECT NAME A 0 1 2 3 4 5 6 7 8 A 0 1 2 3 4 5 6 7 8 A 0 1 2 3 4 5 6 7 8 I O GROUP 00 07 10 17 I O GROUP 00 07 10 17 I O GROUP 00 07...

Page 50: ...l and damage to equipment disconnect all AC and DC power to the Controller before attempting any wiring installation within the enclosure The specific wiring required for each type of I o module is de...

Page 51: ...m are described below Consult the Module s Product Data Sheet for specific wiring connections Strip approximately 3 ft of insulation from the Belden 8761 Cable at the Field Wiring arm end Peel the shi...

Page 52: ...8 Field Wiring Arm Leave Sufficient Slack for Pivoting Figure 3 29 Peeling Foil Shield 1 pair of insulated wires Shield s bare wire Shield s foil strip 10707 I Artisan Technology Group Quality Instrum...

Page 53: ...ng Twist foil and bare wire togeth er White wire Black wire 10708 I Figure 3 31 Trimming Unnecessary Insulated Wire 30 twisted shield 2 wire Strip 3 8 insulation off Wire trimmed off 10709 I Artisan T...

Page 54: ...ding connections results in faulty operation refer to Article 250 21 of the National Electric Code This Article recommends methods of reducing objectionable ground currents Local Codes and Ordinances...

Page 55: ...o the Controller It is intended for any situation where the operator must quickly de energize I o devices When replacing any module replacing output module fuses or working on equipment within the enc...

Page 56: ...In addition to repositioning the jumpers for 220 240V AC operation the main AC fuse of the System Power Supply must be changed The Power Supply is shipped with a 1 amp slow blow fuse installed to acc...

Page 57: ...that the System Power Supply is correctly jumpered for either 120V or 220 240V AC Incorrect jumpering on the terminal strip may cause improper operation or damage to the Power Supply Artisan Technolo...

Page 58: ...cable connections sockets and connectors are configured to mate only in the proper way Cable connections between the Processor and the Industrial Terminal can be made with power applied to both the P...

Page 59: ...2 Isolation X 1 X 2 To minimize EMI generation connecting a supression network is recommended for 120V AC Allen Bradley cat no 1691 N2 for 220 240V AC Electrocube part no RG 1676 13 To minimize gener...

Page 60: ...s CRM CRM 1 4 H 3 H 2 Isolation X 1 X 2 To minimize EMI generation connecting a supression network is recommended for 120V AC Allen Bradley cat no 1691 N2 for 220 240V AC Electrocube part no RG 1676 1...

Page 61: ...0V AC 120V AC L2 EQUIP GND 10132 I Jumper positions indicated at side of terminal strip Figure 3 37 Industrial Terminal Connection Channel A INTERFACE Industrial Terminal 10133 I Cat No 1772 TC 10 Fee...

Page 62: ...those that allow machine motion with power applied to all devices which are controlled by the User Program WARNING Machine motion during system checkout can cause injury to personnel or damage to equi...

Page 63: ...is to check out the system with power applied to all devices except those that cause machine motion Status Indicators Industrial Terminal Use The system is checked out by comparing the actual I O dev...

Page 64: ...Industrial Terminal Cat No 1770 T3 Input Device On or Off Input module Indicator 10134 I Hardware Indicator Comparison Procedures WARNING Machine motion during this procedure can cause injury to pers...

Page 65: ...ssor 2 Turn the Mode Select Switch on the Processor to the PROG position 3 Apply proper AC power to the Controller s Power Supply 4 Turn the Industrial terminal power switch ON 5 After the MODE SELECT...

Page 66: ...ate the switch 3 For each input terminal manually turn the corresponding input device ON and OFF Observe the display and the corresponding Input Module indicator to verify the correct state is indicat...

Page 67: ...Module to be tested The state of each output in the selected Module Group will be displayed 4 Use the and keys to cursor over to the output to be tested Press 1 to turn the output ON Press 0 to turn...

Page 68: ...energize the Master Control Relay This removes all power from the machine Perform the final system checkout as follows 1 Turn the Processor s Mode Select Switch to the PROG position Press SEARCH to di...

Page 69: ...e will be the more difficult output devices to check out than those that cannot be independently tested The machine motion should be enabled as gradually as possible thereby allowing any problems to b...

Page 70: ...lean and straight Install the blank EPROM in the Processor as described in Section 3 5 2 Reinstall the Processor in the I O Chassis and restore AC power 4 Connect one end of the Power Supply Cable Cat...

Page 71: ...i PLC 2 15 Processor will blink ON and OFF When EPROM programming is successfully completed the Memory LED will turn OFF If the Memory LED stays ON after programming either the EPROM is faulty or an e...

Page 72: ...in improper function of the Controller but may also result in damage to the components of the system WARNING To ensure personal safety and to guard against damaging the equipment all connections shou...

Page 73: ...to cycle or remove line power as contact with AC potentials may cause injury to personnel In addition to the flowchart the troubleshooting chart Table 5 B provides a quick summary of corrective proce...

Page 74: ...word capacity 1 1772 CD Mini PLC 2 15 Processor Transport Cable 1 ft 30 5 cm 1 1772 LV Mini PLC 2 15 Processor 1 1772 TC Program Panel Interconnect Cable 10ft 3 05 m I O 1 or 10 1771 1771 I O Modules...

Page 75: ...o determine whether power is getting to the backplane Although measurements do not provide a complete diagnosis of the Power Supply they can identify problems during troubleshooting A voltmeter accura...

Page 76: ...PPLY RELOAD PROGRAM IF NECESSARY AND RECHECK CONTROLLER CORRECT LINE VOLTAGE RECHECK CONTROLLER D C B A YES NO YES NO YES YES NO NO NO YES NO YES YES NO 10138 I CONTROLLED IN RUN OR RUN PROG MODE OUTP...

Page 77: ...LEM RESTART CONTROLLER VERIFY PROPER OPERATION RESTART CONTROLLER VERIFY PROPER OPERATION HAS THE POWER SUPPLY LOAD EXCEEDED 6 5 AMPS REMOVE SYSTEM POWER REPLACE SYSTEM POWER SUPPLY REDUCE POWER SUPPL...

Page 78: ...DISPLAYS RUNG WHERE ERROR OCCURED AND DESCRIBES ERROR CORRECT THE RUN TIME ERROR PRESS SEARCH 5 9 0 FOR RUN PROG OR TURN KEY SWITCH BACK TO RUN VERIFY PROPER OPERATION TURN MODE SELECT SWITCH TO PROG...

Page 79: ...ower Supply Follow these steps to measure the voltages at the end of the I O Power Cable that connects to the I O Chassis 1 Turn the Processor s Mode Select Switch to the PROG mode Support Processor m...

Page 80: ...ARY IS THE OUTPUT MODULE INDICATOR ON YES REMOVE I O POWER DISCONNECT WIRING AT FIELD WIRING ARM TERMINAL RESTORE I O POWER IS THE OUTPUT MODULE INDICATOR ON REMOVE SYSTEM POWER AND I O POWER REPLACE...

Page 81: ...Mode Select Switch to PROG 2 If a run time error occurred correct it 3 If a Processor fault occurred turn keyswitch back to TEST or RUN 4 Replace Processor R or R P OFF OFF OFF ON 1 Check AC line volt...

Page 82: ...is jumpered according to the line voltage 6 Connect the terminal strip wiring and the I O Power Cable to the Power Supply 7 Restore system power There are three indicators on the Processor that are us...

Page 83: ...a run time error press 1 1 for PLC 2 mode The Industrial Terminal will display the rung and intensify the instruction where the run time error occurred This instruction could be the cause or the effe...

Page 84: ...details 6 Install the Processor in the I O Chassis 7 Restore AC power 8 Disconnect the external battery pack from the Processor 9 Connect the 1770 T3 Industrial Terminal and correct the run time erro...

Page 85: ...M after the User Program is verified The I O Modules are powered by the 5 1V DC signal carried across the backplane to the backplane connectors The I O devices connected to the Module s Field Wiring A...

Page 86: ...power source supplying the Field Wiring Arm Failure to remove this external power source causes voltage to be present at Field Wiring Arm terminals 1 Place Mini PLC 2 15 Processor in the PROG mode an...

Page 87: ...upply does not remove the external power source supplying the Field Wiring Arm Failure to remove this external power source causes voltage to be present at the Field Wiring Arm terminals 1 Place the M...

Page 88: ...1 OC 48V DC OUTPUT MODULE ALLEN BRADLEY CO SYSTEM DIVISION CLEVELAND OHIO Remove these 2 Front Screws to remove Cover over Fuses Cover on reverse side 10705 I Figure 5 4 Output Module Fuses Fuses 1077...

Page 89: ...sation Input Voltage nominal 120V AC 50 60 Hz 220 240V AC 50 60 Hz The Mini PLC 2 15 Processor Module has the following specifications Memory Size 2048 2K words Memory Type CMOS RAM optional 2K EPROM...

Page 90: ...nd One 1771 I O Rack 128 I O Location Side plate of Bulletin 1771 I O Chassisor up to 5 cable feet above I O Chassis Battery Type 2 Alkaline D size 1 5V or Lithium D size 3 4V Weight 13 lbs 5 85 Kg Di...

Page 91: ...1771 A4 contains 16 I O slots 8 Module Groups The Industrial Terminal System Cat No 1770 T3 has the following specifications Input Voltage nominal 120V AC220 240V AC Input Voltage Range 98 132V AC 120...

Page 92: ...Input Fuse 2 5 Battery Pack 2 4 Diagnostic Indicators 2 8 Field WIring Arms 2 12 I O Modules 2 11 I O Power Cable 2 4 Industrial Terminal 2 14 INTERFACE Socket 2 11 Memory Write Protect 2 11 Mode Sel...

Page 93: ...h 2 10 Module Chart 2 5 Groups 2 15 Motion Machine 4 7 Mounting I O Chassis 3 17 Power Supply 3 17 O Optional Power Supply 2 7 P Power Supply Checkout 4 2 Fuse Replacement 5 3 Indicators 2 6 Specifica...

Page 94: ...eshooting General 5 1 Power Supply 5 2 Processor 5 11 U User Supplied Equipment 2 14 V Voltage Measurement Power Supply 5 4 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE ww...

Page 95: ...nited Kingdom United States Uruguay Venezuela Yugoslavia World Headquarters Allen Bradley 1201 South Second Street Milwaukee WI 53204 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Allen Bradley has been h...

Page 96: ...uipment Have surplus equipment taking up shelf space We ll give it a new home Learn more Visit us at artisantg com for more info on price quotes drivers technical specifications manuals and documentat...

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