Allen-Bradley 2080-LC10-12AWA User manual

User Manual
Micro810™ Programmable Controllers
Catalog Numbers 2080-LC10-12AWA, 2080-LC10-12QWB, 2080-LC10-12QBB, 2080-LC10-12DWD

Important User Information
Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety
Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from
your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/) describes some
important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference,
and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment
must satisfy themselves that each intended application of this equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from
the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or
software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
Allen-Bradley, Rockwell Software, Rockwell Automation, Micro810, Micro830, Connected Components Workbench, and TechConnect are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous
environment, which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death,
property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the
consequence
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that
dangerous voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that
surfaces may reach dangerous temperatures.
IMPORTANT
Identifies information that is critical for successful application and understanding of the product.

Rockwell Automation Publication 2080-UM001B-EN-E - November 2011 iii
Preface
Read this preface to familiarize yourself with the rest of the manual. It provides
information concerning:
•who should use this manual
•the purpose of this manual
•related documentation
Who Should Use this
Manual
Use this manual if you are responsible for designing, installing, programming, or
troubleshooting control systems that use Micro800™controllers.
You should have a basic understanding of electrical circuitry and familiarity with
relay logic. If you do not, obtain the proper training before using this product.
Purpose of this Manual
This manual is a reference guide for Micro800 controllers, plug-in modules and
accessories. It describes the procedures you use to install, wire, and troubleshoot
your controller. This manual:
•explains how to install and wire your controllers
•gives you an overview of the Micro800 controller system
Refer to the Online Help provided with Connected Components Workbench™
(CCW) software for more information on programming your Micro800
controller.
Additional Resources
These documents contain additional information concerning related Rockwell
Automation products.
Resource Description
Micro800 Programmable Controller External AC
Power Supply Installation 2080-IN001 Information on mounting and wiring the optional external power supply.
Micro810 USB Adapter Plug-in Module Wirng
Diagrams 2080-WD001 Information on mounting and wiring the Micro810 USB Adapter Plug-in Module.
Micro800 1.5" LCD Display and Keypad Module
Wirng Diagrams 2080-WD009 Information on mounting and wiring the
Micro800 1.5" LCD Display and Keypad Module.
Industrial Automation Wiring and Grounding
Guidelines, publication 1770-4.1 Provides general guidelines for installing a
Rockwell Automation industrial system.
Product Certifications website, http://ab.com Provides declarations of conformity, certificates,
and other certification details.
Application Considerations for Solid-State
Controls SGI-1.1 A description of important differences between
solid-state programmable controller products
and hard-wired electromechanical devices.
National Electrical Code - Published by the
National Fire Protection Association of Boston,
MA.
An article on wire sizes and types for grounding
electrical equipment.
Allen-Bradley Industrial Automation Glossary
AG-7.1 A glossary of industrial automation terms and
abbreviations.

iv Rockwell Automation Publication 2080-UM001B-EN-E - November 2011
Chapter Preface Preface
You can view or download publications at
http://www.rockwellautomation.com/literature/. To order paper copies of
technical documentation, contact your local Rockwell Automation distributor or
sales representative.
You can download the latest version of Connected Components Workbench
(CCW) for your Micro800 at the URL below.
http://ab.rockwellautomation.com/Programmable-Controllers/Connected-
Components-Workbench-Software.

Rockwell Automation Publication 2080-UM001B-EN-E - November 2011 v
Table of Contents
Preface Who Should Use this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Purpose of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Hardware Overview Hardware Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Micro810 12-Point Controllers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
About Your Controller Agency Certifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Compliance to European Union Directives. . . . . . . . . . . . . . . . . . . . . . . . . . . 3
EMC Directive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Environment and Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Preventing Electrostatic Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
North American Hazardous Location Approval. . . . . . . . . . . . . . . . . . . 7
Disconnecting Main Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Periodic Tests of Master Control Relay Circuit . . . . . . . . . . . . . . . . . . . 8
Power Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Isolation Transformers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Power Supply Inrush. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Loss of Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Input States on Power Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Other Types of Line Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Preventing Excessive Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Master Control Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Using Emergency-Stop Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Schematic (Using IEC Symbols) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Schematic (Using ANSI/CSA Symbols). . . . . . . . . . . . . . . . . . . . . . . . 14
Install Your Controller Controller Mounting Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Mounting Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Wire Your Controller Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Using Surge Suppressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Recommended Surge Suppressors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Ground the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Micro810 Controllers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Controller I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Minimize Electrical Noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Analog Channel Wiring Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Minimize Electrical Noise on Analog Channels . . . . . . . . . . . . . . . . . 22
Ground Your Analog Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

vi Rockwell Automation Publication 2080-UM001B-EN-E - November 2011
Table of Contents
About Accessories Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
External AC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Wire the Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.5" LCD Display and Keypad Module . . . . . . . . . . . . . . . . . . . . . . . . . 26
Insert the LCD Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Remove the LCD Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Access the Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
USB Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Specifications Micro810 Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Micro800 Programmable Controller External AC Power Supply . 36
Running Programs
with Micro800
Overview of Program Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Execution Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Guidelines and Limitations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
IPID Function Block How to AutoTune. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
PID Application Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
PID Code Sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Troubleshooting Status Indicators on the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Micro810 Controllers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Status Indicators on the LCD Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Controller Error Recovery Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Calling Rockwell Automation for Assistance. . . . . . . . . . . . . . . . . . . . . . . . 53
Quickstarts Use the Micro810 Smart Relay Functionality . . . . . . . . . . . . . . . . . . . . . . . 55
Navigate the LCD Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Configure Count-Up (CTU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Test the CTU Predefined Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Configure On-delay Timing (TON) . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Test the TON Predefined Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Configure DOY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Test the DOY Predefined Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Set up the Clock for Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Test the DOY Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Configure TOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Test the TOW Predefined Function . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Set up the Clock for Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Test the TOW Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Configure Countdown (CTD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Test the CTD Predefined Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Configure TONOFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Test the TONOFF Predefined Function . . . . . . . . . . . . . . . . . . . . . . . 77
Configure Pulse Timing (TP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Test the TP Predefined Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Rockwell Automation Publication 2080-UM001B-EN-E - November 2011 vii
Chapter 1
Configure TOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Test the TOF Predefined Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Flash Update the
Micro800 Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Establish Communication Between RSLinx and a Micro810 12-point
controller through USB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Forcing I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Check if Forces (locks) are Enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Index

viii Rockwell Automation Publication 2080-UM001B-EN-E - November 2011
Table of Contents
Notes:

Rockwell Automation Publication 2080-UM001B-EN-E - November 2011 1
Chapter 1
Hardware Overview
Hardware Features
The Micro800 controller is an economical brick style controller with embedded
inputs and outputs.
Micro810 12-point controllers cannot use Micro800 plug-in modules, but do
support a USB adapter, and an LCD module, which can be used as a backup
memory module.
24V DC powered controllers accommodate any 24V DC output power supply
that meets minimum specifications such as the optional Micro800 power supply
(2080-LC10-12QWB, 2080-LC10-12QBB only).
Micro810 12-Point Controllers
Controller Description
Description Description
1 Optional power supply 5 USB port (for use with USB Adapter only)
2 Status indicator 6 DIN rail mounting latch
3 Input terminal block 7 Output terminal block
4 Mounting screw hole/ mounting foot
123
5
67
45052
4
4

2Rockwell Automation Publication 2080-UM001B-EN-E - November 2011
Chapter 1 Hardware Overview
Status Indicator
State During Normal Operation During Firmware Update or
Program/Data Transfer
Off No power applied to device, or in Fault
mode No power applied to device, or in Fault mode
Solid green Device operating normally Program transfer successful
Flashing green Operating System error Firmware update in progress
Micro810 Controllers
Catalog Number Power Inputs Outputs Analog In 0…10V
(shared with DC In)
120V AC 240V AC 12…24V DC /V AC Relay 24 V DC SRC
2080-LC10-12QWB 24V DC 8 4 4
2080-LC10-12AWA 120…240V AC 8 4
2080-LC10-12QBB 12…24V DC 8 4 4
2080-LC10-12DWD 12V DC 8 4 4

Rockwell Automation Publication 2080-UM001B-EN-E - November 2011 3
Chapter 2
About Your Controller
Agency Certifications
•UL Listed Industrial Control Equipment, certified for US and Canada.
UL Listed for Class I, Division 2 Group A,B,C,D Hazardous Locations,
certified for U.S. and Canada.
•CE marked for all applicable directives
•C-Tick marked for all applicable acts
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 product is tested to meet Council Directive 2004/108/EC Electromagnetic
Compatibility (EMC) and the following standards, in whole or in part,
documented in a technical construction file:
•EN 61131-2; Programmable Controllers (Clause 8, Zone A & B)
•EN 61131-2; Programmable Controllers (Clause 11)
•EN 61000-6-4
EMC - Part 6-4: Generic Standards - Emission Standard for Industrial
Environments
•EN 61000-6-2
EMC - Part 6-2: Generic Standards - Immunity for Industrial
Environments
This product is intended for use in an industrial environment.
Low Voltage Directive
This product is tested to meet Council Directive 2006/95/ECLow Voltage, by
applying the safety requirements of EN 61131-2 Programmable Controllers, Part
2 - Equipment Requirements and Tests.

4Rockwell Automation Publication 2080-UM001B-EN-E - November 2011
Chapter 2 About Your Controller
For specific information required by EN 61131-2, see the appropriate sections in
this publication, as well as the following Allen-Bradley publications:
•Industrial Automation Wiring and Grounding Guidelines for Noise
Immunity, publication 1770-4.1
•Guidelines for Handling Lithium Batteries, publication AG-5.4
•Automation Systems Catalog, publication B115
Installation Considerations
Most applications require installation in an industrial enclosure (Pollution
Degree 2(1)) to reduce the effects of electrical interference (Over Voltage
Category II(2)) and environmental exposure. Locate your controller as far as
possible from power lines, load lines, and other sources of electrical noise such as
hard-contact switches, relays, and AC motor drives. For more information on
proper grounding guidelines, see the Industrial Automation Wiring and
Grounding Guidelines publication 1770-4.1.
(1) Pollution Degree 2 is an environment where normally only non-conductive pollution occurs except that
occasionally temporary conductivity caused by condensation shall be expected.
(2) Overvoltage Category II is the load level section of the electrical distribution system. At this level, transient
voltages are controlled and do not exceed the impulse voltage capability of the products insulation.

Rockwell Automation Publication 2080-UM001B-EN-E - November 2011 5
About Your Controller Chapter 2
WARNING: If you insert or remove the module while power is on, an electrical arc can occur. This could
cause an explosion in hazardous location installations.
Be sure that power is removed or the area is nonhazardous before proceeding.
WARNING: The local programming terminal port is intended for temporary use only and must not be
connected or disconnected unless the area is assured to be nonhazardous.
WARNING: When used in a Class I, Division 2, hazardous location, this equipment must be mounted in a
suitable enclosure with proper wiring method that complies with the governing electrical codes.
WARNING: If you connect or disconnect wiring while the field-side power is on, an electrical arc can
occur. This could cause an explosion in hazardous location installations. Be sure that power is removed or
the area is nonhazardous before proceeding.
WARNING: The USB port is intended for temporary local programming purposes only and not intended for
permanent connection. If you connect or disconnect the USB cable with power applied to this module or
any device on the USB network, an electrical arc can occur. This could cause an explosion in hazardous
location installations.
Be sure that power is removed or the area is nonhazardous before proceeding.
The USB port is a nonincendive field wiring connection for Class I, Division2 Groups A, B, C and D.
WARNING: Exposure to some chemicals may degrade the sealing properties of materials used in the
Relays. It is recommended that the User periodically inspect these devices for any degradation of
properties and replace the module if degradation is found.
WARNING: To comply with the CE Low Voltage Directive (LVD), this equipment must be powered from a
source compliant with the following:
Safety Extra Low Voltage (SELV) or Protected Extra Low Voltage (PELV).
WARNING: To comply with UL restrictions, this equipment must be powered from a source compliant with
the following:
Class 2 or Limited Voltage/Current.
WARNING: Do not wire more than 2 conductors on any single terminal.
WARNING: Be careful when stripping wires. Wire fragments that fall into the controller could cause
damage. Once wiring is complete, make sure the controller is free of all metal fragments.
ATTENTION: Do not remove the protective debris strips until after the controller and all other equipment
in the panel near the module are mounted and wired. Remove strips before operating the controller. Failure
to remove strips before operating can cause overheating.
ATTENTION: Electrostatic discharge can damage semiconductor devices inside the module. Do not touch
the connector pins or other sensitive areas.
ATTENTION: This product is intended to be mounted to a well-grounded mounting surface such as a metal
panel. Additional grounding connections from the power supply's mounting tabs or DIN rail (if used) are not
required unless the mounting surface cannot be grounded. Refer to Industrial Automation Wiring and
Grounding Guidelines, Allen-Bradley publication 1770-4.1, for additional information.
ATTENTION: The USB cable is not to exceed 3.0 m (9.84 ft).

6Rockwell Automation Publication 2080-UM001B-EN-E - November 2011
Chapter 2 About Your Controller
Environment and Enclosure
Preventing Electrostatic Discharge
Safety Considerations
Safety considerations are an important element of proper system installation.
Actively thinking about the safety of yourself and others, as well as the condition
of your equipment, is of primary importance. We recommend reviewing the
following safety considerations.
This equipment is intended for use in a Pollution Degree 2 industrial environment, in
overvoltage Category II applications (as defined in IEC 60664-1), at altitudes up to
2000 m (6562 ft) without derating.
This equipment is considered Group 1, Class A industrial equipment according to
IEC/CISPR 11. Without appropriate precautions, there may be difficulties with
electromagnetic compatibility in residential and other environments due to
conducted and radiated disturbances.
This equipment is supplied as open-type equipment. It must be mounted within an
enclosure that is suitably designed for those specific environmental conditions that
will be present and appropriately designed to prevent personal injury resulting from
accessibility to live parts. The enclosure must have suitable flame-retardant
properties to prevent or minimize the spread of flame, complying with a flame
spread rating of 5VA, V2, V1, V0 (or equivalent) if non-metallic. The interior of the
enclosure must be accessible only by the use of a tool. Subsequent sections of this
publication may contain additional information regarding specific enclosure type
ratings that are required to comply with certain product safety certifications.
In addition to this publication, see:
·Industrial Automation Wiring and Grounding Guidelines, Rockwell Automation
publication 1770-4.1, for additional installation requirements.
·NEMA Standard 250 and IEC 60529, as applicable, for explanations of the degrees of
protection provided by different types of enclosure.
This equipment is sensitive to electrostatic discharge, which can cause
internal damage and affect normal operation. Follow these guidelines
when you handle this equipment:
·Touch a grounded object to discharge potential static.
·Wear an approved grounding wriststrap.
·Do not touch connectors or pins on component boards.
·Do not touch circuit components inside the equipment.
·Use a static-safe workstation, if available.
·Store the equipment in appropriate static-safe packaging when not in use.

Rockwell Automation Publication 2080-UM001B-EN-E - November 2011 7
About Your Controller Chapter 2
North American Hazardous Location Approval
Disconnecting Main Power
The main power disconnect switch should be located where operators and
maintenance personnel have quick and easy access to it. In addition to
disconnecting electrical power, all other sources of power (pneumatic and
hydraulic) should be de-energized before working on a machine or process
controlled by a controller.
The following information applies when operating this equipment
in hazardous locations: Informations sur l’utilisation de cet équipement en environnements dangereux:
Products marked "CL I, DIV 2, GP A, B, C, D" are suitable for use in Class I
Division 2 Groups A, B, C, D, Hazardous Locations and nonhazardous
locations only. Each product is supplied with markings on the rating
nameplate indicating the hazardous location temperature code. When
combining products within a system, the most adverse temperature code
(lowest "T" number) may be used to help determine the overall
temperature code of the system. Combinations of equipment in your
system are subject to investigation by the local Authority Having
Jurisdiction at the time of installation.
Les produits marqués "CL I, DIV 2, GP A, B, C, D" ne conviennent qu'à une
utilisation en environnements de Classe I Division 2 Groupes A, B, C, D
dangereux et non dangereux. Chaque produit est livré avec des marquages
sur sa plaque d'identification qui indiquent le code de température pour les
environnements dangereux. Lorsque plusieurs produits sont combinés dans
un système, le code de température le plus défavorable (code de
température le plus faible) peut être utilisé pour déterminer le code de
température global du système. Les combinaisons d'équipements dans le
système sont sujettes à inspection par les autorités locales qualifiées au
moment de l'installation.
EXPLOSION HAZARD
• Do not disconnect equipment unless power has been
removed or the area is known to be nonhazardous.
• Do not disconnect connections to this equipment unless
power has been removed or the area is known to be
nonhazardous. Secure any external connections that mate to
this equipment by using screws, sliding latches, threaded
connectors, or other means provided with this product.
• Substitution of any component may impair suitability for
Class I, Division 2.
• If this product contains batteries, they must only be changed
in an area known to be nonhazardous.
RISQUE D’EXPLOSION
• Couper le courant ou s'assurer que l'environnement est classé
non dangereux avant de débrancher l'équipement.
• Couper le courant ou s'assurer que l'environnement est classé
non dangereux avant de débrancher les connecteurs. Fixer tous
les connecteurs externes reliés à cet équipement à l'aide de vis,
loquets coulissants, connecteurs filetés ou autres moyens
fournis avec ce produit.
• La substitution de tout composant peut rendre cet équipement
inadapté à une utilisation en environnement de Classe I,
Division 2.
• S'assurer que l'environnement est classé non dangereux avant
de changer les piles.
WARNING: Explosion Hazard
Do not replace components, connect equipment, or disconnect equipment
unless power has been switched off.

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Chapter 2 About Your Controller
Safety Circuits
Circuits installed on the machine for safety reasons, like overtravel limit switches,
stop push buttons, and interlocks, should always be hard-wired directly to the
master control relay. These devices must be wired in series so that when any one
device opens, the master control relay is de-energized, thereby removing power to
the machine. Never alter these circuits to defeat their function. Serious injury or
machine damage could result.
Power Distribution
There are some points about power distribution that you should know:
•The master control relay must be able to inhibit all machine motion by
removing power to the machine I/O devices when the relay is de-
energized. It is recommended that the controller remain powered even
when the master control relay is de-energized.
•If you are using a DC power supply, interrupt the load side rather than the
AC line power. This avoids the additional delay of power supply turn-off.
The DC power supply should be powered directly from the fused
secondary of the transformer. Power to the DC input and output circuits
should be connected through a set of master control relay contacts.
Periodic Tests of Master Control Relay Circuit
Any part can fail, including the switches in a master control relay circuit. The
failure of one of these switches would most likely cause an open circuit, which
would be a safe power-off failure. However, if one of these switches shorts out, it
no longer provides any safety protection. These switches should be tested
periodically to assure they will stop machine motion when needed.
WARNING: Explosion Hazard
Do not connect or disconnect connectors while circuit is live.

Rockwell Automation Publication 2080-UM001B-EN-E - November 2011 9
About Your Controller Chapter 2
Power Considerations
The following explains power considerations for the micro controllers.
Isolation Transformers
You may want to use an isolation transformer in the AC line to the controller.
This type of transformer provides isolation from your power distribution system
to reduce the electrical noise that enters the controller and is often used as a step-
down transformer to reduce line voltage. Any transformer used with the
controller must have a sufficient power rating for its load. The power rating is
expressed in volt-amperes (VA).
Power Supply Inrush
During power-up, the Micro800 power supply allows a brief inrush current to
charge internal capacitors. Many power lines and control transformers can supply
inrush current for a brief time. If the power source cannot supply this inrush
current, the source voltage may sag momentarily.
The only effect of limited inrush current and voltage sag on the Micro800 is that
the power supply capacitors charge more slowly. However, the effect of a voltage
sag on other equipment should be considered. For example, a deep voltage sag
may reset a computer connected to the same power source. The following
considerations determine whether the power source must be required to supply
high inrush current:
•The power-up sequence of devices in a system.
•The amount of the power source voltage sag if the inrush current cannot be
supplied.
•The effect of voltage sag on other equipment in the system.
If the entire system is powered-up at the same time, a brief sag in the power source
voltage typically will not affect any equipment.
Loss of Power Source
The power supply is designed to withstand brief power losses without affecting
the operation of the system. The time the system is operational during power loss
is called program scan hold-up time after loss of power. The duration of the
power supply hold-up time depends on the type and state of the I/O, but is
typically between 10 milliseconds and 3 seconds. When the duration of power
loss reaches this limit, the power supply signals the processor that it can no longer
provide adequate DC power to the system. This is referred to as a power supply
shutdown. The processor then performs an orderly shutdown of the controller.

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Chapter 2 About Your Controller
Input States on Power Down
The power supply hold-up time as described above is generally longer than the
turn-on and turn-off times of the inputs. Because of this, the input state change
from “On” to “Off ” that occurs when power is removed may be recorded by the
processor before the power supply shuts down the system. Understanding this
concept is important. The user program should be written to take this effect into
account.
Other Types of Line Conditions
Occasionally the power source to the system can be temporarily interrupted. It is
also possible that the voltage level may drop substantially below the normal line
voltage range for a period of time. Both of these conditions are considered to be a
loss of power for the system.
Preventing Excessive Heat
For most applications, normal convective cooling keeps the controller within the
specified operating range. Ensure that the specified temperature range is
maintained. Proper spacing of components within an enclosure is usually
sufficient for heat dissipation.
In some applications, a substantial amount of heat is produced by other
equipment inside or outside the enclosure. In this case, place blower fans inside
the enclosure to assist in air circulation and to reduce “hot spots” near the
controller.
Additional cooling provisions might be necessary when high ambient
temperatures are encountered.
Master Control Relay
A hard-wired master control relay (MCR) provides a reliable means for
emergency machine shutdown. Since the master control relay allows the
placement of several emergency-stop switches in different locations, its
installation is important from a safety standpoint. Overtravel limit switches or
mushroom-head push buttons are wired in series so that when any of them opens,
the master control relay is de-energized. This removes power to input and output
device circuits. Refer to the figures on pages 13 and 14.
TIP
Do not bring in unfiltered outside air. Place the controller in an enclosure
to protect it from a corrosive atmosphere. Harmful contaminants or dirt
could cause improper operation or damage to components. In extreme
cases, you may need to use air conditioning to protect against heat build-
up within the enclosure.

Rockwell Automation Publication 2080-UM001B-EN-E - November 2011 11
About Your Controller Chapter 2
Place the main power disconnect switch where operators and maintenance
personnel have quick and easy access to it. If you mount a disconnect switch
inside the controller enclosure, place the switch operating handle on the outside
of the enclosure, so that you can disconnect power without opening the
enclosure.
Whenever any of the emergency-stop switches are opened, power to input and
output devices should be removed.
When you use the master control relay to remove power from the external I/O
circuits, power continues to be provided to the controller’s power supply so that
diagnostic indicators on the processor can still be observed.
The master control relay is not a substitute for a disconnect to the controller. It is
intended for any situation where the operator must quickly de-energize I/O
devices only. When inspecting or installing terminal connections, replacing
output fuses, or working on equipment within the enclosure, use the disconnect
to shut off power to the rest of the system.
Using Emergency-Stop Switches
When using emergency-stop switches, adhere to the following points:
•Do not program emergency-stop switches in the controller program. Any
emergency-stop switch should turn off all machine power by turning off
the master control relay.
•Observe all applicable local codes concerning the placement and labeling
of emergency-stop switches.
WARNING: Never alter these circuits to defeat their function
since serious injury and/or machine damage could result.
TIP
If you are using an external DC power supply, interrupt the DC output
side rather than the AC line side of the supply to avoid the additional
delay of power supply turn-off.
The AC line of the DC output power supply should be fused.
Connect a set of master control relays in series with the DC power
supplying the input and output circuits.
TIP
Do not control the master control relay with the controller. Provide the
operator with the safety of a direct connection between an emergency-
stop switch and the master control relay.

12 Rockwell Automation Publication 2080-UM001B-EN-E - November 2011
Chapter 2 About Your Controller
•Install emergency-stop switches and the master control relay in your
system. Make certain that relay contacts have a sufficient rating for your
application. Emergency-stop switches must be easy to reach.
•In the following illustration, input and output circuits are shown with
MCR protection. However, in most applications, only output circuits
require MCR protection.
The following illustrations show the Master Control Relay wired in a grounded
system.
TIP
In most applications input circuits do not require MCR protection;
however, if you need to remove power from all field devices, you must
include MCR contacts in series with input power wiring.