Honeywell ML200 Series User manual

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

Disclaimer
This document contains Honeywell proprietary information. Information contained herein is to be used
solely for the purpose submitted, and no part of this document or its contents shall be reproduced,
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While this information is presented in good faith and believed to be accurate, Honeywell disclaims the
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In no event is Honeywell liable to anyone for any direct, special, or consequential damages. The
information and specifications in this document are subject to change without notice.
Copyright 2019 - Honeywell International Sàrl
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Contents i
Chapter 1 - Masterlogic components 2
1.1 Types of CPUs 2
1.2 Types of power supply 2
1.3 Types of modules 5
1.4 Types of base 8
1.5 Types of cables 14
Chapter 2 - Calculating the power supply for components 17
2.1 Power module specifications 17
2.2 Selecting the power supply 19
Chapter 3 - Plan and Install MLPLC 23
3.1 Plan for Engineering Station 23
3.1.1 Platform requirements 23
3.1.2 Prerequisites for Installation 23
3.1.3 Grounding requirements 27
3.1.4 Precautions for installing/handling the PLC modules 28
3.2 Mounting Chassis 29
3.3 Achieving the topology 33
3.4 Turn on and start up 42
Chapter 4 - Troubleshooting 51
4.1 4.1 Overview 51
4.2 Basic troubleshooting procedure 51
4.3 Cases and remedies for failures 51
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MASTERLOGIC COMPONENTS
1.1 Types of CPUs
The following are the types of CPUs of the MasterLogic-200 PLC system.
lNon redundant PLCs
l2MLI-CPUU
l2MLI-CPUH
l2MLI-CPUS
l2MLI-CPUS/P
lRedundant PLC
l2MLR-CPUH/T
l2MLR-CPUH/F
The following naming conventions are used across the document.
l2MLI-CPUU, 2MLI-CPUH, and 2MLI-CPUS are represented as ML200-IEC.
l2MLR-CPUH/T and 2MLR-CPUH/F are represented as ML200R.
1.2 Types of power supply
The different types of voltages supported by ML200-IEC and ML200R are as follows:
lAC 110 V
lAC 220 V
lDC 24V
Power supplies for ML200-IEC
The following table lists the types of power modules for ML200-IEC.
Table 1: Power modules for ML200-IEC
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CHAPTER
1

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
2MLR-AC13 Redundant power AC 110V, 8.5A
2MLR-AC23 Redundant power AC 220V, 8.5A
2MLR-DC42 Redundant power DC 24V, 7.5A
The specifications of the power modules for 2MLI CPUS/P and ML200R are the same. For more details,
refer to Table 5: Specifications of the power modules for ML200R .
The following table lists the specifications of the power modules for ML200-IEC.
Table 3: Specifications of the power modules for ML200-IEC
Items 2MLP-
ACF1
2MLP-
ACF2 2MLP-AC23 2MLP-DC42
Input Rated input voltage AC 100V – AC 240V AC 200V –
AC 240V
DC 24V
Input voltage range AC 85V ~ AC 264V AC 170V ~
AC 264V
-
Input frequency 50 / 60 Hz (47 ~ 63 Hz) -
Inrush current 20 A peak or less 80A peak or less
Efficiency 65% or more 60% or more
Input fuse Built-in (user no change), UL standard (Slow Blow
Type)
Allowable
momentary
shutdown
Within 20ms
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Chapter 1 - Masterlogic components

Chapter 1 - Masterlogic components
Items 2MLP-
ACF1
2MLP-
ACF2 2MLP-AC23 2MLP-DC42
Output1 Output voltage DC 5V (±2%) DC5V (±2%)
Output current 3.0A 6.0A 8.5A 6.0A
Over current protect 3.2A or
more
6.6A or
more
9.0A or
more
6.6A or more
Over voltage protect 5.5V ~ 6.5V
Output2 Output voltage DC 24V
(±10%)
- -
Output current 0.6A
Over current protect 0.7A or
more
Over voltage protect None
Relay
Output
Application RUN contact (Refer to the section 8.3)
Rated switching
voltage or current
DC 24V, 0.5A
Minimum
switching load
DC 5V,1 mA
Response time OFF→ON/ ON→OFF: 10 ms or less/12 ms or less
Life Mechanical: More than 20,000,000 times
Electrical: More than 100,000 times at rated switching
voltage/current
RUN signal output Relay output, Rating: DC24V, 0.5A
Voltage indicator Output voltage normal, LED ON
Cable specification 0.75 ~ 2mm2
Compressed terminal RAV 1.25 - 3.5, RAV 2 - 3.5
Weight 0.4kg 0.6kg 0.5kg
ATTENTION
1. Allowable Momentary Power Failure Time: It is the time that the input voltage keeps
normal output voltage (normal operation) in the state that AC 110/220V voltage is lower
than the rated value (AC85/170V).
- 4 -

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.
3. Over voltage protection: The over voltage protection device shuts down the circuit to
stop the system, if the voltage is greater than the standard and is applied to the DC 5V
circuit
Power supplies for ML200R
ATTENTION
The main reason for using redundant power supply is that it has a component and the CPU
checks this component for the status of power failure. This component is not available in a non-
redundant power supply.
The following table provides the specifications of the power modules for ML200R.
1.3 Types of modules
The following are the different types of modules supported for ML200 IEC and ML200R.
lInput/Output module
lSpecial module
lCommunication module
Input/Output module
The following table provides details about the different types of input and output modules.
Table 6: Types of I/O modules
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Chapter 1 - Masterlogic components

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)
2MLI-D24B DC 24V input, 32 points (current source input)
2MLI-D28B DC 24V input, 64 points (current source input)
2MLI-A12A AC 110V input, 16 points
2MLI-A21A AC 220V input, 8 points
Digital output module 2MLQ-RY1A Relay output, 8 points (2A, independent COM)
2MLQ-RY2A Relay output, 16 points (2A)
2MLQ-RY2B Relay output, 16 points (2A), built-in varistor
2MLQ-TR2A Transistor output, 16 points (0.5A, sink output)
2MLQ-TR4A Transistor output, 32 points (0.1A, sink output)
2MLQ-TR8A Transistor output, 64 points (0.1A, sink output)
2MLQ-TR2B Transistor output 16 points (0.5A, source output)
2MLQ-TR4B Transistor output 32 points (0.1A, source output)
2MLQ-TR8B Transistor output 64 points (0.1A, source output)
2MLQ-SS2A Triac output, 16 points (0.6A)
Special module
The following table provides the details about the different types of special modules.
Table 7: Types of special modules
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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-
AD16A
Voltage or current input, 16 channels
2MLF-AC4H Current input, 4 channels
Analog output module 2MLF-DV4A Voltage output, 4 channels
2MLF-DC4A Current output, 4 channels
2MLF-DC8A Current output, 8 channels
2MLF-DV8A Voltage output, 8 channels
2MLF-DC4S Current output, 4 channels, isolated
2MLF-DC4H Current output, 4 channels
High speed counter
module
2MLF-HO2A Pulse input, 2 channels, open collector
2MLF-HD2A Pulse input, 2 channels, line drive
Temperature input module 2MLF-RD4A RTD input, 4 channels
2MLF-RD8A RTD input, 8 channles
2MLF-RD4S RTD input, 4channels, Isolated
2MLF-TC4S Thermocouple input, 4channels, Isolated
Event input module 2MLF-SOEA Event input SOE, 32 channels
Communication module
The following table provides details about the different types of communication modules.
Table 8: Types of communication modules
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Chapter 1 - Masterlogic components

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
2MLL-PSEA Profibus slave interface
2MLL-PSRA Profibus remote interface, DP standard
ATTENTION
The 2MLL-PSRA must be installed only on ML200-IEC CPU bases.
1.4 Types of base
The ML200-IEC and ML200R comprises of main base and expansion base.
ML200-IEC Main base
The main base of ML200-IEC consists of the power module, CPU module, I/O module, special module,
and the communication module.
The following table lists the types of bases for ML200-IEC.
Table 9: Types of bases for ML200-IEC
PLC Types Part Number Description
2MLI-CPUH
2MLI-CPUS
2MLI-CPUU
2MLB-M04A Main base 4 slot
2MLB-M06A Main base 6 slot
2MLB-M08A Main base 8 slot
2MLB-M12A Main base 12 slot
2MLI-CPUS/P
2MLR-M06P Main base 6 slot
2MLR-E08P Main base 8 slot
2MLR-E12P Main base 12 slot
- 8 -

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
1 Base attached guide
hole
For attaching the main base to the panel in the control
panel.
2 Power module
connector
For installation of Power supply module.
3 Module built-in
connector
For installation of I/O, special and other communication
modules.
4 FG terminal The ground terminal connected to the shielded pattern
of the PCB board.
5 Expansion cable
connector
Connects the main base (CPU base) with the
expansion base.
6 CPU module
connector
For installation of the CPU module.
ML200-IEC Expansion base
The expansion base consists of the power module, I/O module, special module, and the communication
module.
ATTENTION
2MLI CPUS/P does not support the Expansion base.
The following table lists the types of expansion bases for ML200-IEC.
Table 11: Types of expansion bases for ML200-IEC
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Chapter 1 - Masterlogic components

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.
Table 12: Expansion base of ML200-IEC
Index Part Function
1 Base attached guide hole For attaching the main base to the panel in the
control panel.
2 Power module connector I/O module built-in connector.
3 Expansion driver module
connector
I/O module built-in connector
4 FG terminal The ground terminal connected to the shielded
pattern of PCB board.
5 Expansion cable
connector
Connects the main base (CPU base) with the
expansion base.
ML200R Main base
The main base of ML200R consists of the power module, CPU module, and the communication module
(only Ethernet module is allowed in the main base).
The following table lists the types of bases for ML200R.
- 10 -

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.
Figure 3: Main base of 2MLR-M06P
The following table provides the main base details of 2MLR-M02P and 2MLR-M06P.
Table 14: Main base details of 2MLR-M02P and 2MLR-M06P
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Chapter 1 - Masterlogic components

Chapter 1 - Masterlogic components
Index Part Function
1 Base attached
guide hole
For attaching the main base to the panel in the control
panel.
2 Power module
connector
For installation of the Power supply module.
3 CPU module
connector
For installation of the CPU module (2 slots).
4 Module built-in
connector
For installation of the communication modules.
5 FG terminal The ground terminal connected to the shielded pattern of
the PCB board.
ML200R Expansion base
ML200R input/output base communication includes expansion base and expansion driver modules.
The following are the two types of IO link topology for ML200R.
lExpansion base without dual IO link redundancy
lExpansion base with dual IO link redundancy
Expansion base without dual IO link redundancy
The expansion base of ML200R consists of the power module, expansion driver module, I/O module,
special module, and the communication module. (Ethernet module is not allowed in the expansion
base).
The following table provides details about the expansion base and expansion driver modules for
ML200R.
Table 15: Expansion base and expansion driver module for ML200R
PLC types Part number Description
ML200R 2MLR-E08P Expansion base 8 slot
2MLR-E12P Expansion base 12 slot
2MLR-DBSF Expansion driver module FO
2MLR-DBST Expansion driver module TP
2MLR-DBSH Expansion driver module TP/FO
The following image illustrates the expansion base of ML200R, which does not support dual I/O link
redundancy.
- 12 -

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
1 Base attached guide
hole
For attaching the main base to the panel in the control
panel.
2 Power module
connector
For installation of power supply module.
3 Expansion driver
module connector
For installation of expansion driver module.
4 Module built-in
connector
For installation of I/O, special and communication
modules other than Ethernet module.
5 FG terminal The ground terminal connected to the shielded pattern
of the PCB board.
Expansion base with dual IO link redundancy
The expansion base of ML200R consists of the power module, expansion driver module, I/O module,
special module, and the communication module. (Ethernet module is not allowed in the expansion
base).
The following table provides details about the expansion base and expansion driver module for
ML200R (with dual IO link redundancy).
Table 17: Expansion base and expansion driver module for ML200R
PLC Types Part Number Description
ML200R 2MLR-E12H Expansion redundancy Base 12 slot
2MLR-DBDF Expansion redundancy Driver module FO
2MLR-DBDT Expansion redundancy Driver module TP
2MLR-DBDH Expansion redundancy Driver module TP/FO
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Chapter 1 - Masterlogic components

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
1 Base attached guide hole For attaching the main base to the panel in the
control panel.
2 Power module connector For installation of power supply module.
3 Expansion redundancy drive
module connector
For installation of expansion redundancy driver
modules.
4 Module built-in connector For installation of I/O, special and other
communication modules.
5 FG terminal The ground terminal connected to the shielded
pattern of the PCB board.
1.5 Types of cables
Cables for ML200-IEC
Expansion cable connection
The expansion cables contain high frequency noise. Therefore, to meet the CE conformance standards,
attach a ferrite core to the expansion cable as illustrated in the following figure.
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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.
lOptical cable
lEthernet cable
The electrical and optical cables are provided for use in accordance with the network type.
Optical cables
The communication between the optical cables is through Multi Mode Fiber (MMF) 50/65 um LC type
cable. In ML200R systems, cables are used based on the installation site, indoor type, outdoor type, or
conduit type.
ATTENTION
2MLC-F201 (Multimode Fiber Optic Cable, LC connector, 2.0m) is the synchronization cable part
number used for ML200R.
The following figure illustrates the MMF (LC Type) optical cable.
Figure 7: MMF (LC Type) optical cable
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Chapter 1 - Masterlogic components

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. The twisted pair cables are known as Cat5 cables. The
twisted pair cables are categorized on the following two criteria.
lShielding: It is classified into three types. The following table lists the three types of twisted pair
based on the shielding used.
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CALCULATING THE POWER SUPPLY FOR
COMPONENTS
2.1 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 960
2MLI-CPUH 960
2MLI-CPUS 940
2MLI-CPUS/P 940
Redundant CPU Module 2MLR-CPUH/T 980
2MLR-CPUH/F 1310
Expansion Driver Module 2MLR-DBST 550
2MLR-DBSF 550
2MLR-DBSH 550
2MLR-DBDT 550
2MLR-DBDH 550
2MLR-DBDF 550
Digital Input Module (DC 24V) 2MLI-D21A 20
2MLI-D22A 30
2MLI-D22B 30
2MLI-D24A 50
2MLI-D24B 50
2MLI-D28A 60
2MLI-D28B 60
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CHAPTER
2

Module Types of Model Current consumption (mA)
Digital Input Module (AC 110V) 2MLI-A12A 30
Digital Input Module (AC220V) 2MLI-A21A 20
Relay output module 2MLQ-RY1A 250
2MLQ-RY2A 500
2MLQ-RY2B 500
Digital Output Module (Transistor) 2MLQ-TR2A 70
2MLQ-TR2B 70
2MLQ-TR4A 130
2MLQ-TR4B 130
2MLQ-TR8A 230
2MLQ-TR8B 230
Digital Output Module (Triac) 2MLQSS2A 300
2MLFDV4S 200
Analog Input Module 2MLF-AV8A 420
2MLF-AC8A 420
2MLF-AD8A 420
2MLF-AD16A 330
2MLF-AD4S 610
Analog Output Module 2MLF-DV4A 190
2MLF-DC4A 190
2MLF-DV8A 147
2MLF-DC8A 243
2MLF-DC4S 200
2MLF-DV4S 200
Temperature Input Module 2MLF-TC4S 610
2MLF-RD4A 490
High-Speed Counter Module 2MLF-HO2A 270
2MLF-HD2A 330
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Chapter 2 - Calculating the power supply for components