Allen-Bradley Bulletin 1772 Assembly And Installation Manual
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Allen-Bradley Bulletin 1772 Assembly And Installation Manual

Allen-Bradley Bulletin 1772 Assembly And Installation Manual

Mini-plc-2/15 programmable controller
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Bulletin 1772 Mini-PLC-2/15
Programmable Controller
Assembly and Installation Manual

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  • Page 1 Bulletin 1772 Mini-PLC-2/15 Programmable Controller Assembly and Installation Manual...

  • Page 2: Table Of Contents

    Table of Contents Introduction ........General .
  • Page 3 Table of Contents Specifications ........General ......... . . Mini-PLC-2/15 Processor .

  • Page 4: Introduction

    Chapter Introduction General The Bulletin 1772 Mini-PLC-2/15 Programmable Controller is a digital, electronic, solid state industrial programmable controller capable of monitoring and controlling up to 128 I/O devices. The Controller has a Processor, a power supply and a number of user-selected I/O Modules chosen for the number and type of I/O devices in the user’s application.

  • Page 5: Pre Assembly & Installation

    Chapter 1 Introduction The Processor stores all I/O device status data in a central read/write memory. This allows the latest status data to be accessible during the scanning of the user program. PC programming instructions allow the Processor to perform: Timing/Counting operations Arithmetic (+, -, x, :) operations Data transfers and comparisons...

  • Page 6: Controller Components

    Chapter Controller Components General The Mini-PLC-2/15 Programmable Controller (Figure 2.1) is made up of the following major components: System Power Supply(Cat. No. 1771-P1) I/O Chassis (Cat. No. 1771-A1, -A2 or -A4) Mini-PLC-2/15 Processor Module (Cat. No. 1772-LV) A number of Bulletin 1771 I/O Modules. Each of these components and their associated cables must be specified by the user when ordering the Mini-PLC-2/15 Programmable Controller.
  • Page 7 Chapter 2 Controller Components Figure 2.1 Mini PLC 2/15 Programmable ControllerComponents Mini PLC 2/15 Processor (Cat. No. 1772 LV) System Power Supply (Cat. No. 1771 P1) I/O Chassis Assembly (Cat. No. 1771 A1, A2, A4) 32 I/O 64 I/O 128 I/O Battery Pack (Cat.

  • Page 8: System Power Supply

    Chapter 2 Controller Components System Power Supply The System Power Supply (Cat. No. 1771-P1) is the required power source for the Mini-PLC-2/15 Controller (Figure 2.1). It converts the incoming AC voltages into the proper DC voltages to power the Processor and I/O Modules. The System Power Supply can operate on either 120V AC or 220/240V AC.
  • Page 9 Chapter 2 Controller Components Battery Pack The Battery Pack (Cat. No. 1771-BB) is shipped standard with the System Power Supply and consists of: A metal Battery Housing (Cat. No. 1771-BH) A mounting Hardware Set (Cat. No. 1771-BX) Two D-size alkaline batteries (Cat. No. 1771-BA) An optional lithium battery (Cat.
  • Page 10 Chapter 2 Controller Components Table 1.A Module Reference Chart Module's Load on Keying Band Field Module Cat. No. System Positions Wiring Arm Color Power Between Nos. (Cat. No. Coded Supply 1771 ) Label AC/DC (120V) Input 1771 IA 74mA 4 6, 10 12 DC (12 24V) Input 1771 IB 74mA...
  • Page 11 Chapter 2 Controller Components Terminal Strip AC input connections are made to the terminals on the Power Supply labeled L1 and L2. L1 is the high side of the AC line and L2 is the low side (Figure 2.2). Power Supply Indicators The two indicators on the front of the System Power Supply (Figure 2.2) are: DC ON BATTERY LOW...

  • Page 12: I/O Chassis

    Chapter 2 Controller Components Optional Power Supply Source It is permissible to use the 1771-P2 Auxiliary Power Supply in place of the 1771-P2 System Power Supply. It should be noted, however, that RAM memory will be lost if an AC power loss occurs. One of two cables is used with this power supply: 1771-CE Power Cable (1 ft/30.5 cm) 1771-CD Power Cable (5 ft/1.5 m)

  • Page 13: Mini Plc 2/15 Processor

    Chapter 2 Controller Components Mini PLC 2/15 Processor The Mini-PLC-2/15 Processor Module (Cat. No. 1772-LV) is the central processing unit and memory of the programmable controller. It has 2K words of memory for the Data Table, User Program and messages. it can monitor and control up to 128 I/O devices that are wired to I/O Modules in the I/O Chassis.
  • Page 14 Chapter 2 Controller Components memory, a discrepancy in memory data, or a parity error. This indicator is normally OFF. In the PROGRAM mode this red indicator is used during EPROM programming. While EPROM programming is in progress, this indicator will blink ON and OFF.
  • Page 15 Chapter 2 Controller Components Mode Select Switch The Mode Select Switch (Figure 2.5) places the Processor in one of four operating modes: PROG - This switch position places the Processor into the PROGRAM mode of operation. The User Program instructions are entered into memory in this switch position.

  • Page 16: Input/Output Modules

    Chapter 2 Controller Components INTERFACE Socket The 15-pin socket labeled INTERFACE is used in connecting the Processor to the Industrial Terminal (Cat. No. 1770-T3) for programming, report generation or monitoring. This socket is also used to connect an external Battery Pack to the Processor so the Processor can be removed from the I/o Chassis without loss of memory.
  • Page 17 Chapter 2 Controller Components Figure 2.6 Typical Input and Output Modules (a) Output Module (b) Input Module 10841 I Field Wiring Arms Wiring to and from user I/O devices connects to a separate Field Wiring Arm for each I/O module. The Field Wiring Arm is a terminal strip that pivots up and down for quick, easy insertion and removal of I/O modules (Figure 2.7) without disturbing filed wiring.
  • Page 18 Chapter 2 Controller Components I/O Addressing Each terminal on a Field Wiring Arm is identified by a 5-digit address (Figure 2.8). The 5 digits in the terminal address directly correspond to a memory location in the Processor’s Data Table and designate the following: The first digit is either a 0 for outputs or a 1 for inputs.

  • Page 19: Industrial Terminal

    Chapter 2 Controller Components Industrial Terminal The Industrial Terminal System (Cat. No. 1770-T3) is used to enter, monitor, edit and troubleshoot the User Program in the memory of the Mini-PLC-2/15 Processor (Figure 2.10). In addition, it can be used for report generation or to interface peripheral devices to the Processor.
  • Page 20 Chapter 2 Controller Components Figure 2.9 Module Groups 32 I/O 64 I/IO 128 I/O 10108-I Figure 2.10 Industrial Terminal (Cat. No. 1770 T3) 10296 I 2 15...

  • Page 21: Assembly And Installation

    Chapter Assembly and Installation General Safety is a primary consideration in programmable controller installations and operations. The procedures in this section consider the safety of the operator, of the controlled equipment and of the Controller. These procedures are intended to supplement the applicable codes and ordinances that govern wiring and installation practices.
  • Page 22 Chapter 3 Assembly and Installation EXCESSIVE HEAT For most applications, normal convection cooling keeps Controller components within the 0 to 60 C ambient operating range. Thus, the proper spacing of components within the enclosure is usually sufficient for heat dissipation. There are however, some applications where a substantial amount of heat is generated by equipment either inside or outside the enclosure.
  • Page 23 Chapter 3 Assembly and Installation Figure 3.1 Typical Suppression for Small AC Inductive Load 120V AC µ Ω Discrete Component Equivalent Allen–Bradley surge Suppressors: Cat. No. 1691–N2: General Purpose Cat. No. 599–K04: Bulletin 509 Starters Cat. No. 700–N5. N9 N24: 700 N Relays Cat.
  • Page 24 Chapter 3 Assembly and Installation Figure 3.3 Typical Suppression for Large AC Inductive Load 120V AC Electrocube Part No. RG1676 14 0.47 V130 LA1 Discrete Component Equivalent General Electric MOV (Metal Oxide Varistor) 10111 I Figure 3.4 Typical Suppression for Small DC Inductive Load V DC PIV (Peak Inverse Voltage) rating of diode must be at least twice the applied DC voltage...
  • Page 25 Chapter 3 Assembly and Installation CONSTANT VOLTAGE TRANSFORMER In applications where the AC line is especially unstable and subject to unusual variation, a constant voltage transformer can be used to stabilize the input voltage to the System Power Supply as well as the input voltage to the user devices.
  • Page 26 Chapter 3 Assembly and Installation Enclosure Considerations An enclosure is usually provided by the user for housing the Mini-PLC-2/15 Controller. The enclosure is the primary means of protecting the Controller from atmospheric contaminants (oil, moisture, conductive dust or particles, or any corrosive or otherwise harmful airborne substance).
  • Page 27 Chapter 3 Assembly and Installation Rule 1 - Allow at least 6 vertical inches above and below all Controller components. when more than one Controller is mounted in an enclosure, allow at least 6 vertical inches between Controllers. Do not mount any component above a 60 C air temperature level.

  • Page 28: General Grounding Information

    (EMI). Allen-Bradley Programmable Controller components and their enclosures must be properly grounded. All applicable Codes and Ordinances should be observed when wiring the Controller.
  • Page 29 (5.08cm) 10114 I PC Component Grounding The recommended configuration for grounding Allen-Bradley Programmable Controller components within an enclosure is illustrated 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.
  • Page 30 Enclosure Grounding The enclosure that contains the Allen-Bradley Programmable Controller components must 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 safely to earth ground with minimum impedance.

  • Page 31: Chassis Pre Assembly

    Chapter 3 Assembly and Installation Chassis Pre Assembly Before the Mini-PLC-2/15 Controller is mounted to an enclosure, the I/O Chassis must be partly assembled. This involves setting the Switch Group Assembly, installing keying bands and installing the Battery Pack. In addition, if the side mounting configuration is used, the System Power Supply should be mounted to the Chassis before the Chassis is mounted to the enclosure back panel.
  • Page 32 Chapter 3 Assembly and Installation Figure 3.10 Ground Connections at Enclosure Wall Enclosure Wall (Inside) Scrape paint on both sides Bolt Star washer Ground lug Enclosure Wall (Outside) Equipment Grounding Conductor Star washer 10020 Switch Group Assembly Located near the lower left side of the I/O Chassis are numbered switches in a Switch Group Assembly (Figure 3.11).
  • Page 33 Chapter 3 Assembly and Installation Figure 3.11 Switch Group Assembly 4 slot I/O Switch Group Assembly 10698 I Battery Pack The Mounting Hardware Set (Cat. No 1771-BX), which consists of two mounting brackets with screws, is mounted to the left side plate of the I/O Chassis (Figure 3-13).
  • Page 34 Chapter 3 Assembly and Installation Install one lithium batter in the front battery compartment, seam side down, with the polarity shown in Figure 3-15. Reconnect the 3-pin connector at the base of the Battery Pack. When the batteries are installed, slide the Battery Pack onto the tracks and tighten the thumbscrew.
  • Page 35 Chapter 3 Assembly and Installation Figure 3.13 Mounting Hardware Set Brackets installed by user Battery Pack slides on tracks 10699 I Figure 3.14 Alkaline Battery Installation Orientation Alkaline Alkaline Battery Battery Battery Contacts 10120a I 10680 I 3 15...
  • Page 36 Chapter 3 Assembly and Installation Figure 3.15 Lithium Battery Installation Orientation Lithium Battery Battery Contacts 10120b I 10680 I Figure 3.16 Keying Band Installation Keying Bands Backplane Socket 10112-I Keying Bands Plastic keying bands (Cat. No. 1777-RK), shipped with each I/O Chassis, can be inserted into the top backplane sockets of the I/O Chassis (Figure 3.16).

  • Page 37: I/O Chassis And Power Supply Mounting

    Chapter 3 Assembly and Installation Before installing the keying bands, I/O Module placement with the I/O Chassis must be determined. A general rule of thumb is to group I/O Modules by signal type. For field wiring guidelines and considerations, refer to Section titled Field Wiring Considerations and Field Wiring Guidelines.

  • Page 38: I/O Chassis Assembly

    Chapter 3 Assembly and Installation I/O Chassis Assembly Once the Chassis and Power Supply are mounted, the remaining Controller parts can be installed in the I/O Chassis. This includes installing the I/O Power Cable, keying bands, EPROM, Processor, Field Wiring Arms and I/O Modules. Figure 3.17 Mounting Assembly Details Scrape paint and use...
  • Page 39 Chapter 3 Assembly and Installation Figure 3.18 I/O Chassis Dimensions 23.4” (59.44cm) 128 I/O 13.4” 64 I/O (34.04cm) 11.25” 10.0” (28.5cm) (25.4cm) 6.75” 14.15” 64 I/O (17.15cm) (35.94cm) 8.51” 128 I/O 24.15” (21.62cm) (61.34cm) 10124-I I/O Power Cable For ease of installation, the I/O Power Cable is installed prior to installing the Mini-PLC-2/15 Processor Module.
  • Page 40 Chapter 3 Assembly and Installation EPROM Installation If the optional EPROM (Cat. No. 1770-XP) is to be used for non-volatile memory, it should be installed in the Mini-PLC-2/15 Processor before the Processor is installed in the I/O Chassis. Refer to the EPROM data sheet, Publication 1770- 915, for a complete description of the EPROM.
  • Page 41 Chapter 3 Assembly and Installation Figure 3.19 Power Supply and I/O Chassis Dimensions 1.55" (3.93cm) 10.0" (25.4cm) 7.16" (18.2cm) 32 I/O 12.71" (32.54cm) 8.51" 64 I/O (21.62cm) 17.71" 128 I/O (44.98cm) 27.71" (70.38cm) Note: For ease of assembly, Power Supply and I/O Chassis should be a unit before mounting. 10125 I 3 21...
  • Page 42 Chapter 3 Assembly and Installation Figure 3.20 System Power Supply Dimensions 2.0” (5.0cm) 10.0” 11.25” (25.4cm) (28.5cm) 7.16” 4.56” (11.6cm) (18.2cm) 10126-I Figure 3.21 I/O Power Cable Thumbscrew 3 Pin Socket I/O Chassis 9 Pin Socket Socket I/O Power Cable 10127 I (Cat.
  • Page 43 Chapter 3 Assembly and Installation Figure 3.22 EPROM Installation Notch Lock 24 Pin EPROM Release 10128 I Line up the right side of the EPROM pin with the right side of the socket and seat the EPROM in the socket. Lock the EPROM in place by pushing the OFF tab toward the right.
  • Page 44 Chapter 3 Assembly and Installation When a pair of I/O Modules (a Module group) is seated, the Module Locking Latch at the the top of the I/O Chassis 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.

  • Page 45: Wiring/Cabling Installation

    Chapter 3 Assembly and Installation Wiring/Cabling Installation Before actually running the signal wiring, refer to the wiring guidelines as outlined under “Field Wiring Considerations” and “Field Wiring Guidelines,” Section titled Field Wiring Considerations and Field Wiring Guidelines. Wiring installation will be discussed as it related to components. WARNING: To avoid injury to personnel and damage to equipment, disconnect all AC and DC power to the Controller before attempting any wiring installation within the enclosure.
  • Page 46 Chapter 3 Assembly and Installation Figure 3.24 Attaching Filed Wiring Arms Wiring Arm Horizontal Bar Remove C Shaped Bracket 10842 I Install Field Wiring Considerations When planning duct layout, the following categories of wires and cables associated with an A-B Programmable Controller should be considered: I/O Power Cable carries regulated 5V to the Processor and the I/O Rack.
  • Page 47 Chapter 3 Assembly and Installation Figure 3.25 I/O Module Insertion Module Locking Latch Wiring Arm Locking Tab Plastic Tracks Guide I/O Modules into Position 10843 I Field Wiring Guidelines The following are general wiring guidelines for A-B Programmable Controller components. These guidelines are applicable to typical installations for user wiring inside and outside the enclosure: Use 14 AWG (stranded) wire or smaller as permitted by local codes to connect to the Field Wiring Arms.
  • Page 48 Chapter 3 Assembly and Installation Figure 3.26 1771 Input/Output Assignment Form Bulletin 1771 I/O Chassis CONNECTION DIAGRAM ADDRESSING (Publication 5039 – September, 1980) PAGE DATE PROJECT NAME DESIGNER I/O GROUP I/O GROUP I/O GROUP I/O GROUP 00–07 10–17 00–07 10–17 00–07 10–17 00–07 10–17 MINI-PLC-2...
  • Page 49 Chapter 3 Assembly and Installation Figure 3.27 Field Wiring Arm/Indicator Labeling Label for Status Indicators Label for Field Wiring Arm Terminals 10844 I All Low Level DC I/O lines must be properly shielded and run in a separate duct. Serial Communication Cables may also be run with these lines. I/O Power Cable should remain external to all wiring ducts or in a duct not shared with other wiring within the enclosure.
  • Page 50 Chapter 3 Assembly and Installation Bend the end of the wire to to the right and place the bare copper wire under the pressure plate of the terminal screw. (Optionally, a spade lug can be used.) Tighten the screw, and check that the wire is firmly in place. Bundle each Module’s wires together and push them into the wiring duct.
  • Page 51 Chapter 3 Assembly and Installation Figure 3.28 Field Wiring Arm Leave Sufficient Slack for Pivoting Figure 3.29 Peeling Foil Shield Shield’s bare wire 1 pair of insulated Shield’s wires foil strip 10707-I 3 31...
  • Page 52 Chapter 3 Assembly and Installation Figure 3.30 Twisting Foil Shield and Wiring White wire Twist foil Black and bare wire wire togeth- 10708-I Figure 3.31 Trimming Unnecessary Insulated Wire Wire trimmed Strip 3/8” insulation 30” 2” twisted wire shield 10709-I 3 32...
  • Page 53 Chapter 3 Assembly and Installation Figure 3.32 Cable Shield Connection Ground Shield at I/O Chassis Mounting Bold Shield and Drain Twisted into Single Strand Field Wiring Arm 17798 The shield cable at the field devices can be configured as described in Figure 3.33.
  • Page 54 Chapter 3 Assembly and Installation When the System Power Supply Chassis cannot be directly connected to the enclosure or the enclosure ground bus, an equipment grounding conductor must be connected to the terminal labeled “Equipment Ground” on the System Power Supply’s terminal strip.

  • Page 55: Incoming Ac Wiring Guidelines

    Chapter 3 Assembly and Installation WARNING: To avoid injury to personnel and damage to equipment, disconnect all AC and DC power to the Controller before attempting any wiring installation within the enclosure. Figure 3.33 Shielded Cable at User's Device Insulated wires connect to user device.
  • Page 56 Chapter 3 Assembly and Installation CAUTION: The user must make certain 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. 3 36...

  • Page 57: Industrial Terminal Installation

    Chapter 3 Assembly and Installation Industrial Terminal Installation The Bulletin 1770 Industrial Terminal System (Cat. No. 1770-T3) is used to program the Mini-PLC-2/15 Processor. The Industrial Terminals (Cat. No. 1770-- T1 or -T2) can be used, however they will limit the capabilities of the Mini- PLC-2/15 Processor.
  • Page 58 Devices 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 generation, connecting a supression network is recommended: for 120V AC, Electrocube part no. RG 1676-14; for 220/240V AC, Electrocube part no. 1676-28.
  • Page 59 Device 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 EMI generation, connecting a supression netwrok is recommended: for 120V AC, Electrocube part no. RG 1676-14; for 220/240V AC, Electrocube part no. 1676-28.
  • Page 60 Chapter 3 Assembly and Installation Figure 3.36 External Power Terminal Strip Jumper positions indicated at side of 120V AC terminal strip 220/240V AC 120V AC EQUIP GND 10132-I Figure 3.37 Industrial Terminal Connection Industrial Terminal INTERFACE Channel A Cat. No. 1772 TC (10 Feet, 3.05cm) 10133 I 3 40...

  • Page 61: Start-Up

    Chapter System Start-Up Start-Up Careful start–up procedures are essential for proper Mini–PLC–215 Controller operation. These procedures should be followed after the complete Controller system has been assembled and installed as described in Section 3. A cautious approach must be taken toward the initial start–up procedure. Care and patience during start–up will isolate problems that might occur in the form of programming errors, wiring mistakes, or equipment malfunction.

  • Page 62: Checkout With Power Applied To Selected Devices

    Chapter 4 System Start-Up Verify that the I/O Power Cable connectors are plugged securely into their sockets. Verify that all modules are securely held in the I/O Chassis. Verify that the Field Wiring Arms are fully seated on their I/O Modules and locked in place on the locking tables.
  • Page 63 Chapter 4 System Start-Up Figure 4.1 I/O and Industrial Terminal Status Indicators Input module Indicator Module Indicator Illuminates when Device is On Input Device (On or Off) Diaplay Intensifies TRUE Instruction Industrial Terminal (Cat. No. 1770 T3) 10134 I 10134 I Hardware/Indicator Comparison Procedures WARNING: Machine motion during this procedure can cause injury to personnel or damage to equipment.
  • Page 64 Chapter 4 System Start-Up The user must make certain that a program has not been entered into the Mini– PLC–2/15 Processor’s memory. Only one rung at a time should be in memory for the start–up procedures. To clear the Processor’s memory, connect the Industrial Terminal to the Mini–PLC–2/15 Processor and perform the following steps.
  • Page 65 Chapter 4 System Start-Up TESTING INPUTS Hardware/indicator comparison should begin with the testing of input devices and modules. Perform the following steps for each input device: Turn the Processor’s Mode Select Switch to the TEST position. Press [SEARCH][5][3] and enter the word address of the Input Module to be tested.
  • Page 66 Chapter 4 System Start-Up CAUTION: If an I/O Module is to be replaced, System power and I/O power must be removed. Failure to remove power could result in damage to the Module and/or unexpected machine motion. Perform steps 2 and 3 until all inputs have been tested. TESTING OUTPUTS After all inputs have been tested, the outputs should be checked next.

  • Page 67: Checkout Of Machine Motion

    Chapter 4 System Start-Up Checkout of Machine Motion At this point, the Controller, the connections and mot of the user’s hardware will have been tested. The final procedure is to check out the machine motion or process controlled by the actual User Program. The basic approach initiates testing with the least amount of machine motion.
  • Page 68 Chapter 4 System Start-Up WARNING: Never reach into a machine to actuate a switch because unexpected machine motion could occur and cause injury to personnel. Do not use a metal rod since this could result in an electrical shock if it touches and exposed terminal. Instead, use a wooden stick or other nonconductive device to activate the switch.
  • Page 69 Chapter 4 System Start-Up If an EPROM needs to be installed, perform the following steps to program an EPROM and refer to Figure 4–3: Turn the Processor’s Mode Select Switch to the PROG position and connect an external battery pack to support RAM memory as shown in Figure 4–4.
  • Page 70 Chapter 4 System Start-Up Figure 4.4 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) 10137–I Connect the other end of the Power Supply Cable to the INTERFACE socket on the Processor.

  • Page 71: Maintenance And Troubleshooting

    Chapter Maintenance and Troubleshooting General The Mini–PLC–2/15 Controller has been designed to minimize the need for maintenance and troubleshooting. Status and diagnostic indicators on the Controller help to trace the source of a fault to the user’s hardware or the Controller.
  • Page 72 Chapter 5 Maintenance and Troubleshooting Generally, the sources of problems can be grouped into two board areas: User’s hardware Programmable Controller The most likely source of a problem is the user’s hardware. This includes the wiring, I/O devices, I/O power source and system power. Programmable Controller faults can originate from the System Power Supply, Mini–PLC–2/15 Processor or the I/O Rack.

  • Page 73: System Power Supply

    Chapter 5 Maintenance and Troubleshooting Table 5.A Recommended Spare Parts Quantity Cat. No. Description POWER SUPPLY 1770-XO Lithium Battery 1771-BA D-size Alkaline Battery 1771-BB Battery Pack (includes 2 alkaline batteries) 1771-CL I/O Power Cable (1 ft./30.5 cm) 1771-CM I/O Power Cable (5 ft./1.5 m) 1771-FP Fuse Package for Power Supply;...
  • Page 74 Chapter 5 Maintenance and Troubleshooting Remove AC power from the System Power Supply using the main disconnect. Remove the fuse cap by pushing in slightly and turning counterclockwise. The fuse cap and the fuse holder will pop out of the fuseholder. Install the replacement fuse (1 amp for 120V AC;...
  • Page 75 Chapter 5 Maintenance and Troubleshooting Figure 5.1 Troubleshooting Flowchart START CONTROLLED IN RUN OR RUN/PROG MODE OUTPUTS DO NOT BEHAVE AS PROGRAMMED IF NECESSARY, DISABLE I/O POWER, USE EMERGENCY STOP SWITCH DC ON INDICATOR MEMORY INDICATOR PROCESSOR INDICATOR INDICATOR LINE VOLTAGE CORRECT LINE-VOLTAGE WITHIN NORMAL RANGE?
  • Page 76 Chapter 5 Maintenance and Troubleshooting WARNING: REMOVE CHECK POSITION OF JUMPERS SYSTEM POWER SUPPLY ON POWER SUPPLY TERMINAL FUSE BLOWN POWER STRIP BEFORE CHECKING FUSE REPLACE FUSE RESTART CONTROLLER AND VERIFY PROPER OPERATION CORRECT LINE–VOLTAGE AT SUPPLY INPUTS CORRECT LINE–VOLTAGE PROBLEM CYCLE LINE POWER TO SYSTEM POWER SUPPLY...
  • Page 77 Chapter 5 Maintenance and Troubleshooting CONNECT INDUSTRIAL TERMINAL TO PROCESSOR AND TURN POWER ON PROCESSOR FAULT OR RUN– TIME ERROR WILL BE DISPLAYED. PROCESSOR FAULT OCCURED IF MODE SELECT SWITCH IS IN TURN MODE SELECT SWITCH RUN/PROG, INDUSTRIAL TERMINAL TO PROG AND BACK TO PLACES THE PROCESSOR IN REMOTE RUN OR RUN/PROG.
  • Page 78 Chapter 5 Maintenance and Troubleshooting CYCLE LINE POWER TO SYSTEM POWER SUPPLY. PROCESSOR RESTART CONTROLLER. INDICATOR VERIFY PROPER OPERATION. ON ? REPLACE MINI–PLC–2/15 PROCESSOR. RELOAD PROGRAM AND VERIFY PROPER OPERATION. 10141–I Remove AC power from the Power Supply using the main disconnect. Remove the I/O Power Cable from the Power Supply socket.
  • Page 79 Chapter 5 Maintenance and Troubleshooting System Power Supply Replacement The System Power Supply should be replaced if it is unable to provide the correct output voltages to power the Processor and I/O Modules. perform the following steps to replace the Power Supply: Turn the Processor’s Mode Select Switch to the PROG mode and support Processor memory.
  • Page 80 Chapter 5 Maintenance and Troubleshooting Table 5.B Troubleshooting Chart Controller Troubleshooting Indicators Mode[1] Processor Memory DC ON Procedures to Correct Fault 1. Cycle line power. 2. Replace Processor T, R, 1. Check Power Supply fuse. or R/P 2. Check AC line voltage. 3.
  • Page 81 Chapter 5 Maintenance and Troubleshooting Figure 5.2 Power Supply/Power Cable Outputs Pin No. Function Logic Voltage, +5.1V DC + – 3% Chassis Ground Common Battery Fail (Low-True) Battery (+) (2.7-3.7V DC) Memory Voltage +5V DC 5% – Processor Enable (Low-True) System Power I/O Power Battery Voltage at Pin No.
  • Page 82 Chapter 5 Maintenance and Troubleshooting nature of the problem. The possible combinations of indicator status are summarized in Table 5.B. Processor Faults and Run-Time Errors Any time the PROCESSOR indicator goes ON by itself during operation, this indicates that a hardware fault in the Processor has occurred. The only way to correct this type of fault is by cycling line power using the main disconnect or by replacing the Processor.

  • Page 83: Mini-Plc-2/15 Processor

    Chapter 5 Maintenance and Troubleshooting CAUTION: When removing the Mini–PLC–2/15 Processor from the I/O Chassis, always remove system power and I/O power first. This will avoid damage to the Processor Module’s circuitry. Turn Mode Select Switch to the PROG position. Connect an external battery pack to the Processor (Figure 4–4).

  • Page 84: 1771 I/O Modules

    Chapter 5 Maintenance and Troubleshooting Remove the Processor from the I/O Chassis. Remove the EPROM if installed in the Processor and install it in the replacement Processor if necessary. Install the replacement Processor in the I/O Chassis and turn the Mode Select Switch to the PROG position.
  • Page 85 Chapter 5 Maintenance and Troubleshooting Output Module Fuse Replacement If the FUSE BLOWN indicator on any of the Output Modules is illuminated, one or more Output Module fuses is blown. Perform the following steps to replace a blown Output Module fuse: CAUTION: Replacement fuses must be the correct type and rating.
  • Page 86 Chapter 5 Maintenance and Troubleshooting I/O Module Replacement If the I/O Module is the suspected source of the fault, it should be replace with the identical type and compatible series Module. Perform the following steps to replace the I/O Module: WARNING: Contact with AC line potentials may cause injury to personnel.
  • Page 87 Chapter 5 Maintenance and Troubleshooting Figure 5.3 Removing Fuse Access Cover CAT. NO. 1771 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...
  • Page 88 Chapter Specifications General This section contains physical, electrical and functional information on each Mini–PLC–2/15 Controller component. The following are overall specifications for this equipment: Ambient Temperature Rating Operational: 0 to 60 C (32 F)Storage: -40 to 85 C (-40 to 185 Humidity Rating 5 to 95% (without condensation) Input Voltage (nominal)
  • Page 89 Chapter 6 Specification System Power Supply Input Voltage Range 98-132V AC (120V AC operation) 196-250V AC (220/240V AC operation) Frequency Range 50/60 Hz (47-63 Hz) Output Voltage +5.1V DC (logic circuitry) +5V DC (memory) Maximum Output Current 6.5 amps Input Power 75 VA (approx.) Power Capability One Mini-PLC-2/15...
  • Page 90 Chapter 6 Specification I/O Equipment The following are summary specifications for Bulletin 1771 I/O Chassis. For specifications on individual I/O modules, refer to the product data sheets. Chassis Dimensions (WxHxD) Inches 32 I/O: 9.15 x 11.25 x 6.75 64 I/O: 14.15 x 11.25 x 6.75 128 I/O: 24.15 x 11.25 x 6.75 Centimeters 32 I/O: 23.24 x 28.58 x 17.15...
  • Page 91 Index Symbols Controller, Run-Time Errors, 5 12 **Empty**, Definition, Description Input Fuse, AC Input Fuse, Wiring, 3 33 Battery Pack, Access, EPROM, 2 11 Diagnostic Indicators, Address, Five Digit, 2 14 Field WIring Arms, 2 12 I/O Modules, 2 11 Addressing, I/O, 2 13 I/O Power Cable,...
  • Page 92 Index I–2 Ground Optional Power Supply, Component, Enclosure, General, Power Supply Checkout, Fuse Replacement, Indicators, Chassi, Pre-Assembly, 3 11 Specifications, Chassis, Assembly, 3 18 Troubleshooting, Chassis, Sizes, Powr Supply, Description, Module, Description, 2 11 Prepower Checkout, Module, Installation, 3 20 Preventive Maintenance, Module, Replacement, 5 16...
  • Page 93 Index I–3 Troubleshooting General, Voltage Measurement, Power Supply, Power Supply, Processor, 5 11 User Supplied Equipment, 2 14...

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