Honeywell ML200 Series Installation And Commissioning Manual
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Honeywell ML200 Series Installation And Commissioning Manual

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ML200 Installation and Commissioning Guide
EPDOC-X366-en-515A
November2019

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Summary of Contents for Honeywell ML200 Series

  • Page 1 ML200 Installation and Commissioning Guide EPDOC-X366-en-515A November2019...
  • Page 2 Honeywell International Sàrl. While this information is presented in good faith and believed to be accurate, Honeywell disclaims the implied warranties of merchantability and fitness for a purpose and makes no express warranties except as may be stated in its written agreement with and for its customer.

  • Page 3: Table Of Contents

    Contents Chapter 1 - Masterlogic components 1.1 Types of CPUs 1.2 Types of power supply 1.3 Types of modules 1.4 Types of base 1.5 Types of cables Chapter 2 - Calculating the power supply for components 2.1 Power module specifications 2.2 Selecting the power supply Chapter 3 - Plan and Install MLPLC 3.1 Plan for Engineering Station...

  • Page 4: Chapter 1 - Masterlogic Components

    CHAPTER ASTERLOGIC COMPONENTS Types of CPUs The following are the types of CPUs of the MasterLogic-200 PLC system. Non redundant PLCs 2MLI-CPUU 2MLI-CPUH 2MLI-CPUS 2MLI-CPUS/P Redundant PLC 2MLR-CPUH/T 2MLR-CPUH/F The following naming conventions are used across the document. 2MLI-CPUU, 2MLI-CPUH, and 2MLI-CPUS are represented as ML200-IEC. 2MLR-CPUH/T and 2MLR-CPUH/F are represented as ML200R.
  • Page 5 Chapter 1 - Masterlogic components Model Number Specification 2MLP-ACF1 Free Voltage (AC 110V,220V)/DC5V, 3A, DC24V,0.6A 2MLP-ACF2 Free Voltage(AC 110V,220V)/DC5V, 6A 2MLP-AC23 AC 220V/DC 5V, 8.5A 2MLP-DC42 DC 24V/DC 5V Table 2: Power modules for 2MLI CPUS/P Model Number Specification 2MLR-AC12 Redundant power AC 110V, 5.5A 2MLR-AC22 Redundant power AC 220V, 5.5A...
  • Page 6 Chapter 1 - Masterlogic components 2MLP- 2MLP- Items 2MLP-AC23 2MLP-DC42 ACF1 ACF2 Output1 Output voltage DC 5V (±2%) DC5V (±2%) Output current 3.0A 6.0A 8.5A 6.0A Over current protect 3.2A or 6.6A or 9.0A or 6.6A or more more more more Over voltage protect 5.5V ~ 6.5V Output2...

  • Page 7: Types Of Modules

    Chapter 1 - Masterlogic components 2. Over current protection: If the current is more than the standard and flows in DC 5V, DC 24V circuit, the over current protection device shuts down 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.
  • Page 8 Chapter 1 - Masterlogic components Item Type Description Digital input module 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 input, 64 points (current source/sink input) 2MLI-D22B DC 24V input, 16 points (current source input)
  • Page 9 Chapter 1 - Masterlogic components Item Type Description Analog input module 2MLF-AV8A Voltage input, 8 channels 2MLF-AC8A Current input, 8 channels 2MLF-AD8A Voltage or current input, 8 channels 2MLF-AD4S Voltage or current input, 4 channels, Isolated 2MLF- Voltage or current input, 16 channels AD16A 2MLF-AC4H Current input, 4 channels...

  • Page 10: Types Of Base

    Chapter 1 - Masterlogic components Item Type Description Snet 2MLL-C22A Serial communication, RS-232C 2channels 2MLL-C42A Serial communication, RS-422 2channels 2MLL-CH2A Serial communication, RS-232C/RS-422 (1ch each) Dnet 2MLL-DMEA DeviceNet interface module FEnet 2MLL-EFMT Fast Ethernet, 100/100Mbps, RJ-45 (Electric) 2MLL-EFMF Fast Ethernet, 100/100Mbps, SC Type (Fiber Optic) Pnet 2MLL-PMEA Profibus, master, 12Mbps, DP Standard...
  • Page 11 Chapter 1 - Masterlogic components The following image illustrates the main base of ML200-IEC. Figure 1: Main base of ML200-IEC The following table lists the details of the main base. Table 10: Details of main base Index Part Function Base attached guide For attaching the main base to the panel in the control hole panel.
  • Page 12 Chapter 1 - Masterlogic components PLC types Part number Description ML200-IEC 2MLB-E04A Expansion base 4 slot 2MLB-E06A Expansion base 6 slot 2MLB-E08A Expansion base 8 slot 2MLB-E12A Expansion base 12 slot The following image illustrates the expansion base of ML200-IEC. The following table lists the details of the expansion base.
  • Page 13 Chapter 1 - Masterlogic components Table 13: Types of bases for ML200R PLC types Part number Description ML200R 2MLR-M02P Main base 2 slot 2MLR-M06P Main base 6 slot The following image illustrates the 2MLR-M02P. Figure 2: Main base of 2MLR-M02P The following image illustrates the 2MLR-M06P.
  • Page 14 Chapter 1 - Masterlogic components Index Part Function Base attached For attaching the main base to the panel in the control guide hole panel. Power module For installation of the Power supply module. connector CPU module For installation of the CPU module (2 slots). connector Module built-in For installation of the communication modules.
  • Page 15 Chapter 1 - Masterlogic components Figure 4: Expansion base of ML200R (without dual I/O link redundancy) The following table provides the expansion base details of ML200R, without dual I/O link redundancy. Table 16: Expansion base details of ML200R Index Part Function Base attached guide For attaching the main base to the panel in the control...

  • Page 16: Types Of Cables

    Chapter 1 - Masterlogic components The following image illustrates the expansion base of ML200R, which supports dual I/O link redundancy. Figure 5: Expansion base of ML200R (with dual I/O link redundancy) The following table provides the expansion base details of ML200R, with dual I/O link redundancy. Table 18: Expansion base details of ML200R Index Part Function...
  • Page 17 Chapter 1 - Masterlogic components Figure 6: Expansion cable connection for ML200 IEC Cables for ML200R Expansion cable connection Expansion cables are Ethernet cables used for connecting the main bases and expansion bases. The expansion cables are classified into the following two categories. Optical cable Ethernet cable The electrical and optical cables are provided for use in accordance with the network type.
  • Page 18 Chapter 1 - Masterlogic components Ethernet cables The communication between the Ethernet cables is achieved through 100MB twisted pair cables. However, the data transmission in expansion cables is in 10s of micro units. As external noise affects the system performance and control, the Ethernet cables used in ML200R systems must be twisted pair cables such as UTP, FTP, STP, or FSTP cables.

  • Page 19: Chapter 2 - Calculating The Power Supply For Components

    CHAPTER ALCULATING THE POWER SUPPLY FOR COMPONENTS Power module specifications The following table lists the power specifications for all the modules within the PLC. Table 20: Power specifications Module Types of Model Current consumption (mA) Non redundant CPU Module 2MLI-CPUU 2MLI-CPUH 2MLI-CPUS 2MLI-CPUS/P...
  • Page 20 Chapter 2 - Calculating the power supply for components Module Types of Model Current consumption (mA) Digital Input Module (AC 110V) 2MLI-A12A Digital Input Module (AC220V) 2MLI-A21A Relay output module 2MLQ-RY1A 2MLQ-RY2A 2MLQ-RY2B Digital Output Module (Transistor) 2MLQ-TR2A 2MLQ-TR2B 2MLQ-TR4A 2MLQ-TR4B 2MLQ-TR8A 2MLQ-TR8B...

  • Page 21: Selecting The Power Supply

    Chapter 2 - Calculating the power supply for components Module Types of Model Current consumption (mA) FEnet Module 2MLL-EFMF 2MLL-EFMT Snet Module 2MLL-C22A 2MLL-C42A 2MLL-CH2A Profibus-DP Module 2MLL-PMEA Profibus Remote Interface 2MLL-PSRA Profibus Remote Slave Interface 2MLL-PSEA Selecting the power supply The selection of a power module is determined by the current and voltage needed by the system.
  • Page 22 Chapter 2 - Calculating the power supply for components Example of current consumption/power calculations for ML200R This section describes which power supply module must be used in coordination with the corresponding modules for ML200R. Main base Type Model Quantity Voltage (5V) CPU Module 2MLR-CPUH/F 1.31A...
  • Page 23 Chapter 2 - Calculating the power supply for components 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 the current consumption is 3/7 of the output power. The calculation is as follows: = 3/7 {(I5V X 5) + (I24V X 24)} (W) I (DC Current consumption of DC 5V circuit of each module (internal current...
  • Page 24 Chapter 2 - Calculating the power supply for components i. W X E X Input point X Simultaneous ON rate (W) ii. I : Input current (actual value in case of AC) (A) iii. E: Input voltage (voltage in actual use) (V) 6.

  • Page 25: Plan For Engineering Station

    CHAPTER MLPLC LAN AND NSTALL Plan for Engineering Station 3.1.1 Platform requirements The SoftMaster is installed in the Engineering station. The following table lists the system requirements for installing SoftMaster. Table 21: System requirements for installing SoftMaster Item Specification Personal computer and memory A Pentium computer and 128 MB memory COM port RS-232C serial port or USB port...

  • Page 26: Chapter 3 - Plan And Install Mlplc

    Chapter 3 - Plan and Install MLPLC Basic/expansion base, power module, CPU module, expansion driver (only for ML200R), I/O modules. Synchronization cable (only for ML200R) and expansion cable. USB programming cable. SoftMaster (PLC Configuration and Programming Software) Environmental conditions Install PLC in a control panel, which is waterproof and can withstand vibration. ○...
  • Page 27 Chapter 3 - Plan and Install MLPLC Precautions for installing the base The following precautions must be taken while installing a PLC on the Control Panel. Ensure sufficient ventilation for the modules, especially the upper part of the modules. In addition, this helps in changing the modules, if required.
  • Page 28 Chapter 3 - Plan and Install MLPLC 8. 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. 9. Installing a base on top of another leads to a rise in temperature of the cabinet. Install a fan for air circulation or keep maximum distance between the bases.

  • Page 29: Grounding Requirements

    Chapter 3 - Plan and Install MLPLC ATTENTION If bases are installed without adequate spacing, the air temperature (Tb + Tr) may rise up to 15°C for the fiber optic module and the module installed right above the power module. Ensure that air temperature around the module does not exceed 55°C.

  • Page 30: Precautions For Installing/Handling The Plc Modules

    Chapter 3 - Plan and Install MLPLC 5. Use more than 2mm cables for grounding. Place the earth point near the PLC as much as possible to limit the length of grounding cable. 6. Separate Line Ground (LG) of power module and Frame Ground (FG) of base board for grounding.

  • Page 31: Mounting Chassis

    Chapter 3 - Plan and Install MLPLC 5. Wiring The I/O must be wired using high-voltage cables or power cables. Lower-voltage wires can cause inductive disturbance that may result in abnormalities or failure of the PLC operation. Ensure that the cables do not pass in front of the I/O operation indicator (LED), as it may obstruct the indicator.
  • Page 32 Chapter 3 - Plan and Install MLPLC Step Action Loosen the cover from the base by unscrewing the screw on top of the cover. Remove the cover from the base as illustrated in the following image. Insert the projection on the lower part of the module into the module-fixing hole of the PLC base, as shown in the figure.
  • Page 33 Chapter 3 - Plan and Install MLPLC Figure 11: Inserting a module While 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.
  • Page 34 Chapter 3 - Plan and Install MLPLC Installation of terminal board for I/O module Perform the following for I/O modules with less than 32 points. 1. Remove the terminal board by unscrewing the black screws. 2. Connect field wires onto the terminal board. 3.

  • Page 35: Achieving The Topology

    Chapter 3 - Plan and Install MLPLC Step Action From the base, loosen the fixed screws on the upper part of the module. Hold the module and thoroughly press the fixed hook of the module. By pressing the hook, pull the upper part of the module from the axis of the lower part.
  • Page 36 Chapter 3 - Plan and Install MLPLC Figure 13: ML200-IEC architecture ATTENTION The base has its base number as ‘0’ and the expansion base has a switch to set the base number. The module starts operating once the the module type and I/O parameter are set using SoftMaster and the correct module type is mounted on the base.
  • Page 37 Chapter 3 - Plan and Install MLPLC Connecting the Terminating resistance ATTENTION This section is not applicable for 2MLI CPUS/P. If a system requires the main base and the expansion base to be connected, the terminating resistance must be attached to the expansion connector (OUT) of the last expansion base. The terminal resistance is not required to be installed, if the system has only the main (without expansion bases).
  • Page 38 ON (right): For normal CPU operation mode. OFF (left): Downloads new operating system. It is reserved for use by Boot/Nor Honeywell factory/authorized personnel. Switching to this position by user switches is strictly prohibited. Note: Both Boot/Nor switches must always be set to the ON (right) position.
  • Page 39 Chapter 3 - Plan and Install MLPLC Achieving the topology for ML200R ML200R has a redundant system for CPU, power supply, and communication modules. Install two identical sets of main bases consisting of same power supply, CPU, and communication modules and connect two CPU modules with synchronization cable. One of the two CPU modules is a master system in control of the main operation and another is a standby system for backup control, if the master fails during operation.
  • Page 40 Chapter 3 - Plan and Install MLPLC Both CPU modules must have the same version of the operating system. The configuration of both the CPU modules must be in the same sequence. For example: If 2MLL-EFMT is installed in the slot 0 of CPU-A, 2MLL-EFMT in the CPU-B must be installed in the slot 0.
  • Page 41 Chapter 3 - Plan and Install MLPLC Fiber Optic cable : Tx to Rx, Rx to Tx (Multi-mode FO, LC connector type) The following image illustrates the ML200R architecture with dual I/O link redundancy. Figure 16: ML200R architecture with dual I/O link redundancy ATTENTION The images illustrate the architecture of 2MLR-CPUH/T (Electrical).
  • Page 42 Chapter 3 - Plan and Install MLPLC Item ML200R Comprises of Main Base Two main base with identical module Maximum 31 Expansion bases Expansion Base Max. I/O Up to 372 (31 X 12) I/O modules (Up to 372 (31 X 12) I/O modules can modules be installed in expansion base.) Maximum...
  • Page 43 Chapter 3 - Plan and Install MLPLC Item ML200R Comprises of of I/O points) is assigned to main base and main base has station number of 0. Address in main base ATTENTION The base has its base number as ‘0’ and the expansion base has a switch to set the base number.

  • Page 44: Turn On And Start Up

    ON (right): For normal CPU operation mode. OFF (left): Downloads new operating system. It is reserved BOOT/NORMAL for use by Honeywell factory/authorized personnel. switch Switching to this position by user is strictly prohibited. Note: Both Boot/Nor switches must always be set to ON (right) position.
  • Page 45 Chapter 3 - Plan and Install MLPLC Ensure that the modules are mounted correctly in both the CPU base and the I/O base. Ensure the following: Synchronization cable is connected between Master and Standby CPUs. Expansion cable is connected between I/O racks and CPUs in a Ring Configuration. Ensure that both the CPUs are set to different CPU sides.
  • Page 46 Chapter 3 - Plan and Install MLPLC ATTENTION Current leakage may occur if the wiring is connected for distances greater than 200m. This may be caused by the capacitance. Power wiring Perform the following steps for power wiring. 1. Connect a voltage regulated transformer, if the power variance is higher than the specified range.
  • Page 47 Chapter 3 - Plan and Install MLPLC 4. AC 110V/AC 220V/DC 24V cables must be properly twisted and connected with the shortest distance. 5. AC 110V/AC 220V cable must be as thick as possible (2mm ), to reduce the voltage drop. AC 110V/ DC 24V cables must not be installed close to the main circuit cable (high voltage/high current) and I/O signal cable.
  • Page 48 Chapter 3 - Plan and Install MLPLC Description Specifies the operation status of the CPU module. Green light: Implies the CPU operation is in ‘RUN’ mode either by any of the following: ‘RUN/STOP’ switch in CPU set to RUN mode. REMOTE ‘RUN’...
  • Page 49 Chapter 3 - Plan and Install MLPLC Description Expansion base power error. Red Blink: Arithmetic Operation Error during RUN. OFF: Normal operation. LED indicators for ML200R The following table describes the LED indicators for ML200R. Table 26: LED indicators for ML200R Description RUN/STOP Specifies the operation status of the CPU module.
  • Page 50 Chapter 3 - Plan and Install MLPLC STOP mode DEBUG mode ATTENTION Refer to ML200 CPU and SoftMaster User’s Guide for further information about the module state transition. Changing operation mode The following methods are used for changing the operation mode. Using the mode key of the CPU module.
  • Page 51 Chapter 3 - Plan and Install MLPLC Remote mode can be changed with ‘Remote: On’ and ‘Mode switch: Stop’ To change the remote ‘RUN’ mode to ‘Stop’ by switch, move the switch (STOP) > RUN > STOP. ATTENTION While changing the remote ‘RUN’ mode to ‘RUN’ mode using the switch, the PLC operates continuously without suspension.
  • Page 52 Chapter 3 - Plan and Install MLPLC I/F : ON RING : ON Tx/Rx and LINK : ON (At least one of two ports should blink) ATTENTION When the system is started for the first time an error may appear. Rectify the errors and bring back PLC to the Run state.

  • Page 53: Chapter 4 - Troubleshooting

    CHAPTER ROUBLESHOOTING 4.1 Overview This chapter describes the types of potential errors that may occur while operating the system, causes of errors, ways 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.
  • Page 54 Chapter 4 - Troubleshooting Phenomena Causes Measures Leakage current of an Connect a proper resistance or external device capacitor so that the voltage between terminals of input module is (if operating by less than the return voltage. proximate switch and others).
  • Page 55 Chapter 4 - Troubleshooting Phenomena Causes Measures plural different preventive diode. See the following power sources. figure. Input signal cannot be off Trouble types and measures of output circuit The followings table lists examples of common faults and the recommended measure. Phenomena Causes Measures...
  • Page 56 Chapter 4 - Troubleshooting Phenomena Causes Measures Leakage current from surge absorbing Operate the C-R type Abnormal time circuit connected to an output element in timer by mediating a when load is a parallel. relay. C-R type timer Use other one but a C- -R type timer.
  • Page 57 Chapter 4 - Troubleshooting Phenomena Causes Measures Output transistor is destructed. As soon as it lights up, it may have 10 times higher inrush current. Source type transistor output Error codes list Measures Operation Diagnostic Code Error Causes Restart mode after the Status Status Timing...
  • Page 58 Chapter 4 - Troubleshooting Measures Operation Diagnostic Code Error Causes Restart mode after the Status Status Timing measure. still exists after turning it turning it on again. Abnormal base Contact A/S service if it STOP ERR : On When information still exists after turning it turning it on on again.
  • Page 59 Chapter 4 - Troubleshooting Measures Operation Diagnostic Code Error Causes Restart mode after the Status Status Timing measure. reloaded, check the storage condition and if any fault is found, replace the CPU module. The module set in Check the wrong slot STOP ERR : On Converting...
  • Page 60 Chapter 4 - Troubleshooting Measures Operation Diagnostic Code Error Causes Restart mode after the Status Status Timing measure. Special/link Check the position of a STOP ERR : On When the module data slot with access error by (RUN) (P.S. : scan ends.
  • Page 61 Chapter 4 - Troubleshooting Measures Operation Diagnostic Code Error Causes Restart mode after the Status Status Timing measure. Use of Timer Modify the timer index STOP RUN: When scan Index error program, reload, and (RUN) OnERR : ends. start. Error of external Repair a fault device by STOP ERR : On...
  • Page 62 Chapter 4 - Troubleshooting Measures Operation Diagnostic Code Error Causes Restart mode after the Status Status Timing measure. Redundancy During redundancy STOP E300 Switch to system operating, redundancy synchronous synchronization error operation. operating error. occurs. Standby CPU Restart as redundancy STOP E301 Start...
  • Page 63 Documentation feedback You can find the most up-to-date documents on the Honeywell Process Solutions support website at: http://www.honeywellprocess.com/support If you have comments about Honeywell Process Solutions documentation, send your feedback to: hpsdocs@honeywell.com...
  • Page 64 For support, contact your local Honeywell Process Solutions Customer Contact Center (CCC). To find your local CCC visit the website, https://www.honeywellprocess.com/en-US/contact-us/customer- support-contacts/Pages/default.aspx. Training classes Honeywell holds technical training classes that are taught by process control systems experts. For more information about these classes, contact your Honeywell representative, or see http://www.automationcollege.com. - 2 -...

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