1772-6.6.3 Bulletin 1772 MINI-PLC-2 PROGRAMMABLE CONTROLLER Assembly and Installation Manual ALLEN-BRADLEY ay Cleveland, Ohio 44143Because of the variety of uses for this equipment and because of the differences between this solid stete equi ment and electromechanical equipment, the user of, and ‘those responsible for applying, this equipment must satisfy themselves as to the acceptability of each applica: ion and_use of the equipment. Inno event will Allen Bradley Company be responsible or liable for indirect or ‘consequential damages resulting ‘rom the use or applica: tion of this equipment, The illustrations, charts, and layout examples shown in this manual are intended solely ‘0 illustrate the installa tion "and “woubleshooting principles of ‘programmable controllers and some of the methods used to apply them ‘0 machine or process control. Particularly because of the Many variables and requirements associated with any particular installation, Allen-Bradley Company cannot assume responsibility or liability for actual use based upon the illustrative uset or applications. [No patent liability is assumed by Allen-Bradley Company with respect to use of information, circuits, equipment or software deseribed in this text. Reproduction of the content of this manual, in whole or in part, without written permission of the Allen-Bradley Company is prohibited. Copyright ©1978 Allen-Bradley Company History of Printing! First Edition ~ December, 1979i Paragraph RoREST BOSS Shpyepepprsmnyss” pee ee eeernneeeens 2WWL WULEUOEBODOBESHBMwWBBoE 88 Roetbnaaahases® SSSSESEE™ KSSSSS: BRERS TABLE OF CONTENTS Title General INTRODUCTION PC Definition Lt Organization of Manual PC installation and Start-Up ‘Support Documentation CONTROLLER DESCRIPTION Components oes eee 110 Chassis Assembly Mini-Processor Module 1/0 Modules ‘Wiring Arms S:Digit Address urput Fuses =: : Bulletin 1777/1778 Compatibility ‘system Power Supply Tnput-Line Monitoring Fuse Power Cable Battery Pack ‘Get. No. 1777-88 Battory Pack Gat, No. 1771-BP Battery Pack Program Panels . User Supplied Equiprient ASSEMBLY AND INSTALLATION General oe : Recommendations for System Layout Enclosure Considerations : ‘Component Spacing ‘Typical Condition Worst-Case Condition Wiring Layout Layout Examples Grounding Mester Control Relay Gormon AC Source ransformer Rating Special Considerations Excessive Heat Excessive Noise : Constant Voltage Transformer Procedures for Installation Battery Pack. ‘Cat, No. 1771-88 Battery Pack Gat No. 1771-BP Battory Pack Mounting - Input Power Connection Power Cable Connection Last State Switch 170 Module Installation and Wiring Preparation. Procedures Shielded Cable ‘Mini-Processor Installation Program Panel Connection 'PLC-2 Program Panel Connection PLC Program Penel/Adapter Connection SYSTEM START-UP ‘Start-Up Procedure : Gheckour Before Power is Connected Hiardware/Indicator Comparison MO Module Indicators ‘Input Modules Output Modules Program Panel Indicators ‘Comparison Procedures Page SUBSRREREEENRERET sageeszene egegees Rye oer eee gartenttParagraph Title Testing Inputs Testing Outputs 1 Use of Push Bution 2 Use of FORCE Function : “Testing Output Modules — Discennected Devices Checkout of Machine Motion. ‘TROUBLESHOOTING General ao6 : . Mini-Processor Nioduls Diagnostic Indicators Mode Select Switch INTERFACE Socket Program Pane! Messagae Power Supply : Power Supply Indicators Dc ON. BATTERY LOW Power Supply Replacement Power Supply Output Battery Replacement Fuse Replacement Troubleshooting Possible Fault Sources 1/0 Hardware Contratier : Troubleshooting Procédure” | Hardware/Indicator Comparison for Troubleshooting Input Troubleshooting ae Output Troubleshooting Rules for Module Replacement VO Module Replacement Mini Processor Replacement ‘Output Module Fuse Replacement ‘SPECIFICATIONS General. Mini-Proceésor nodule ‘System Power Supply. 1/0 Equipment PLC-2 Program Panel PLC Program Panel ‘SUPPLEMENTARY DOCUMENTATION General . S Manuals : Block Diagrams LIST OF FIGURES i Tale Mini-PLC-2 Programmable Controller Components of Mini-PLC-2 Controller Mini-Processor Module Input and Output Modules (typical) Field Wiring Arms... Five-Digit Address ‘System Power Supply Compatible Program Panels | Unobstructed Space Requirements Example Wiring and Duct Layout essere saree F z SEZ QgLEee eeeegeeererergererce SeSEREysEsFigure SSCeaLassasesl geese 3 3 3 3 4 4 4 4 4 5. 8. 8 8 5 5 8. Ey 5 Table 28 BSSee) Title Example Layout ~ Typical Spacing Example Layout — Separately Mounted Supply, Example Layout — Worst-Case Spacing Controller Grounding Connections Maser Control Relay Configuration Typical Interference Suppressica for Smal Apparatus Typical Interference Suppressicn for Large Apparatus ‘Typical Interference Suppressica for 3-Phase Apparatus Typical Interference Suppressicn for DC Relays Mounting Hardware Set (Cat. No. 1771-BX) at, No. 1771-B8 Battery Pack at. No. 1771-BP Battery Pack Cthium Battery Placement Mounted Plastic Battery Shell ‘System Power Supply Dimensions 1/0 Chassis Dimensions (Power Supply Separate) YO Chasis Dimensions (Mouried Fower Supoly) Bolt Mounting Assembly Stud Mounting Assembly Power Supely Input Connections 1/0 Chassis Backplane Power Cable Connection Switch Group Accembly, Wiring Arm Labeling Indicator Labeling Module Keying Bands 1/0 Module Insertion Bundling Wire to the Arm" ‘Snapping Wiring Arm onto Chassis Wiring a Terminal Completed Terminal Wiring Completed Module Wiring Wiring Arm Pivoting Removing Cable Jacket Peeling Feil Shield “Twisting Shield Foil and Wire Trim Unnecessary Insulated Wire Shielded Cable Connection Shield Protection at User Device PLC-2 Program Panel Connection ‘Connecting for 120 oF 220V Operation PLC Program Panel Connection Extended Cable Wiring Diagrant MO Device Status Indicators 1/0 Module Status Indicators Rung for Inout Teng Fung for Ourout Testing ~ Push Button Use Fung for Outout Testing — FORCE Function Use MiniProcessor Diagnostic Indivators Mode Select Switch Power Supply Indicators ‘System Power Supply Voltages Possible Controller Fault Sources ‘Troubleshooting Flow Chart Module Removal : ‘Screws for Fuse Access Output Module Fuses LIST OF TABLES Title Module Reference Chart 110 Modules Requiring Shielded Cable Connections ‘Adapter Cable Extension — Parts List Program Panel Status Indication Fault Summary Mini-PLC-2 Spare Fuse List 39 EeCEe Cee ee eeees eee eEEEEHE 320 eee 42 BESSLLSSLE peroonPage 1-1 Section 1 INTRODUCTION 1.0 General — The Bulletin 1772 Mini-PLC-2 program: ‘able controller is a microprocessor-based controller for industrial applications. Adaptable in size and configura. tion, it can monitor and control up to 128 input and ‘output (1/0) devices. (Refer to Figure 1.1) “The controller has a central control logic unit — the Mini Processor Module, and a number of user-selected 110 Modules, chosen for the number and types of 1/0 deviess in the application. By selecting the appropriate modules, a User assembles his Mini-PLC-2 controller around the re {uirements of his application. ‘The selected 1/0 modules and the Mini-Processor Module are all housed in a single Chassis which ean be mounted ‘within an enclosure of inch working depth, 1.1 PC Definition — A programmable controller (PC) isa solid-state logic control device for industrial applications. As the term “orogrammable” indicates, ine controller hae {an essential difference from hard-wired controls. Its loge function is determined by a user-entered program, which specifies how output devices operate in response to input devices. Because the program is stored In a read/write memory, 2 change in a controlled process ie accomplished by reprogramming rather than by extensive rewiring, 25 hard-wired control systems require ‘The controller continuously monitors the status of devices connected as inputs, Based on user program instructions, the controller then controls the devices connected a8 out: puts. Input and output devices may be of several types, with various voltage and current ranges. These devices ‘may include any of the following * Limit, float, selector, and pressure switches © Thumbwheel switches * Push buttons * Alarms, indicators, and annunciator panels + Solenoids ‘¢ Motors and motor starters 1 Transducers © Various solid-state devices, including TTL-compatible instrumentation ‘The controller stores all I/O device status data in a central read/write memory. This allows the controller full access to the latest status data in the application. Operations Which can be performed based on this data include the following: ‘Timing (1.0, and 0.1- and 0.01-second time bases) ‘© Counting ‘= Arithmetic operations * Comparison * Data manipulation The Mini-PLC-2 controller program uses readily under standable symbols in a simple format — the ladder dia gram. Manual entry of the ladder diagram program is done through a Program Panel. This device is also used to edit the program and monitor 1/0 device status. In addition, Program Panels can be used to interface the Mini PLC. controller with 2 peripheral data terminal. Data terminals include tape punches/readers, Keybaard/printers, and the Digital Cassette Recorder (Cat. No. 1770-SA). These data terminals allow a variety of additional capabilities, including ‘* Loading/storing the program on magnetic or punched tape * Generating a hard-copy printout of program '* Generation of various kinds of reports, in @ user-pro- rammed format, Figure 1.1 ~ Mini:PLC-2 Programmable Controller