Micro820 Programmable

Controllers
Catalog Numbers 2080-LC20-20QWB, 2080-LC20-20QBB,
2080-LC20-20AWB, 2080-LC20-20QWBR, 2080-LC20-20QBBR,
2080-LC20-20AWBR

User Manual Original Instructions

Micro820 Programmable Controllers User Manual

Important User Information

Read this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before you
install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to
requirements of all applicable codes, laws, and standards.

Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to be carried out by suitably trained
personnel in accordance with applicable code of practice.

If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.

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.

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.

IMPORTANT Identifies information that is critical for successful application and understanding of the product.

These labels may also be on or inside the equipment to provide specific precautions.

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.

ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc
Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory
requirements for safe work practices and for Personal Protective Equipment (PPE).

The following icon may appear in the text of this document.

Identifies information that is useful and can help to make a process easier to do or easier to understand.

Rockwell Automation recognizes that some of the terms that are currently used in our industry and in this publication are not in alignment with the
movement toward inclusive language in technology. We are proactively collaborating with industry peers to find alternatives to such terms and
making changes to our products and content. Please excuse the use of such terms in our content while we implement these changes.

2 Rockwell Automation Publication 2080-UM005G-EN-E - December 2023

 Table of Contents

Preface
About This Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Conformal Coated Catalogs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Download Firmware, AOP, EDS, and Other Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Summary of Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Chapter 1
Hardware Overview Hardware Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Inputs and Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Embedded microSD Card Slot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Embedded RS-232/RS-485 Serial Port Combo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Embedded Ethernet Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Chapter 2
About Your Controller Programming Software for Micro800 Controllers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Obtain Connected Components Workbench Software . . . . . . . . . . . . . . . . . . . . . . . . . 13
Use Connected Components Workbench Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Controller Changes in Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Using Run Mode Change (RMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Uncommitted Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
RMC Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Limitations of RMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Using Run Mode Configuration Change (RMCC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Using Modbus RTU Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Using EtherNet/IP Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Daylight Saving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Disconnecting Main Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Safety Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Periodic Tests of Master Control Relay Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Power Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Isolation Transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Power Supply Inrush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Loss of Power Source. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Input States on Power Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Other Types of Line Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Preventing Excessive Heat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Master Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Using Emergency-stop Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Chapter 3
Install Your Controller Controller Mounting Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Module Spacing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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DIN Rail Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Panel Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Panel Mounting Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Connect the Controller to an EtherNet/IP Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Install the microSD Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Install the 2080-REMLCD Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Chapter 4
Wire Your Controller Wiring Requirements and Recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Wire Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Use Surge Suppressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Recommended Surge Suppressors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Grounding the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Controller I/O Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Minimize Electrical Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Analog Channel Wiring Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Minimize Electrical Noise on Analog Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Grounding Your Analog Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Wiring Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Wiring Analog Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Chapter 5
Communication Connections Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Supported Communication Protocols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Modbus RTU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
CIP Serial Client/Server – RS-232 only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
ASCII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Modbus TCP Client/Server . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
CIP Symbolic Client/Server. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
CIP Client Messaging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Sockets Client/Server TCP/UDP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
CIP Communications Pass-thru. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Examples of Supported Architectures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Use Modems with Micro800 Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Making a DF1 Point-to-Point Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Construct Your Own Modem Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Configure Serial Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Configure CIP Serial Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Configure Modbus RTU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Configure ASCII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Configure Ethernet Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Validate IP Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Ethernet Host Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
OPC Support Using FactoryTalk Linx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

4 Rockwell Automation Publication 2080-UM005G-EN-E - December 2023

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Chapter 6
Program Execution in Micro800 Overview of Program Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Execution Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Optional Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Controller Load and Performance Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Periodic Execution of Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Power Up and First Scan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Variable Retention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Memory Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Guidelines and Limitations for Advanced Users. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Chapter 7
Controller Security Operation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Exclusive Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Password Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Compatibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Work with a Locked Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Upload from a Password-Protected Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Debug a Password-Protected Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Download to a Password-Protected Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Transfer Controller Program and Lock Receiving Controller . . . . . . . . . . . . . . . . . . . . 67
Back Up and Restore a Password-Protected Controller. . . . . . . . . . . . . . . . . . . . . . . . 68
Configure Controller Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Recover from a Lost Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Chapter 8
Using the Micro800 Remote LCD Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
USB Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Text Display Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Startup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Navigate the Remote LCD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
User-defined Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Backup and Restore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
ASCII Code for Special Characters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Chapter 9
Using microSD Cards Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Project Backup and Restore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Backup and Restore Directory Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Power-up Settings in ConfigMeFirst.txt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
General Configuration Rules in ConfigMeFirst.txt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
ConfigMeFirst.txt Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Deliver Project Updates to Customers Through Email . . . . . . . . . . . . . . . . . . . . . . . . . 83
Datalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Datalog Directory Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Datalog Function (DLG) Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Recipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

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Recipe Directory Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Recipe Function (RCP) Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Quick Start Projects for Datalog and Recipe Function Blocks . . . . . . . . . . . . . . . . . . . . . . . 93
Use the Recipe Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Appendix A
Modbus Mapping for Micro800 Modbus Mapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Controllers Endian Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Mapping Address Space and supported Data Types . . . . . . . . . . . . . . . . . . . . . . . . . 103
Example 1, PanelView Component HMI (Master) to Micro800 (Slave) . . . . . . . . . . . . . 104
Example 2, Micro800 (Master) to PowerFlex 4M Drive (Slave) . . . . . . . . . . . . . . . . . . 105
Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Appendix B
Troubleshooting Status Indicators on the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Error Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Fault Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Corrective Action for Recoverable and Non-recoverable Faults . . . . . . . . . . . . . . . . 115
Retrieve a Fault Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Controller Error Recovery Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Calling Rockwell Automation for Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Appendix C
Quick Starts Update Your Micro800 Controller Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Firmware Update From microSD Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Establish Communications between RSLinx and a Micro820 Controller Through USB . . . 121
Configure Controller Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Set Controller Password. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Change Password. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Clear Password. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Forcing I/Os . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Checking if Forces (locks) are Enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
I/O Forces After a Power Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Using Run Mode Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Create the Project. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Edit the Project Using Run Mode Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Appendix D
PID Function Blocks PID Function Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
IPIDCONTROLLER Function Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
How to Auto Tune . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
How Auto Tune Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Troubleshooting an Auto Tune Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
PID Application Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145

6 Rockwell Automation Publication 2080-UM005G-EN-E - December 2023

 Preface

About This Publication Use this manual if you are responsible for designing, installing, programming, or troubleshooting
control systems that use Micro800™ controllers.

This manual is a reference guide for Micro820® controllers. 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.

See the Online Help provided with Connected Components Workbench™ software for more
information on programming your Micro800 controller.

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.

Conformal Coated Catalogs Catalog numbers with the suffix ‘K’ are conformal coated and their specifications are the same as
non-conformal coated catalogs.

Download Firmware, AOP, Download firmware, associated files (such as AOP, EDS, and DTM), and access product release
notes from the Product Compatibility and Download Center at rok.auto/pcdc.
EDS, and Other Files
Summary of Changes This publication contains the following new or updated information. This list includes substantive
updates only and is not intended to reflect all changes.
Topic Page
Updated template throughout
Important User
Added statement on inclusive language Information
Added Daylight Saving section 22
Added Operation Mode section 65

Additional Resources These documents contain additional information concerning related products from Rockwell
Automation. You can view or download publications at rok.auto/literature.
Additional Resources
Resource Description
Micro800 Programmable Controller Family Selection Guide, Provides information to help you select the Micro800 controller, plug-ins, expansion I/O, and
publication 2080-SG001 accessories, based on your requirements.
Provides detailed specifications for Micro800 controllers, expansion I/O modules, plug-in
Micro800 Programmable Controllers Technical Data, publication 2080-TD001 modules, and accessories.
Provides information on features, configuration, installation, wiring, and specifications for the
Micro800 Plug-in Modules User Manual, publication 2080-UM004 Micro800 plug-in modules.
Micro800 Programmable Controllers General Instructions Reference Manual, Provides nformation on instruction sets for developing programs for use in Micro800 control
publication 2080-RM001 systems.
Micro800 Programmable Controllers: Getting Started with CIP Client Messaging Provides quick start instructions for using CIP GENERIC and CIP Symbolic Messaging.
Quick Start, publication 2080-QS002
Micro800 Programmable Controllers: Getting Started with PanelView Plus Quick Provides quick start instructions for using global variables for Micro800 controllers together with
Start, publication 2080-QS003 PanelView™ Plus HMI terminals.
Configuring Micro800 Controllers on FactoryTalk Linx Gateway Quick Start, Provides quick start instructions for configuring a Micro800 controller on FactoryTalk Linx
publication 2080-QS005 Gateway.
Micro800 Programmable Controllers Installation Instructions, Provides information on mounting and wiring Micro800 Controllers.
publication 2080-IN013
Micro800 RS-232/RS-485 Isolated Serial Port Plug-in Module Wiring Diagrams, Provides nformation on mounting and wiring the Micro800 RS-232/485 Isolated Serial Port Plug-
publication 2080-WD002 in Module.
Micro800 Non-isolated Unipolar Analog Input Plug-in Module Wiring Diagrams, Information on mounting and wiring the Micro800 Non-isolated Unipolar Analog Input Plug-in
publication 2080-WD003 Module.

Rockwell Automation Publication 2080-UM005G-EN-E - December 2023 7

Preface

Additional Resources (Continued)

Resource Description
Micro800 Non-isolated Unipolar Analog Output Plug-in Module Wiring Diagrams, Information on mounting and wiring the Micro800 Non-isolated Unipolar Analog Output Plug-in
publication 2080-WD004 Module.
Micro800 Non-isolated RTD Plug-in Module Wiring Diagrams, Provides information on mounting and wiring the Micro800 Non-isolated RTD Plug-in Module.
publication 2080-WD005
Micro800 Non-isolated Thermocouple Plug-in Module Wiring Diagrams, Provides information on mounting and wiring the Micro800 Non-isolated Thermocouple Plug-in
publication 2080-WD006 Module.
Micro800 Remote LCD Installation instructions, publication 2080-IN010 Provides information on mounting and wiring the Micro800 remote LCD module.
Micro800 6-Channel Trimpot Analog Input Plug-In Module Wiring Diagrams, Provides information on mounting and wiring the Micro800 6-Channel Trimpot Analog Input Plug-
publication 2080-WD008 In Module.
Micro800 Digital Relay Output Plug-in Module Wiring Diagrams, Provides information on mounting and wiring the Micro800 Digital Relay Output Plug-in Module.
publication 2080-WD010
Micro800 Digital Input, Output, and Combination Plug-in Modules Wiring Provides information on mounting and wiring the Micro800 Digital Input, Output, and Combination
Diagrams, publication 2080-WD011 Plug-in Modules.
Micro800 High Speed Counter Plug-in Module Wiring Diagrams, Provides information on mounting and wiring the High Speed Counter Plug-in module.
publication 2080-WD012
Micro800 DeviceNet Plug-in Module Wiring Diagrams, publication 2080-WD013 Provides information on mounting and wiring the Micro800 DeviceNet plug-in module.
Describes how to configure and use EtherNet/IP devices to communicate on the EtherNet/IP
EtherNet/IP Network Devices User Manual, publication ENET-UM006 network.
Ethernet Reference Manual, publication ENET-RM002 Describes basic Ethernet concepts, infrastructure components, and infrastructure features.
Provides guidance on how to conduct security assessments, implement Rockwell Automation
System Security Design Guidelines Reference Manual, publication SECURE-RM001 products in a secure system, harden the control system, manage user access, and dispose of
equipment.
Assists original equipment manufacturers (OEMs) with construction of panels, to help ensure that
UL Standards Listing for Industrial Control Products, publication CMPNTS-SR002 they conform to the requirements of Underwriters Laboratories.
American Standards, Configurations, and Ratings: Introduction to Motor Circuit Provides an overview of American motor circuit design based on methods that are outlined in the
Design, publication IC-AT001 NEC.
Industrial Components Preventive Maintenance, Enclosures, and Contact Ratings Provides a quick reference tool for Allen-Bradley industrial automation controls and assemblies.
Specifications, publication IC-TD002
Designed to harmonize with NEMA Standards Publication No. ICS 1.1-1987 and provides general
Safety Guidelines for the Application, Installation, and Maintenance of Solid-state guidelines for the application, installation, and maintenance of solid-state control in the form of
Control, publication SGI-1.1 individual devices or packaged assemblies incorporating solid-state components.
Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Provides general guidelines for installing a Rockwell Automation industrial system.
Helps configure complete, valid catalog numbers and build complete quotes based on detailed
Product Selection and Configuration webpage, rok.auto/systemtools product information.
Product Certifications website, rok.auto/certifications Provides declarations of conformity, certificates, and other certification details.

You can download the latest version of Connected Components Workbench software for your
Micro800 controller at rok.auto/ccw.

8 Rockwell Automation Publication 2080-UM005G-EN-E - December 2023

 Chapter 1
Hardware Overview

This chapter provides an overview of the Micro820 hardware features.

Hardware Features Micro820 controllers are 20-point economical brick style controllers with embedded inputs and
outputs. These controllers can accommodate up to two plug-in modules and can connect to a
remote LCD (2080-REMLCD) for configuring. The Micro820 controller also has a microSD™ card slot
for project backup and restore, and datalog and recipe. Only Allen-Bradley® microSD cards,
2080-SD-2GB are supported.

IMPORTANT The Micro820 controller supports all Micro800 plug-in modules, except for
2080-MEMBAK-RTC and 2080-MEMBAK-RTC2.
For more information, see the Micro800 Plug-in Modules User Manual,
publication 2080-UM004.

For information on the REMLCD module, see Using the Micro800 Remote LCD on page 69.

The controller also accommodates any class 2 rated 24V DC output power supply that meets
minimum specifications such as the optional Micro800 power supply.

Rockwell Automation Publication 2080-UM005G-EN-E - December 2023 9

Chapter 1 Hardware Overview

Micro820 Controllers
1 3

13

12 4

11

10

9
6
8
7

Micro820 Controller Description

Description Description
1 Optional power supply slot 8 Mounting feet
2 Plug-in latch 9 RJ45 Ethernet connector port
3 Mounting screw hole 10 Power supply
4 40-pin high-speed plug-in connector slot 11 Status indicators
5 microSD (Micro Secure Digital) card slot 12 RS-232/RS-485 non-isolated combo Serial ports
6 Removable/fixed terminal blocks 13 Removable/fixed terminal blocks
7 DIN rail mounting latch

Status Indicators

2 5
3 6
4 7

Micro820 Controller Status Indicator Description(1)

Description Description
1 Input status 5 Fault status
2 Run status 6 Comm status
3 Force status 7 SD status
4 ENET status 8 Output status
(1) For detailed description of the different status indicators, see Troubleshooting on page 109.

ATTENTION: Removable terminal blocks are available on catalog numbers that

end in R (for example, 2080-LC20-20QBBR). Fixed terminal blocks are available on
catalog numbers that do not end in R (for example, 2080-LC20-20QBB).
You can order a replacement terminal block, catalog number 2080-RPL24RTB,
separately.

10 Rockwell Automation Publication 2080-UM005G-EN-E - December 2023

 Chapter 1 Hardware Overview

Inputs and Outputs

Table 1 - Micro820 Controllers – Number and Types of Inputs/Outputs

Inputs Outputs
Analog Out Analog In
Catalog Number
120V AC 120/240V AC 24V DC Relay 24V DC 24V DC 0…10V DC 0…10V (shared with DC In) PWM Support
Source Sink
2080-LC20-20AWB 8 – 4 7 – – 1 4 –
2080-LC20-20AWBR 8 – 4 7 – 1 4 –
2080-LC20-20QWB – – 12 7 – – 1 4 –
2080-LC20-20QWBR – – 12 7 – – 1 4 –
2080-LC20-20QBB – – 12 7 – 1 4 1
2080-LC20-20QBBR – – 12 – 7 – 1 4 1

Embedded microSD Card Slot

Micro820 controllers support Micro Secure Digital (microSD) cards through an embedded microSD
card slot. The design supports Class 6 and 10 SDSC and SDHC microSD cards, with FAT32/16
formats. The microSD file system supports only one file partition. Only Allen-Bradley microSD cards,
2080-SD-2GB are supported.

The microSD card is primarily used for project backup and restore, as well as datalog and recipe
functions. It can also be used to configure power-up settings (such as controller mode, IP address,
and so on) through an optional ConfigMeFirst.txt file.

For more information, see Using microSD Cards on page 79.

To help you troubleshoot microSD card-related errors, see Troubleshooting on page 109.

WARNING: The microSD card slot only supports Allen-Bradley microSD card 2080-
SD-2GB. Other microSD cards may not work and are not recommended.

Embedded RS-232/RS-485 Serial Port Combo

The Micro820 controller supports an embedded non-isolated RS-232/RS-485 combo
communications port. Only one port (RS-232 or RS-485) can work at any given time. The
communication rate of this port supports up to 38.4 K.
The communication port uses a 6-pin 3.5 mm terminal block with pin definition shown in Table 2.

IMPORTANT Serial port cables should not exceed 3 m (9.84 ft.) length.

Table 2 - RS-232/RS-485 Serial Port Pin Definition

Pin Definition RS-485 Example RS-232 Example
D+ G Tx

1 2 3 4 5 6 1 RS-485+ RS-485+ (not used)

D- Rx G
2 RS-485- RS-485- (not used)
3 GND GND GND
4 RS-232 input (receiver) (not used) RxD
5 RS-232 output (driver) (not used) TxD
6 GND GND GND

Rockwell Automation Publication 2080-UM005G-EN-E - December 2023 11

Chapter 1 Hardware Overview

The communication port (both RS-232 and RS-485) are non-isolated. The signal ground of the port
is not isolated to the logic ground of the controller.

The RS-232 port supports connection to the Micro800 Remote LCD module (2080-REMLCD).

REMLCD to Micro820 Serial Port Terminal Block Wiring

REMLCD Serial Port Micro820 Serial Port
Terminal Block Terminal Block
Signal Pin number Pin number Signal
RS-232 TX 1 <--------> 4 RX RS-232
RS-232 RX 2 <--------> 5 TX RS-232
RS-232 G 3 <--------> 6 G RS-232

Embedded Ethernet Support

A 10/100 Base-T Port is available for connection to an Ethernet network through any standard RJ45
Ethernet cable.
RS-485

RJ45 Ethernet Port Pin Mapping

Contact RJ45 connector
Signal Direction Primary Function
Number
1 TX+ OUT Transmit data +
2 TX- OUT Transmit data - 1

3 RX+ IN Receive data +

4 – – – 8

5 – – –
6 RX- IN Receive data -
7 – – –
8 – – –

Ethernet port pin-to-pin connection

1 white-orange
2 orange
3 white-green
4 blue

5 white-blue
6 green
7 white-brown
8 brown

1 white-orange
2 orange
3 white-green
4 blue

5 white-blue
6 green
7 white-brown
8 brown

For descriptions of the ENET status indicator, see Troubleshooting on page 109.

12 Rockwell Automation Publication 2080-UM005G-EN-E - December 2023

 Chapter 2
About Your Controller
Programming Software for Connected Components Workbench software is a set of collaborative tools supporting Micro800
controllers. It is based on Rockwell Automation and Microsoft® Visual Studio® technology and offers
Micro800 Controllers controller programming, device configuration and integration with HMI editor. Use this software to
program your controllers, configure your devices and design your operator interface applications.

Connected Components Workbench software provides a choice of IEC 61131-3 programming

languages (ladder diagram, function block diagram, structured text) with user-defined function
block (UDFB) support that optimizes machine control.

Obtain Connected Components Workbench Software

There are two editions for the Connected Components Workbench software:
• You can download Connected Components Workbench Standard Edition software for
free at rok.auto/pcdc.
• To purchase Connected Components Workbench Developer Edition software,
visit rok.auto/ccw.

Use Connected Components Workbench Software

To help you program your controller through the Connected Components Workbench software, you
can see the Connected Components Workbench Online Help that comes with the software.

Controller Changes in Run Micro820 controllers allow you to make certain changes while in Run mode by using the following
features:
Mode
• Run Mode Change (RMC)
Allows logic modifications to a running project without going to Remote Program mode.
For more information, see Using Run Mode Change (RMC) on page 13.
• Run Mode Configuration Change (RMCC)
Allows changing the address configuration of the controller to be made within a program
during run mode.
For more information, see Using Run Mode Configuration Change (RMCC) on page 17.

Using Run Mode Change Run Mode Change (RMC) is a productivity enhancement feature introduced in software version 8 for
Micro820 controllers. The feature saves the user time by allowing logic modifications to a running
(RMC) project without going to remote program mode and without disconnecting from the controller. You
must use the Connected Components Workbench Developer Edition software version 8 software, or
later, to use this feature.

IMPORTANT You must use Micro820 controller firmware revision 8.xxx or later to use Run
Mode Change.
RMC is useful during project development, when you add small changes incrementally to the logic
and want to see the effects of the changes on the machine immediately. With RMC, since the
controller stays in Remote Run mode, the controller logic and machine actuators do not have to
reinitialize constantly, which can occur if the controller is switched to Remote Program mode (for
example, the first scan bit is checked in the program logic to clear outputs).

Rockwell Automation Publication 2080-UM005G-EN-E - December 2023 13

Chapter 2 About Your Controller

When you edit, build, and download a project without using RMC, a full build of the entire controller
project is performed and a full download of the project is performed. During RMC an incremental
build is performed and only incremental changes are downloaded to the controller.

IMPORTANT Do not disconnect from the controller after you perform Run Mode Change,
do a full build, and then try to reconnect. Connected Components
Workbench software treats the project in the controller as different from
the project in Connected Components Workbench software, even though
the logic is identical, and asks to either upload or download the project.
RMC is performed incrementally at the end of every program scan in order to prevent a large delay
in the program scan. This adds up to an additional 12 ms to the scan time. For example, if the
program scan is normally 10 ms, it may increase to 22 ms during RMC until the update is finished.
Similarly user interrupts may be delayed.
Table 3 - Example of the Benefits of Using RMC – 20% Reduction in Download Time
Number of Time to Perform Conventional Download Time to Test Logic and Accept Changes
Changes (seconds) (seconds)
1 36 29
5 180 130
10 360 255
Memory size of project used for comparison:
Data = 14,784 bytes; Program = 2,352 bytes
Note: The duration starts when the RMC button is clicked while connected to the controller and ends when the accept is
finished. For example:
1. When connected to the controller, select RMC.
2. Modify the program.
3. Select Test Logic.
4. Select Accept to finish, or select Test Logic to make another change.

ATTENTION: Use extreme caution when you use Run Mode Change. Mistakes can
injure personnel and damage equipment. Before using Run Mode Change:
• Assess how machinery will respond to the changes.
• Notify all personnel about the changes.

A new global variable __SYSVA_PROJ_INCOMPLETE is added to indicate when Run Mode Changes
are being made. Use the variable to notify you on the HMI that there are uncommitted changes in
the controller.
Table 4 - Bit Definitions of Global Variable – __SYSVA_PROJ_INCOMPLETE
Bit Definition
Set when the Run Mode Change process starts.
Clears once the Run Mode Change is written permanently to the controller (completion of Accept or
0 Undo).
Use the bit to warn you that a Run Mode Change is in progress and that there are uncommitted
changes in the controller.
Set if an error occurs while saving the changes to flash memory or if an integrity check fails during
1 Run Mode Change.
Clears on the next successful Run Mode Change.

When you perform a Test Logic Change, the value of the variable changes from zero to one. After
you choose to accept or undo the changes, the value of the variable resets to zero.

IMPORTANT When you perform a Test Logic is performed, or undo changes after the
Test Logic is completed, any active communication instructions are
aborted while the changes download to the controller.

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 Chapter 2 About Your Controller

Uncommitted Changes
Uncommitted changes are changes that are made in RMC that have not been accepted or are
undone after a Test Logic Change is performed.

If the controller power loses power while there are uncommitted changes, you cannot reenter RMC
upon reconnection. You can choose to download the project again to keep the changes, or upload
to discard the uncommitted changes.

If you choose to upload a project with uncommitted changes from the controller, you cannot enter
RMC until you have performed a full download.

RMC Memory
Use Run Mode Change (RMC) memory to store both the logic and user variable changes made
during RMC. The default amount of memory allocated is 2 KB and you can increased it up to 8 KB.
However there is still a limit of 2 KB for logic and user variables changes per Test Logic. To adjust
the amount of RMC memory, the controller must be offline. After you have adjusted the amount, you
must build the project and download it to the controller.

IMPORTANT In a Connected Components Workbench software version 8 project, the

available user data space is reduced by 6 KB to support optimal project
settings for the new RMC feature.
If you have a project that is developed before software version 8, you may
need to reduce the default “Allocated” 8 KB Temporary Variables section
from the Memory page in order to compile the project successfully.
Figure 1 - Controller Memory Diagnostics Page in Connected Components Workbench Software

During RMC an incremental build is performed and only incremental changes are downloaded to
the controller until the RMC memory is filled.
Figure 2 - RMC Memory Usage Example
Controller Memory RMC Memory
(for User Program + Data) (Default size = 2KB)

First change Second change Third change

and Test Logic and Test Logic and Test Logic
(Add logic) (Remove logic) (Add logic)

Free memory

Free RMC memory Used RMC memory

Used memory

Rockwell Automation Publication 2080-UM005G-EN-E - December 2023 15

Chapter 2 About Your Controller

If insufficient RMC memory is available to make more changes (for example, a “not enough
memory” error message appears during the RMC build or Test Logic), then you must perform a full
download to transfer the incremental changes from the RMC memory to the standard user program
and data memory.
Transfer Contents in RMC Memory to Controller Memory

The changes that you made during RMC are stored in the RMC memory and remain there until you
perform a full build and download (while the controller is disconnected).
Figure 3 - RMC Memory Usage When Performing Full Build and Download Example
Controller Memory RMC Memory
(for User Program + Data) (Default size = 2KB)

Free memory Free RMC memory

Used RMC memory is copied

New used memory to controller memory

However, if the controller memory has insufficient space remaining to copy the contents of the RMC
memory as shown in Figure 4, the operation will fail and a “not enough memory” error message will
appear. Do not use RMC if you are near the limits of your controller memory.
Figure 4 - Insufficient Controller Memory Example
Controller Memory RMC Memory
(for User Program + Data) (Default size = 2KB)

Free RMC memory

Error occurs due to insufficient

Used memory remaining controller memory

Limitations of RMC
Take note of the following limitations when using the Run Mode Change (RMC) feature:
• You cannot make configuration changes (for example, change filter times).
• You can add up to 2 KB of logic (approximately 150 boolean instructions) and user variables
for each Test Logic.
• You can increase the total memory allocated for RMC (cumulative of all Test Logic Changes)
from 2 KB to 8 KB, but the 2 KB limit for logic and user variables per Test Logic remains.
• You can add a total of 20 Program Organizational Units (POU) for each RMC (for example, if
you currently have 5 POU, you can add 20 more for a total of 25 POU).
• If you modify a user defined function block (UDFB) that changes the local variables, the local
variables are reinitialized or reset to zero and a warning message shows during the build. If
you want to reapply the initial value, right-click on the UDFB and select
Refactor > Reset Initial Values of Instances.
• RMC is not possible after you perform a Discover Project operation, if a new module is
detected, because the configuration has changed.
• You cannot import exchange files when in RMC because an import is considered a
configuration change.

16 Rockwell Automation Publication 2080-UM005G-EN-E - December 2023

 Chapter 2 About Your Controller

• If you make changes to the display configuration (for example, hiding comments), they are
treated as logic changes and you must build the project.
• You can add global variables in RMC, but you cannot delete or modify them. To delete or
modify a global variable, you must disconnect the controller from the Connected
Components Workbench software.
• If you create a global variable in RMC, it does not show in the LCD display.
• When using Common Industrial Protocol (CIP™) messaging in RMC, setting the CIPTARGETCFG
data type parameter ConnClose to TRUE has no effect. The Ethernet session does not close
immediately upon successful messaging and you have to wait for the connection to timeout
after 60 seconds. This behavior applies to Connected Components Workbench software
version 9 or earlier projects. For version 10 or later projects you can configure the CIP
connection timeout.

WARNING: If you delete the output rung when in Run Mode Change and accept the
changes, the output on the controller will remain ON.

For an example of how to use this feature, see Using Run Mode Change on page 129.

Using Run Mode Run Mode Configuration Change (RMCC) is a productivity enhancement feature that is supported in
Connected Components Workbench software for Micro820 controllers. It allows you to reuse an
Configuration Change identical program with multiple controllers by changing the address configuration of a controller
(RMCC) within the program during run mode. You must have Micro820 controller firmware revision 9.011 or
later to use this feature.

You can use RMCC to change the address configuration of the controller during run mode, when
you set the communication protocol to Modbus RTU for the Serial ports, or EtherNet/IP™ for the
Ethernet port. RMCC uses a CIP Generic message, which you can only send from within a controller
program and not from an external device to the controller.
Figure 5 - CIP Generic Message Instruction for Run Mode Configuration Change

Only the controller that is sending the message can perform RMCC. To perform RMCC, you must
configure the CIP Generic message as a loop-back message by setting the path to “0,0”.
Figure 6 - Configure CIP Generic Message as a Loop-back Message

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Chapter 2 About Your Controller

For Micro820 controllers, the address configuration change is not permanent and is lost when the
controller is power cycled (for firmware revision 9 or earlier). If you want the address to change
immediately after a power cycle, you must perform this CIP Generic message after every power up.
You can do this by doing the following:
• Use the system variable __SYSVA_POWER_UP_BIT.
• Set the Retained flag for the variable containing the new address.

From firmware revision 10 or later, Micro820 controllers now retains the address configuration
when you cycle power to the controller.
Figure 7 - Set Retained Flag – Modbus Address

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 Chapter 2 About Your Controller

Figure 8 - Set Retained Flag – EtherNet/IP Address

Using Modbus RTU Communication

To use RMCC with the Modbus RTU communication protocol, you must set the Serial port to the
Modbus slave role. A CIP Generic message is sent from within a program with the following
parameters.
Table 5 - CIP Generic Message Parameters for RMCC using Modbus RTU
Parameter Value
Service 16
Class 70
2 – Embedded Serial port
Instance 5, 6, 7, 8, or 9 – Plug-in modules
Attribute 100
ReqData New node address, 1
ReqLen 2

Figure 9 - RMCC Modbus Example – Set the Parameters

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Chapter 2 About Your Controller

Figure 10 - RMCC Modbus Example – Set the New Node Address

The first byte indicates the new node address for the controller. For this example, the new node
address is “3”. The second byte must always be “1”, this indicates that the Modbus role is
configured as Slave.
Figure 11 - RMCC Modbus Example – Set the Message Length

When the new node address is configured and applied, the port is not restarted.

IMPORTANT You must ensure that the new node address being configured is unique as
it will not be checked against existing node addresses of other devices.

You can verify that the node address has changed after performing RMCC by examining the
Communication Diagnostics tab for the controller.
Figure 12 - RMCC Modbus Example – Verify Address Change

Using EtherNet/IP Communication

To use RMCC with the EtherNet/IP communication protocol, you must configure the controller to use
a static IP address. If you configure the controller to use BOOTP or DHCP, the change is rejected. A
CIP Generic message is sent from within a program with the following parameters.

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 Chapter 2 About Your Controller

Table 6 - CIP Generic Message Parameters for RMCC using EtherNet/IP

Parameter Value
Service 16
Class 245
Instance 1
Attribute 5
ReqData IP address, Subnet mask, Gateway address
ReqLen 22 bytes

Figure 13 - RMCC EtherNet/IP Example – Set the Parameters

Figure 14 - RMCC EtherNet/IP Example – Set the New IP Address

For this example, the new IP Address is set to the following:

• IP address = 192.168.1.10
• Subnet mask = 255.255.255.0
• Gateway address = 192.168.1.1
Figure 15 - RMCC EtherNet/IP Example – Set the Message Length

After the new IP address is configured and applied, the controller disconnects from the Connected
Components Workbench software if communication is through Ethernet.

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Chapter 2 About Your Controller

IMPORTANT You should not perform IP address changes continuously. Allow an interval
of at least six seconds before you perform the next IP address change in
order for duplicate address detection to work properly.

You can verify that the IP address has changed after performing RMCC by examining the Ethernet
settings for the controller.
Figure 16 - RMCC EtherNet/IP Example – Verify Address Change

Daylight Saving
The Adjust for Daylight Saving (+01:00) option allows you to configure the controller to shift the
clock by 1 hour during the summer time. The feature is available for Micro820 controllers in the
Connected Components Workbench software version 22.00 or later.
Figure 17 - Daylight Saving

To enable daylight savings, do the following:

1. On the device configuration tree, go to the Controller properties and select Real Time Clock.
2. Select the Adjust for Daylight Saving (+01:00) option.
3. Download the project to the controller.
You can adjust the setting during runtime.

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.

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 Chapter 2 About Your Controller

Disconnecting Main Power

WARNING: Explosion Hazard

Do not replace components, connect equipment, or disconnect equipment unless
power has been switched off.

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.

Safety Circuits

WARNING: Explosion Hazard

Do not connect or disconnect connectors while circuit is live.

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.

Power Considerations The following explains power considerations for the Micro800 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.

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Chapter 2 About Your Controller

The only effect of limited inrush current and voltage sag on the Micro800 is that the power supply
capacitors charge more slowly. However, consider the effect of a voltage sag on other equipment.
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 optional Micro800 AC 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 power consumption of controller system, but is typically between 10 milliseconds
and 3 seconds.

Input States on Power Down

The power supply hold-up time as described earlier is longer than the turn-on and turn-off times of
the inputs. Because of this behavior, the controller may record the input state change from “On” to
“Off” that occurs when power is removed before the power supply shuts down the system. It is
important to understand this concept. You should write your program to account for this effect.

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.
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.

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. See
Figure 18 and Figure 19.

WARNING: Never alter these circuits to defeat their function since serious injury
and/or machine damage could result.

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 Chapter 2 About Your Controller

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.
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.
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.
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.
• Install emergency-stop switches and the master control relay in your system. Verify that
relay contacts have a sufficient rating for your application. Emergency-stop switches must
be easy to reach.
• In Figure 18 and Figure 19, 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.
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.

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Chapter 2 About Your Controller

Figure 18 - Schematic with IEC Symbols

L1 L2
230V AC

Disconnect
Fuse MCR

230V AC
I/O circuits

Isolation Operation of either of these contacts will remove

transformer power from the external I/O circuits and stops
Master Control Relay (MCR)
115V AC or machine motion.
X1 X2 Catalog Number 700-PK400A1
230V AC
Emergency stop Stop Start Suppressor
Fuse push button Catalog Number 700-N24
Overtravel limit
switch
MCR

Suppressor
MCR

MCR
115V AC or 230V AC
I/O circuits

DC power supply.
Use IEC 950/EN 60950.
_ MCR
+
24V DC
(Lo) (Hi)
I/O circuits
Line terminals: Connect to terminals of power supply
Line terminals: Connect to 24V DC terminals of power supply

Figure 19 - Schematic with ANSI/CSA Symbols

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 Chapter 2 About Your Controller

L1 L2
230V AC

Disconnect
Fuse MCR
230V AC
Output
Circuits

Isolation Operation of either of these contacts will remove

transformer power from the external I/O circuits, stopping
Master Control Relay (MCR)
115V AC or machine motion.
X1 X2 Catalog Number 700-PK400A1
230V AC Emergency stop Suppressor
push button Start Catalog Number 700-N24
Fuse Overtravel limit Stop
switch
MCR

Suppressor
MCR

MCR

115V AC or 230V AC
I/O circuits

DC power supply. Use NEC

Class 2 for UL Listing.
MCR
_ +
(Lo) (Hi)
24V DC
Line terminals: Connect to terminals of power supply I/O circuits

Line terminals: Connect to 24V DC terminals of power supply

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Chapter 2 About Your Controller

Notes:

28 Rockwell Automation Publication 2080-UM005G-EN-E - December 2023

 Chapter 3
Install Your Controller
This chapter serves to guide you on how to install the controller.

Controller Mounting Mounting dimensions do not include mounting feet or DIN rail latches.
Dimensions 104 (4.09) 75 (2.95)

90 (3.54)

Measurements in mm (in.)

Module Spacing
Maintain spacing from enclosure walls, wireways, and adjacent equipment. Allow 50.8 mm (2 in.) of
space on all sides. This provides ventilation and electrical isolation. If optional accessories/
modules are attached to the controller, such as the power supply 2080-PS120-240VAC or
expansion I/O modules, make sure that there is 50.8 mm (2 in.) of space on all sides after attaching
the optional parts.

DIN Rail Mounting

The module can be mounted using the following DIN rails: 35 x 7.5 x 1 mm and 35 x 15 mm (EN 50
022 - 35 x 7.5 and EN 50 022 - 35 x 15).
For environments with greater vibration and shock concerns, use the panel
mounting method, instead of DIN rail mounting.
Before mounting the module on a DIN rail, use a flat-blade screwdriver in the DIN rail latch and pry
it downwards until it is in the unlatched position.
1. Hook the top of the DIN rail mounting area of the controller onto the DIN rail, and then press
the bottom until the controller snaps onto the DIN rail.
2. Push the DIN rail latch back into the latched position.
Use DIN rail end anchors (Allen-Bradley part number 1492-EAJ35 or 1492-EAHJ35) for
vibration or shock environments.

To remove your controller from the DIN rail, pry the DIN rail latch downwards until it is in the
unlatched position.

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Chapter 3 Install Your Controller

Panel Mounting
The preferred mounting method is to use four M4 (#8) screws per module. Hole spacing tolerance:
±0.4 mm (0.016 in.).

Follow these steps to install your controller using mounting screws.

1. Place the controller against the panel where you are mounting it. Make sure the controller is
spaced properly.
2. Mark drilling holes through the mounting screw holes and mounting feet, then remove the
controller.
3. Drill the holes at the markings, then replace the controller and mount it.
Leave the protective debris strip in place until you are finished wiring the controller and any
other devices.

Panel Mounting Dimensions

Micro820 20-point controllers
2080-LC20-20AWB, 2080-LC20-20QWB, 2080-LC20-20QBB 2080-LC20-20AWBR, 2080-LC20-20QWBR,
2080-LC20-20QBBR
86 mm (3.39 in.)

100 mm
(3.94 in.)

Connect the Controller to an Connect the RJ45 connector of the Ethernet cable to the Ethernet port on the controller. The port is
on the bottom of the controller.
EtherNet/IP Network

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 Chapter 3 Install Your Controller

WARNING: If you connect or disconnect the communications cable with power

applied to this module or any device on the 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.

Install the microSD Card 1. Insert the microSD card into the card slot.
You can install the microSD card in one orientation only. The beveled corner must be at the
bottom. If you feel resistance when you insert the microSD card, pull it out and change the
orientation.

Insert the microSD card

into the slot.

2. Gently press the card until it clicks into place.

3. To remove the microSD card from the slot, gently press the card until it clicks back and
releases itself from the slot.

Install the 2080-REMLCD The Micro820 controller supports the 2080-REMLCD module, a simple text display interface for
configuring settings such as IP address. It can be mounted through a front panel or on the same
Module DIN rail as the controller.

For information on how the Remote LCD interfaces with the Micro820 controller, see Using the
Micro800 Remote LCD on page 69.

To learn about installation, hardware features, and specifications of the 2080-REMLCD module, see
the Micro800 Remote LCD Installation Instructions, publication 2080-IN010 in the Literature Library.

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Chapter 3 Install Your Controller

Notes:

32 Rockwell Automation Publication 2080-UM005G-EN-E - December 2023

 Chapter 4
Wire Your Controller
This chapter provides information on the Micro820 controller wiring requirements.

Wiring Requirements and

Recommendation WARNING: Before you install and wire any device, disconnect power to the
controller system.

WARNING: Calculate the maximum possible current in each power and common
wire. Observe all electrical codes dictating the maximum current allowable for
each wire size. Current above the maximum ratings may cause wiring to
overheat, which can cause damage.
United States Only: If the controller is installed within a potentially hazardous
environment, all wiring must comply with the requirements stated in the National
Electrical Code 501-10 (b).

• Allow for at least 50 mm (2 in.) between I/O wiring ducts or terminal strips and the
controller.
• Route incoming power to the controller by a path separate from the device wiring. Where
paths must cross, their intersection should be perpendicular.
Do not run signal or communications wiring and power wiring in the same conduit.
Wires with different signal characteristics should be routed by separate paths.
• Separate wiring by signal type. Bundle wiring with similar electrical characteristics together.
• Separate input wiring from output wiring.
• Label wiring to all devices in the system. Use tape, shrink-tubing, or other dependable
means for labeling purposes. In addition to labeling, use colored insulation to identify wiring
based on signal characteristics. For example, you may use blue for DC wiring and red for AC
wiring.

Wire Requirements
Table 7 - Wire Requirements for Fixed Terminal Blocks
Min Max
Solid 0.14 mm2 (26 AWG) 2.5 mm2 (14 AWG)
Rated @ 90 °C (194 °F) insulation max
Stranded 0.14 mm2 (26 AWG) 1.5 mm2 (16 AWG)

Table 8 - Wire Requirements for Removable Terminal Blocks

Min Max
Solid and stranded 0.2 mm2 (24 AWG) 2.5 mm2 (14 AWG) Rated @ 90 °C (194 °F) insulation max

Table 9 - Wire Requirements for RS-232/RS-485 Serial Port Terminal Block

Min Max
Solid 0.14 mm2 (26 AWG) 1.5 mm2 (16 AWG)
Rated @ 90 °C (194 °F) insulation max
Stranded 0.14 mm2 (26 AWG) 1.0 mm2 (18 AWG)

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Chapter 4 Wire Your Controller

Use Surge Suppressors Because of the potentially high current surges that occur when switching inductive load devices,
such as motor starters and solenoids, the use of some type of surge suppression to protect and
extend the operating life of the controllers output contacts is required. Switching inductive loads
without surge suppression can significantly reduce the life expectancy of relay contacts. By
adding a suppression device directly across the coil of an inductive device, you prolong the life of
the output or relay contacts. You also reduce the effects of voltage transients and electrical noise
from radiating into adjacent systems.

Figure 20 shows an output with a suppression device. We recommend that you locate the
suppression device as close as possible to the load device.
Figure 20 - Output with Suppression Device

+DC or L1
Suppression
device
VAC/DC
Out 0
Out 1

AC or DC Out 2
outputs Out 3 Load
Out 4
Out 5
Out 6
COM
DC COM or L2

If the outputs are DC, we recommend that you use an 1N4004 diode for surge suppression, as
shown in Figure 21. For inductive DC load devices, a diode is suitable. A 1N4004 diode is acceptable
for most applications. A surge suppressor can also be used. See Recommended Surge
Suppressors on page 35. These surge suppression circuits connect directly across the load device.
Figure 21 - DC Outputs with Surge Suppression
+24V DC

VAC/DC
Out 0
Out 1
Out 2
Relay or solid- Out 3
state DC outputs Out 4 1N4004 diode
Out 5
Out 6
24V DC common A surge suppressor can
COM
also be used.

Suitable surge suppression methods for inductive AC load devices include a varistor, an RC
network, or an Allen-Bradley surge suppressor, all shown below. These components must be
appropriately rated to suppress the switching transient characteristic of the particular inductive
device. See Recommended Surge Suppressors on page 35 for recommended suppressors.
Figure 22 - Surge Suppression for Inductive AC Load Devices

Output device Output device Output device

Surge
suppressor
Varistor RC network

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 Chapter 4 Wire Your Controller

Recommended Surge Suppressors

Use the Allen-Bradley surge suppressors in Figure 10 for use with relays, contactors, and starters.
Table 10 - Recommended Surge Suppressors
Device Coil Voltage Suppressor Catalog Number Type(1)
24…48V AC 100-KFSC50
110…280V AC 100-KFSC280 RC
380…480V AC 100-KFSC480
Bulletin 100/104K 700K 12…55V AC, 12…77V DC 100-KFSV55
56…136V AC, 78…180V DC 100-KFSV136 MOV
137…277V AC, 181…250V DC 100-KFSV277
12…250V DC 100-KFSD250 Diode
24…48V AC (2)
100-FSC48
110…280V AC 100-FSC280(1) RC
380…480V AC 100-FSC480(1)
12…55V AC, 12…77V DC 100-FSV55(1)
Bulletin 100C, (C09…C97)
56…136V AC, 78…180V DC 100-FSV136(1)
MOV
137…277V AC, 181…250V DC 100-FSV277(1)
278…575V AC 100-FSV575(1)
12…250V DC 100-FSD250(1) Diode
12…120V AC 599-K04
Bulletin 509 Motor Starter Size 0…5 MOV
240…264V AC 599-KA04
12…120V AC 199-FSMA1(3) RC
Bulletin 509 Motor Starter Size 6
12…120V AC 199-GSMA1(4) MOV
AC coil Not Required
24…48V DC 199-FSMA9
Bulletin 700 R/RM Relay
50…120V DC 199-FSMA10 MOV
130…250V DC 199-FSMA11
6…150V AC/DC 700-N24 RC
24…48V AC/DC 199-FSMA9
Bulletin 700 Type N, P, PK or PH Relay 50…120V AC/DC 199-FSMA10 MOV
130…250V AC/DC 199-FSMA11
6…300V DC 199-FSMZ-1 Diode
Miscellaneous electromagnetic devices limited to 35 6…150V AC/DC 700-N24 RC
sealed VA
(1) Do not use RC Type with Triac outputs. Varistor is not recommended for use on the relay outputs.
(2) Catalog numbers for screwless terminals include the string ’CR’ after ’100-’. For example: Cat. No. 100-FSC48 becomes Cat. No. 100-CRFSC48; Cat. No. 100-FSV55 becomes 100-CRFSV55; and so on.
(3) For use on the interposing relay.
(4) For use on the contactor or starter.

Grounding the Controller This product is intended to be mounted to a well grounded mounting surface such as a metal
panel. Refer to the Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1, for
additional information.

WARNING: All devices connected to the RS-232/RS-485 communication port

must be referenced to controller ground, or be floating (not referenced to a
potential other than ground). Failure to follow this procedure may result in
property damage or personal injury.

Rockwell Automation Publication 2080-UM005G-EN-E - December 2023 35

Chapter 4 Wire Your Controller

Wiring Diagrams Figure 23 to Figure 31 show the wiring diagrams for the Micro820 controllers. Controllers with DC
inputs can be wired as either sinking or sourcing inputs. Sinking and sourcing does not apply to AC
inputs.

High-speed inputs and outputs are indicated by .

Figure 23 - 2080-LC20-20AWB, 2080-LC20-20QWB, 2080-LC20-20AWBR, 2080-LC20- 20QWBR
Input Terminal Block

+DC10 I-00 I-02 COM0 I-05 I-07 I-09 I-11

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
-DC24 I-01 I-03 I-04 I-06 I-08 I-10 NU

Output Terminal Block

+DC24 -DC24 NU O-00 O-01 O-02 CM3 O-05

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
-DC24 VO-0 CM0 CM1 CM2 O-03 O-04 O-06

IMPORTANT Note the following:

• The “-DC24” terminals on the Input (terminal 2) and Output (terminals 2 and
3) Terminal Blocks are internally shorted.
• “NU” means that the terminal is not used / no connection.
• Inputs I-00, I-01, I-02, and I-03 are shared between digital and analog inputs.
• Inputs I-00, I-01, I-02, and I-03 can only be used in sinking input
configuration.
• I-00 to I-03 are non-isolated input channels, do not connect -DC24 (Input
terminal 2) to Earth/Chassis ground.
• Do not connect -DC24 (Output terminal 2) to Earth/Chassis ground.
Figure 24 - 2080-LC20-20AWB, 2080-LC20-20AWBR — Sinking Input Configuration
L1 L2 +DC a
L2 a L1 a

2080-PSAC12W
-DC a

L
+DC10 I-00 I-02 COM0 I-05 I-07 I-09 I-11

N 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
-DC24 I-01 I-03 I-04 I-06 I-08 I-10 NU

+DC24 -DC24 NU O-00 O-01 O-02 CM3 O-05

+24 VDC
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
-DC24 VO-0 CM0 CM1 CM2 O-03 O-04 O-06
-24 VDC

CR CR CR CR
+DC b
L1 b L1 c +DC c
-DC b L2 c
L2 b -DC c

ATTENTION: For 2080-LC20-20AWB/R catalogs, inputs 00…03 are limited to

24V DC. All other inputs (04…11) are limited to 120V AC.

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 Chapter 4 Wire Your Controller

Table 11 - Digital Input

Terminal Input Common Terminal Input Terminal
Controller Number Terminal Label Number Label
3 I-00
4 I-01
2 “-DC24” (24V DC sink only)
5 I-02
6 I-03
8 I-04
2080-LC20-20AWB, 9 I-05
2080-LC20-20AWBR 10 I-06
11 I-07
7 CM0 (120V AC)
12 I-08
13 I-09
14 I-10
15 I-11

Table 12 - Digital Output

Terminal Input Common Terminal Input Terminal
Controller Number Terminal Label Number Label
6 CM0 (VAC/DC) 7 O-00
2080-LC20-20AWB, 8 CM1 (VAC/DC) 9 O-01
2080-LC20-20AWBR 10 CM2 (VAC/DC) 11, 12 O-02, O-03
13 CM3 (VAC/DC) 14, 15, 16 O-04, O-05, O-06

Figure 25 - 2080-LC20-20QWB, 2080-LC20-20QWBR — DC Sinking Input Configuration – Inputs 00...11

L1 L2 +DC a -DC b +DC b

2080-PSAC12W -DC a

L
+DC10 I-00 I-02 COM0 I-05 I-07 I-09 I-11

N 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
-DC24 I-01 I-03 I-04 I-06 I-08 I-10 NU

+DC24 -DC24 NU O-00 O-01 O-02 CM3 O-05

+24 VDC
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
-DC24 VO-0 CM0 CM1 CM2 O-03 O-04 O-06
-24 VDC

CR CR CR CR
+DC c

-DC c L1 a +DC d -DC d +DC e

L2 a -DC e

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Chapter 4 Wire Your Controller

Figure 26 - DC Sourcing Input Configuration – Inputs 4...11

L1 L2
+DC a +DC b -DC b

2080-PSAC12W
-DC a

L
+DC10 I-00 I-02 COM0 I-05 I-07 I-09 I-11

N 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
-DC24 I-01 I-03 I-04 I-06 I-08 I-10 NU

+DC24 -DC24 NU O-00 O-01 O-02 CM3 O-05

+24 VDC
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
-DC24 VO-0 CM0 CM1 CM2 O-03 O-04 O-06
-24 VDC

CR CR CR CR
+DC c

-DC c L1 a +DC d -DC d +DC e

L2 a -DC e

Table 13 - Digital Input

Terminal Input Common Terminal Input Terminal
Controller Number Terminal Label Number Label
3 I-00
4 I-01
2 “-DC24” (24V DC sink only)
5 I-02
6 I-03
8 I-04
2080-LC20-20QWB, 9 I-05
2080-LC20-20QWBR 10 I-06
11 I-07
7 CM0 (24V DC sink/source)
12 I-08
13 I-09
14 I-10
15 I-11

Table 14 - Digital Output

Terminal Input Common Terminal Input Terminal
Controller Number Terminal Label Number Label
6 CM0 (VAC/DC) 7 O-00
2080-LC20-20QWB, 8 CM1 (VAC/DC) 9 O-01
2080-LC20-20QWBR 10 CM2 (VAC/DC) 11, 12 O-02, O-03
13 CM3 (VAC/DC) 14, 15, 16 O-04, O-05, O-06

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 Chapter 4 Wire Your Controller

Figure 27 - 2080-LC20-20QBB / 2080-LC20-20QBBR

Input Terminal Block

+DC10 I-00 I-02 COM0 I-05 I-07 I-09 I-11

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
-DC24 I-01 I-03 I-04 I-06 I-08 I-10 NU

Output Terminal Block

+DC24 -DC24 NU O-00 O-02 -CM0 O-04 O-06

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
-DC24 VO-0 +CM0 O-01 O-03 +CM1 O-05 -CM1

IMPORTANT Note the following:

• The “-DC24” terminals on the Input (terminal 2) and Output (terminals 2 and
3) Terminal Blocks are internally shorted.
• “NU” means that the terminal is not used / no connection.
• Inputs I-00, I-01, I-02, and I-03 are shared between digital and analog inputs.
• Inputs I-00, I-01, I-02, and I-03 can only be used in sinking input
configuration.
• I-00 to I-03 are non-isolated input channels, do not connect -DC24 (Input
terminal 2) to Earth/Chassis ground.
• Do not connect -DC24 (Output terminal 2) to Earth/Chassis ground.
Figure 28 - DC Sinking Input Configuration – Inputs 00...11
L1 L2 +DC a
-DC b +DC b

2080-PSAC12W -DC a

L
+DC10 I-00 I-02 COM0 I-05 I-07 I-09 I-11

N 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
-DC24 I-01 I-03 I-04 I-06 I-08 I-10 NU

+DC24 -DC24 NU O-00 O-02 -CM0 O-04 O-06

+24 VDC
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
-DC24 VO-0 +CM0 O-01 O-03 +CM1 O-05 -CM1
-24 VDC

CR CR CR

+DC c +DC d
-DC c
-DC d

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Chapter 4 Wire Your Controller

Figure 29 - DC Sourcing Input Configuration – Inputs 4...11

L1 L2 +DC a
+DC b -DC b

2080-PSAC12W -DC a

L
+DC10 I-00 I-02 COM0 I-05 I-07 I-09 I-11

N 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
-DC24 I-01 I-03 I-04 I-06 I-08 I-10 NU

+DC24 -DC24 NU O-00 O-02 -CM0 O-04 O-06

+24 VDC
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
-DC24 VO-0 +CM0 O-01 O-03 +CM1 O-05 -CM1
-24 VDC

CR CR CR

+DC c +DC d
-DC c
-DC d

Table 15 - Digital Input

Terminal Input Common Terminal Input Terminal
Controller Number Terminal Label Number Label
3 I-00
4 I-01
2 “-DC24” (24V DC sink only)
5 I-02
6 I-03
8 I-04
2080-LC20-20QBB, 9 I-05
2080-LC20-20QBBR 10 I-06
11 I-07
7 CM0 (24V DC sink/source)
12 I-08
13 I-09
14 I-10
15 I-11

Table 16 - Digital Output

Terminal Input Common Terminal Input Terminal
Controller Number Terminal Label Number Label
6 +CM0 (VDC source) O-00, O-01, O-02, O-
7, 8, 9, 10
2080-LC20-20QBB, 11 -CM0 03
2080-LC20-20QBBR 12 +CM1 (VDC source)
13, 14, 15 O-04, O-05, O-06
16 -CM1

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 Chapter 4 Wire Your Controller

Figure 30 - Serial Port Terminal Block

(View into terminal block)

D+ G Tx Pin 1 RS-485 Data +
1 2 3 4 5 6 Pin 2 RS-485 Data -
D- Rx G Pin 3 RS-485 Ground(1)
Pin 4 RS-232 Receive
Pin 5 RS-232 Transmit
Pin 6 RS-232 Ground(1)

(1) Non-isolated.

Figure 31 - Serial Port Wiring

Non-isolated Serial Port of a Serial Port of External

Micro820 controller Device

RS-485
D+ D+

D- D-

G G

Rx
If the length of the Serial cable is greater than
Tx 3 meters (9.84 feet), use an isolated Serial
port, catalog number 2080-SERIALISOL.
G

D+
If the length of the Serial cable is greater than
D-
3 meters (9.84 feet), use an isolated Serial
port, catalog number 2080-SERIALISOL.
G
RS-232
Rx Tx

Tx Rx

G G

IMPORTANT Do not connect G terminals of the Serial port to Earth/Chassis ground.

Controller I/O Wiring This section contains some relevant information about minimizing electrical noise and also includes
some wiring examples.

Minimize Electrical Noise

Because of the variety of applications and environments where controllers are installed and
operating, it is impossible to ensure that all environmental noise will be removed by input filters. To
help reduce the effects of environmental noise, install the Micro800 system in a properly rated (for
example, NEMA) enclosure. Make sure that the Micro800 system is properly grounded.

A system may malfunction due to a change in the operating environment after a period of time. We
recommend periodically checking system operation, particularly when new machinery or other
noise sources are installed near the Micro800 system.

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Chapter 4 Wire Your Controller

Analog Channel Wiring Guidelines

Consider the following when wiring your analog channels:
• The analog common (-DC24) is not electrically isolated from the system, and is connected to
the power supply common.
• Analog channels are not isolated from each other.
• Use Belden cable #8761, or equivalent, shielded wire.
• Under normal conditions, the drain wire (shield) should be connected to the metal mounting
panel (earth ground). Keep the shield connection to earth ground as short as possible.
• To ensure optimum accuracy for voltage type inputs, limit overall cable impedance by
keeping all analog cables as short as possible. Locate the I/O system as close to your
voltage type sensors or actuators as possible.

Minimize Electrical Noise on Analog Channels

Inputs on analog channels employ digital high-frequency filters that significantly reduce the effects
of electrical noise on input signals. However, because of the variety of applications and
environments where analog controllers are installed and operated, it is impossible to ensure that all
environmental noise will be removed by the input filters.

Several specific steps can be taken to help reduce the effects of environmental noise on analog
signals:
• Install the Micro800 system in a properly rated enclosure, for example, NEMA/IP. Make sure
that the shield is properly grounded.
• Use Belden cable #8761 for wiring the analog channels, making sure that the drain wire and
foil shield are properly earth grounded.
• Route the Belden cable separately from any AC wiring. Additional noise immunity can be
obtained by routing the cables in grounded conduit.

Grounding Your Analog Cable

Use shielded communication cable (Belden #8761). The Belden cable has two signal wires (black
and clear), one drain wire, and a foil shield. The drain wire and foil shield must be grounded at one
end of the cable.

Foil shield
Black wire

Insulation
Drain wire

Clear wire

IMPORTANT Do not ground the drain wire and foil shield at both ends of the cable.

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 Chapter 4 Wire Your Controller

Wiring Examples
Examples of sink/source, input/output wiring are shown in Figure 32, Figure 33, and Figure 34.
Figure 32 - Sink Input Wiring Example

Com 24V
DC
~ +

I/P
Fuse

Figure 33 - Source Output Wiring Example

+V DC
Fuse
Logic side
User side
S OUT +

G –
Load
24V Supply

DC COM

IMPORTANT For 2080-LC20-20QBB(R) discrete output 06, shielded cable is required if the
output is used as PWM. Otherwise, unshielded cable can be used.
Figure 34 - Source Input Wiring Example

Com
Fuse
~
+
I/P
24V
DC

Wiring Analog Channels Analog input circuits can monitor voltage signals and convert them to Serial digital data as shown
in Figure 35 and Figure 36.

ATTENTION: Analog inputs and outputs are not isolated.

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Chapter 4 Wire Your Controller

Figure 35 - Analog Input to Sensors

Sensor 3
(V) Voltage

Sensor 2
(V) Voltage

Sensor 1
(V) Voltage

Sensor 0
(V) Voltage

Note: Terminal block to wire commons 1 2 3 4

is not included in Micro800 package. 1 2 3 4

+DC10 I-00 I-02 COM0 I-05 I-07 I-09 I-11

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
-DC24 I-01 I-03 I-04 I-06 I-08 I-10 NU

The “-DC24” terminal is the analog ground connection for analog inputs (I-00…I-03).

Figure 36 - Analog Input to Thermistors

Thermistor 3

Thermistor 2

Thermistor 1

Thermistor 0

Note: Terminal block to wire commons 1 2 3 4

is not included in Micro800 package. 1 2 3 4

+DC10 I-00 I-02 COM0 I-05 I-07 I-09 I-11

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
-DC24 I-01 I-03 I-04 I-06 I-08 I-10 NU

The “+DC10” terminal supplies 10V DC power source to the Thermistor inputs (I-00…I-03).

Calculate for Thermistor Resistance

While connecting Analog input to thermistor as shown in previous diagram, calculate input voltage
using the following equation:
Ri
Vi = * Vref
Ri + Rt

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 Chapter 4 Wire Your Controller

To calculate for thermistor resistance, use the following equation:

RiVref - ViRi
Rt =
Vi

Where:
Vi = Voltage input (±5% without calibration; ±2% with calibration)
Ri = Resistance input (14.14 kΩ ±2%)
Rt = Thermistor resistance (10 kΩ Thermistor is recommended)
Vref = 10V ±0.5V

IMPORTANT Micro820 controllers support 10 kΩ type thermistors.

In order to get the best results, the system must be calibrated.

To convert this resistance into a temperature, use the following Steinhart-Hart equation:
1
= a + bln(R) + c[ln(R)]3
T

Where:
Coefficients a, b, and c are provided by the thermistor manufacturer.
Calibrate Thermistor
1. Connect a resistor (10 kΩ is recommended) across Vref and Analog Input 00 of your
Micro820 controller following the diagram, Analog Input to Thermistors on page 44. The
resistor is measured as Ri using a precision multimeter.
2. Calculate the ideal counts (C1) for resistor (Ri) following this equation: C1 = 14.14 kΩ /
(14.14 kΩ + Ri) * 4095
3. Read the actual counts (C2) of Analog Input 00 from Connected Components Workbench
software.
4. Calculate for calibration Gain.
Gain = C1/C2

For example:
If Ri is measured as 10.00 kΩ, then
C1 = 14.14 / (14.14 + 10.00) * 4095 = 2399 counts;
C2 is read from Connected Components Workbench software as 2440; so
Gain = 2399/2440 = 98%.
5. In Connected Components Workbench software, go to Embedded I/O configuration page.
Change the Gain parameter value to 98 for Input 0.

No changes are required to the Offset parameter value.

6. Repeat the same steps to calibrate all the other analog input channels.

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Chapter 4 Wire Your Controller

Transmitters to Analog Input

2-wire Transmitter

+ – Controller
Power + I-00, I-01, I-02 or I-03
Supply
– -DC24

3-wire Transmitter

Supply GND Signal Controller

Power + I-00, I-01, I-02 or I-03
Supply
– -DC24

4-wire Transmitter

Supply Signal Controller

Power + + + I-00, I-01, I-02 or I-03
Supply
– – – -DC24

Analog Output

The analog output can support voltage function as shown in the following illustration.

Voltage
load

+DC24 -DC24 NU O-00 O-01 O-02 CM3 O-05

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
-DC24 VO-0 CM0 CM1 CM2 O-03 O-04 O-06

The “-DC24” terminal is the analog ground connection for analog output (VO-0).

46 Rockwell Automation Publication 2080-UM005G-EN-E - December 2023

 Chapter 5
Communication Connections
Overview This chapter describes how to communicate with your control system and configure
communication settings. The method that you use and cabling that is required to connect your
controller depends on what type of system you are employing. This chapter also describes how the
controller establishes communication with the appropriate network.

The Micro820 controllers have the following embedded communication channels:

• A non-isolated RS-232/RS-485 combo port
• RJ45 Ethernet port

Supported Communication Micro820 controllers support communication through the embedded RS-232/RS-485 Serial port
and any installed Serial port plug-in module. In addition, Micro820 controllers also support
Protocols communication through the embedded Ethernet port, and can be connected to a local area
network for various devices providing 10 Mbps/100 Mbps transfer rate.

Micro820 controllers support the following communication protocols:

• Modbus RTU Master and Slave
• CIP Serial Client/Server (RS-232 only)
• ASCII
• EtherNet/IP Client/Server
• Modbus TCP Client/Server
• CIP Symbolic Client/Server
• DHCP Client
• Sockets Client/Server TCP/UDP
Table 17 - Connection Limits for Micro820 Controllers
Description Connections
CIP Connections
Total number of client plus server connections 24
Maximum number of client connections for all ports 16
Maximum number of server connections for all ports 24
Client 16
Maximum number of EtherNet/IP connections
Server 24
Client
Maximum number of USB connections –
Server
Client 16
Maximum number of Serial connections
Server 24
TCP Connections
Total number of client plus server connections 64
Client 16
Maximum number for EtherNet/IP
Server 16
Client 16
Maximum number for Modbus TCP
Server 16
Maximum number for User Programmable Sockets 8
User Programmable Sockets
Total number of User Programmable Sockets 8
(any combination of UDP plus TCP Client/Server)

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Chapter 5 Communication Connections

The 2080-REMLCD USB uses the CIP Serial server connections for
embedded Serial port.

IMPORTANT If all client/server connections are fully loaded, performance may be

affected, such as data loss and intermittent delays during
communication.
Here are some configuration examples based on the limits described in Table 17:
1. The maximum number of drives that can be controlled over EtherNet/IP is 16. This is due to
the maximum limit of TCP Client connections being 16, and the maximum limit of EtherNet/IP
Client connections being 16.
2. If you have 10 devices that are controlled over EtherNet/IP, the maximum number of devices
that can be controlled over Serial is six. This is due to the maximum limit of Client
connections being 16.
3. The total number of UDP sockets plus TCP Client/Server sockets has a maximum limit of
eight.

Modbus RTU
Modbus is a half-duplex, master-slave communications protocol. The Modbus network master
reads and writes bits and registers. Modbus protocol allows one master to communicate with a
maximum of 247 slave devices. Micro800 controllers support Modbus RTU Master and Modbus RTU
Slave protocol. For more information on how to configure your Micro800 controller for Modbus
protocol, refer to the Connected Components Workbench Online Help. For more information about
the Modbus protocol, see Modbus Protocol Specifications available from www.modbus.org.
For information on Modbus mapping, see Modbus Mapping for Micro800 on page 175.

To configure the Serial port as Modbus RTU, see Configure Modbus RTU on page 54.

Use MSG_MODBUS instruction to send Modbus messages over the Serial port.

CIP Serial Client/Server – RS-232 only

CIP Serial Client/Server allows CIP protocol to be used over an RS-232 Serial port. It is typically used
with modems. The advantage over non-CIP Serial protocols is that since the protocol is CIP,
program downloads are supported including CIP pass-through from the Serial port to Ethernet.

ASCII
ASCII provides connection to other ASCII devices, such as bar code readers, weigh scales, Serial
printers, and other intelligent devices. You can use ASCII by configuring the embedded or any plug-
in Serial RS-232 or RS-485 port for the ASCII driver. See the Connected Components Workbench
Online Help for more information.

To configure the Serial port for ASCII, see Configure ASCII on page 55.

Modbus TCP Client/Server

The Modbus TCP Client/Server communication protocol uses the same Modbus mapping features
as Modbus RTU, but instead of the Serial port, it is supported over Ethernet. Modbus TCP Server
takes on Modbus Slave features on Ethernet.

The Micro820 controller supports up to 16 simultaneous Modbus TCP Client connections and 24
simultaneous Modbus TCP Server connections.
No protocol configuration is required other than configuring the Modbus mapping table. For
information on Modbus mapping, see Modbus Mapping for Micro800 on page 175.

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 Chapter 5 Communication Connections

Use MSG_MODBUS2 instruction to send Modbus TCP message over Ethernet port.

With Connected Components Workbench software version 12 or later, the Modbus TCP Server is
disabled by default. If you want to use Modbus TCP, you can enable it from the Ethernet settings.

CIP Symbolic Client/Server

CIP Symbolic is supported by any CIP compliant interface including Ethernet (EtherNet/IP) and
Serial Port (CIP Serial). This protocol allows HMIs to easily connect to the Micro820 controller.

CIP Serial, supported on Micro820 controllers, uses the DF1 Full-duplex protocol, which provides
point-to-point connection between two devices.

The Micro800 controllers support the protocol through RS-232 connection to external devices, such
as computers running RSLinx® Classic software, PanelView Component terminals (firmware
revisions 1.70 and above), PanelView 800 terminals or other controllers that support CIP Serial over
DF1 Full-duplex, such as ControlLogix® and CompactLogix™ controllers that have embedded Serial
ports.

EtherNet/IP, supported on Micro820 controllers, uses the standard Ethernet TCP/IP protocol.
The Micro820 controllers support up to 16 simultaneous EtherNet/IP Client connections and 24
simultaneous EtherNet/IP Server connections.

To configure CIP Serial, see Configure CIP Serial Driver on page 53.

To configure for EtherNet/IP, see Configure Ethernet Settings on page 56.

CIP Symbolic Addressing

You can access any global variable through CIP Symbolic addressing except for system and
reserved variables.

One-dimension or two-dimension arrays for simple data types are supported (for example, ARRAY
OF INT[1..10, 1..10]) are supported but arrays of arrays (for example, ARRAY OF ARRAY) are not
supported. Array of strings are also supported.

Supported Data Types in CIP Symbolic

Data Type(1) Description

Logical Boolean with values TRUE(1) and FALSE(0)
BOOL (Uses up 8 bits of memory)
SINT Signed 8-bit integer value
INT Signed 16-bit integer value
DINT Signed 32-bit integer value
(2) Signed 64-bit integer value
LINT
USINT Unsigned 8-bit integer value

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Chapter 5 Communication Connections

Supported Data Types in CIP Symbolic

Data Type(1) Description

UINT Unsigned 16-bit integer value
UDINT Unsigned 32-bit integer value

ULINT(2) Unsigned 64-bit integer value

REAL 32-bit floating point value
(2) 64-bit floating point value
LREAL
STRING Character string (1 byte per character)

DATE(3) Unsigned 32-bit integer value

TIME(3) Unsigned 32-bit integer value

(1) Logix MSG instruction can read/write SINT, INT, DINT, LINT, and REAL data types using “CIP Data Table Read” and “CIP Data Table
Write” message types.
BOOL, USINT, UINT, UDINT, ULINT, LREAL, STRING, SHORT_STRING, DATE, and TIME data types are not accessible with the Logix MSG
instruction.
(2) Not supported in PanelView Component or PanelView 800 terminals.
(3) Can be used by sending data to UDINT, mainly for use with PanelView Plus and PanelView 800 HMI terminals.

CIP Client Messaging

CIP Generic and CIP Symbolic messages are supported on Micro800 controllers through the
Ethernet and Serial ports. The MSG_CIPSYMBOLIC and MSG_CIPGENERIC function blocks enable
these client messaging features.

For more information and sample quickstart projects to help you use the CIP Client Messaging
feature, see Micro800 Programmable Controllers: Getting Started with CIP Client Messaging Quick
Start, publication 2080-QS002.

Sockets Client/Server TCP/UDP

Sockets protocol is used for Ethernet communications to devices that do not support Modbus TCP
and EtherNet/IP. Sockets support client and server, and TCP and UDP. Typical applications include
communicating to printers, barcode readers, and PCs.

CIP Communications The Micro820 controllers support pass-thru on any communications port that supports CIP for
applications such as program download. It does not support applications that require dedicated
Pass-thru connections such as HMI. Micro820 controllers support a maximum of one hop. A hop is defined as
an intermediate connection or communications link between two devices – in Micro800, this is
through EtherNet/IP or CIP Serial.

Examples of Supported Architectures

CIP Serial to EtherNet/IP

USB Serial EtherNet/IP

F1 F2 F3 ESC

F4 F5 F6 OK
MENU

REMLCD
Micro820 Micro820
For program download controller1 controller2

You can download a program from the PC to controller1 through the USB to Serial port
conversion via the Remote LCD. Also, the program can be downloaded to controller2 and
controller3 over USB to EtherNet/IP but the performance is limited by the Serial connection.

Micro820
controller3

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 Chapter 5 Communication Connections

EtherNet/IP to CIP Serial

EtherNet/IP CIP Serial

Micro820 Micro820
controller controller
For program download

EtherNet/IP to DeviceNet®

EtherNet/IP DeviceNet Esc Sel

PowerFlex 525 drive
with
25-COMM-D adapter
(Address 1)
Micro820 controller
with
For program download 2080-DNET20 plug-in scanner
(Address 0)

You can use Connected Components Workbench software to

configure the PowerFlex® drives. CompactBlock™ LDX I/O
(Address 2)

IMPORTANT Micro800 controllers do not support multiple hops (for example, from
EtherNet/IP > CIP Serial > EtherNet/IP).

Use Modems with Micro800 Serial modems can be used with the Micro820 controllers.
Controllers Making a DF1 Point-to-Point Connection
You can connect the Micro820 controller to your Serial modem. The recommended protocol for this
is Modbus RTU.

Construct Your Own Modem Cable

If you construct your own modem cable, the maximum cable length is 3 m (10 ft) with a 25-pin or 9-
pin connector. Figure 37 shows the typical pinout for constructing a straight-through cable.
Figure 37 - Straight-through Cable Pinout Guide
DTE Device DTE Device
(Micro820 controller channel 0) (Modem and so on)

6-pin 25-pin 9-pin

5 TXD TXD 2 3
4 RXD RXD 3 2
6 GND GND 7 5
1 B(+) DCD 8 1
2 A(-) DTR 20 4
3 GND DSR 6 6
CTS 5 8
RTS 4 7

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Chapter 5 Communication Connections

Configure Serial Port You can configure the Serial port driver as CIP Serial, Modbus RTU, ASCII, or Shutdown through the
Controller Configuration tree in Connected Components Workbench software.

By default, when a Micro820 controller is added to the Project Organizer in Connected Components
Workbench, Remote LCD parameters are configured to overwrite Serial Port settings.

To edit Serial Port settings, go to the Remote LCD configuration page and uncheck the Configure
Serial Port for Remote LCD option button.

uncheck this option

When the Remote LCD configuration is unchecked, the Serial Port values are visible and can be
edited.

IMPORTANT After changing the Serial Port settings on the controller, power cycle the
Remote LCD.

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 Chapter 5 Communication Connections

Configure CIP Serial Driver

1. Open your Connected Components Workbench project. On the device configuration tree, go
to the Controller properties. Select Serial Port.

2. Select CIP Serial from the Driver field.

3. Specify a Baud Rate. Select a communication rate that all devices in your system support.
Configure all devices in the system for the same communication rate. Default Baud Rate is
set at 38,400 bps.
4. In most cases, parity and station address should be left at default settings.
5. Select Advanced Settings and set Advanced parameters.
See Table 18 for a description of the CIP Serial parameters.
Table 18 - CIP Serial Driver Parameters
Parameter Options Default
Toggles between the communication rate of 1200, 2400, 4800,
Baud Rate 38400
9600, 19200, and 38400
Specifies the parity setting for the Serial port. Parity provides
Parity additional message-packet error detection. Select Even, Odd, or None
None.
The station address for the Serial port on the DF1 master. The only
Station Address 1
valid address is 0…254.
Configured as Full-
DF1 Mode DF1 Full-duplex (read only) duplex by default
Configured as no
Control Line No Handshake (read only) handshake by default

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Chapter 5 Communication Connections

Table 18 - CIP Serial Driver Parameters (Continued)

Parameter Options Default
Detects and eliminates duplicate responses to a message.
Duplicate Packet Detection Duplicate packets may be sent under noisy communication Enabled
conditions when the sender’s retries are not set to 0. Toggles
between Enabled and Disabled.
Error Detection Toggles between CRC and BCC CRC
To use embedded responses, choose Enabled Unconditionally. If
you want the controller to use embedded responses only when it
detects embedded responses from another device, choose After
Embedded Responses One Received. After One Received
If you are communicating with another Allen-Bradley device,
choose Enabled Unconditionally. Embedded responses increase
network traffic efficiency.
The number of times the controller will resend a message packet
NAK Retries because the processor received a NAK response to the previous 3
message packet transmission.
The number of enquiries (ENQs) that you want the controller to
ENQ Retries 3
send after an ACK timeout occurs.
Specifies the number of times a message is retried after the first
Transmit Retries attempt before being declared undeliverable. Enter a value from 3
0…127.
Specifies the amount of time after a packet is transmitted that an
ACK Timeout (x20 ms) 50
ACK is expected.

Configure Modbus RTU

1. Open your Connected Components Workbench project. On the device configuration tree, go
to the Controller properties. Select Serial Port.

2. Select Modbus RTU on the Driver field.

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3. Specify the following parameters:

• Baud rate
• Parity
• Unit address
• Modbus Role (Master, Slave, Auto)
Table 19 - Modbus RTU Parameters
Parameter Options Default
Baud Rate 1200, 2400, 4800, 9600, 19200, 38400 19200
Parity None, Odd, Even None
Modbus Role Master, Slave, Auto Master
4. You can configure additional parameters under Advanced Settings.
Table 20 - Modbus RTU Advanced Parameters
Parameter Options Default
Media RS-232, RS-232 RTS/CTS, RS-485 RS-232
Data Bits Always 8 8
Stop Bits 1, 2 1
Response Timer 0…999,999,999 milliseconds 200
Broadcast Pause 0…999,999,999 milliseconds 200
Inter-char Timeout 0…999,999,999 microseconds 0
RTS Pre-delay 0…999,999,999 microseconds 0
RTS Post-delay 0…999,999,999 microseconds 0

Configure ASCII
1. Open your Connected Components Workbench project. On the device configuration tree, go
to Controller properties. Select Serial Port.
2. Select ASCII on the Driver field.

3. Specify the following parameters:

- Baud Rate
- Parity
Table 21 - ASCII Parameters
Parameter Options Default
Baud Rate 1200, 2400, 4800, 9600, 19200, 38400 19200
Parity None, Odd, Even None
RS-485
Control Line No Handshake
No Handshake

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Chapter 5 Communication Connections

Table 21 - ASCII Parameters (Continued)

Parameter Options Default
CRT
Deletion Mode Ignore Ignore
Printer
Data Bits 7, 8 8
XON/XOFF Enabled or Disabled Disabled
Stop Bits 1, 2 1
Echo Mode Enabled or Disabled Disabled
Append Chars 0x0D, 0x0A, or user-specified value 0x0D, 0x0A
Termination Chars 0x0D, 0x0A, or user-specified value 0x0D, 0x0A

Configure Ethernet Settings 1. Open your Connected Components Workbench project (for example, Micro820). On the
device configuration tree, go to Controller properties. Select Ethernet.

2. Under Ethernet, select Internet Protocol.

Configure Internet Protocol (IP) settings. Specify whether to obtain the IP address
automatically using DHCP or manually configure IP address, subnet mask, and gateway
address.

The Ethernet port defaults to the following out-of-the box settings:

• DHCP (dynamic IP address)
• Address Duplicate Detection: On

IMPORTANT When a DHCP server fails, the Micro800 controller allocates IP

addresses in the private range 169.254.0.1 to 169.254.255.254. The
Micro800 controller verifies its address is unique on the network
using ARP. When the DHCP server is again able to service requests,
the Micro800 controller updates its address automatically.
3. Select the checkbox Detect duplicate IP address to enable detection of duplicate address.
4. Under Ethernet, select Port Settings.

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5. Set Port State as Enabled or Disabled.

6. To set connection speed and duplexity manually, clear the checkbox Auto-Negotiate speed
and duplexity. Then, set Speed (10 or 100 Mbps) and Duplexity (Half or Full) values.
7. Select Save Settings to Controller if you want to save the settings to your controller.
8. On the device configuration tree, under Ethernet, select Port Diagnostics to monitor
Interface and Media counters. The counters are available and updated when the controller
is in Debug mode.

Validate IP Address
Modules must validate the incoming IP address configuration, whether it is obtained through
explicit configuration or through DHCP.

The following rules must be obeyed when configuring the IP address:

• The IP address for the module cannot be set to zero, a multicast address, a broadcast
address, or an address on the Class A loopback network (127.x.x.x).
• The IP address must not start with zero, and the IP address network ID must be not zero.
• The Network mask cannot be set to 255.255.255.255.
• The Gateway address must be on the same subnet as the IP address that is being
configured.
• The Name Server address cannot be set to zero, a multicast address, a broadcast address,
or an address on the Class A loopback network (127.x.x.x).

The valid range of static IPv4 IP address exclude:

• Broadcast or zero IP (255.255.255.255 or 0.0.0.0)
• IP address starting with 0 or 127 (0.xxx.xxx.xxx or 127.xxx.xxx.xxx)
• IP address ending with 0 or 255 (xxx.xxx.xxx.0 or xxx.xxx.xxx.255)
• IP addresses in range 169.254.xxx.xxx (169.254.0.0 to 169.254.255.255)
• IP addresses in range 224.0.0.0 to 255.255.255.255

Ethernet Host Name

Micro800 controllers implement unique host names for each controller, to identify the controller on
the network. The default host name consists of two parts: product type and MAC address, which
are separated by a hyphen. For example: 2080LC20-xxxxxxxxxxxx, where xxxxxxxxxxxx is the MAC
address.

You can change the host name using the CIP Service Set Attribute Single when the controller is in
Program/Remote Program mode.

OPC Support Using Support for Open Platform Communications (OPC) using CIP symbolic is added from firmware
revision 7.0 onwards. You can use this instead of Modbus addressing.
FactoryTalk Linx
FactoryTalk® Linx software version 5.70 (CPR9 SR7) or later and FactoryTalk® Linx Gateway
software version 3.70 (CPR9 SPR7) or later are required.

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Notes:

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 Chapter 6
Program Execution in Micro800
This chapter provides a brief overview of running or executing programs with a Micro800
controller.

IMPORTANT This section generally describes program execution in Micro800 controllers.

Certain elements may not be applicable or true in certain models (for
example, Micro820 does not support PTO motion control).

For detailed information regarding ladder diagrams, instructions, function blocks and so on, see the
Micro800 Programmable Controllers General Instructions Reference Manual,
publication 2080-RM001.

Overview of Program A Micro800 cycle or scan consists of reading inputs, executing programs in sequential order,
updating outputs, and performing housekeeping (datalog, recipe, communications).
Execution
Program names must begin with a letter or underscore, followed by up to 127 letters, digits or single
underscores. Use programming languages such as ladder logic, function block diagrams, and
structured text.

Up to 256 programs may be included in a project, depending on available controller memory. By

default, the programs are cyclic (executed once per cycle or scan). As each new program is added
to a project, it is assigned the next consecutive order number. When you start up the Project
Organizer in Connected Components Workbench software, it displays the program icons based on
this order. You can view and modify an order number for a program from the program’s properties.
However, the Project Organizer does not show the new order until the next time the project is
opened.

The Micro800 controller supports jumps within a program. Call a subroutine of code within a
program by encapsulating that code as a user defined function (UDF) or UDFB. A UDF is similar to a
traditional subroutine and uses less memory than a UDFB, while a UDFB can have multiple
instances. Although a UDFB can be executed within another UDFB, a maximum nesting depth of five
is supported. A compilation error occurs if this is exceeded. This also applies to UDFs.

Alternatively, you can assign a program to an available interrupt and have it executed only when
the interrupt is triggered. A program assigned to the User Fault Routine runs once just prior to the
controller going into Fault mode.

In addition to the User Fault Routine, Micro800 controllers also support two Selectable Timed
Interrupts (STI). STIs execute assigned programs once every set point interval (1…65535 ms).

The Global System Variables associated with cycles/scans are:

• __SYSVA_CYCLECNT – Cycle counter
• __SYSVA_TCYCURRENT – Current cycle time
• __SYSVA_TCYMAXIMUM – Maximum cycle time since last start

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Chapter 6 Program Execution in Micro800

Execution Rules
This section illustrates the execution of a program. The execution follows four main steps within a
loop. The loop duration is a cycle time for a program.
Figure 38 - Program Execution Steps

1. Read inputs 1
2. Execute POUs/programs
3. Write outputs 2
4. Housekeeping
(datalog, recipe, communications) 3

1
2
3

When you specify a cycle time, a resource waits until this time has elapsed before starting the
execution of a new cycle. The Program Organizational Unit (POU) execution time varies depending
on the number of active instructions. When a cycle exceeds the specified time, the loop continues
to execute the cycle but sets an overrun flag. In such a case, the application no longer runs in real
time.

When you do not specify a cycle time, a resource performs all steps in the loop then restarts a new
cycle without waiting.

Optional Module Normally, before the read inputs step, the controller verifies the presence of any configured plug-in
and expansion I/O modules. If a plug-in or expansion I/O module is missing, the controller faults. In
Connected Components Workbench software release 10 or later, an Optional Module configuration
option is added to prevent a missing plug-in I/O or expansion I/O module from faulting the
controller if enabled. You can enable this option for each plug-in I/O or expansion I/O module
separately.

ATTENTION: If the optional module feature is enabled, use the MODULE_INFO

instruction to verify that the module is present because the controller will not
fault if the module is missing.

Controller Load and Within one program scan cycle, the execution of the main steps (as indicated in Figure 38) could be
interrupted by other controller activities which have higher priority than the main steps. Such
Performance Considerations activities include:
1. User Interrupt events, including STI, EII, and HSC interrupts (when applicable);
2. Communication data packet receiving and transmitting;
3. PTO Motion engine periodical execution (if supported by the controller).

When one or several of these activities occupy a significant percentage of the Micro800 controller
execution time, the program scan cycle time will be prolonged. The Watchdog timeout fault
(0xD011) could be reported if the impact of these activities is underestimated, and the Watchdog
timeout is set marginally. The Watchdog setting defaults to 2 s and generally never needs to be
changed.

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Periodic Execution of Programs

For applications where periodic execution of programs with precise timing is required, such as for
PID, it is recommended that Selectable Timed Interrupt (STI) be used to execute the program. STI
provides precise time intervals.

We do not recommend that you use the system variable __SYSVA_TCYCYCTIME to periodically
execute all programs as this also causes all communication to execute at this rate.

WARNING: Communication timeouts may occur if programmed cycle time is set

too slow (for example, 200 ms) to maintain communications.

Table 22 - System Variable for Programmed Cycle Time

Variable Type Description
Programmed cycle time.
Note: Programmed cycle time only accepts values in multiples
__SYSVA_TCYCYCTIME TIME of 10 ms. If the entered value is not a multiple of 10, it is rounded
up to the next multiple of 10.

Power Up and First Scan In Program mode, all analog and digital input variables hold their last state, and the LEDs are
always updated. Also, all analog and digital output variables hold their last state, but only the
analog outputs hold their last state while the digital outputs are off.

When transitioning from Program mode to Run mode, all analog output variables hold their last
state but all digital output variables are cleared.

Two system variables are available.

Table 23 - System Variables for Scan and Power-up

Variable Type Description
First scan bit.
Can be used to initialize or reset variables immediately after
_SYSVA_FIRST_SCAN BOOL every transition from Program to Run mode.
Note: True only on first scan. After that, it is false.
Power-up bit.
Can be used to initialize or reset variables immediately after
download from Connected Components Workbench software or
_SYSVA_POWER_UP_BIT BOOL immediately after being loaded from memory backup module
(for example, microSD card).
Note: True only on the first scan after a power-up, or running a
new ladder for the first time.

Variable Retention
After a power cycle, all variables inside instances of instructions are cleared. Micro820 controllers
can only retain a maximum of 400 bytes of user-created variable values.
For example: A user-created variable called My_Timer of Time data type is retained after a power
cycle but the elapsed time (ET) within a user created timer TON instruction is cleared. This means
that after a power cycle, global variables are cleared or set to initial value, and depending on the
controller, some or all user-created variables are retained. You can choose which variables to
retain by selecting them on the global variable page.

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Memory Allocation Depending on the base size, available memory on Micro800 controllers is shown in Table 24.

Table 24 - Memory Allocation for Micro800 Controllers

10/16-point 20-point 24-point and 48-point 24-point
Attribute (Micro830®) (Micro820) (Micro830, Micro850) (Micro870)

Program steps(1) 4K 10 K 10 K 20 K
Data bytes 8 KB 20 KB 20 KB 40 KB
(1) Estimated Program and Data size are “typical” – program steps and variables are created dynamically.
1 Program Step = 12 data bytes.

These specifications for instruction and data size are typical numbers. When a project is created
for Micro800 controllers, memory is dynamically allocated as either program or data memory at
build time. This means that program size can exceed the published specifications if data size is
sacrificed and vice versa. This flexibility allows maximum usage of execution memory. In addition
to the user defined variables, data memory also includes any constants and temporary variables
generated by the compiler at build time.

If your project is larger, it affects the power up time. Typical power up time is 10...15 seconds for all
controllers. However if your project has a lot of initial and project values, it may cause power up
time to exceed 30 seconds. After boot up, EtherNet/IP connections may take up to 60 seconds to
establish.
The Micro800 controllers also have project memory, which stores a copy of the entire downloaded
project (including comments), as well as configuration memory for storing plug-in setup
information, and so on.

Guidelines and Limitations Here are some guidelines and limitations to consider when programming a Micro800 controller
using Connected Components Workbench software:
for Advanced Users
• Each program/POU can use up to 64 KB of internal address space. It is recommended that
you split large programs into smaller programs to improve code readability, simplify
debugging and maintenance tasks.
• A UDF uses significantly less memory than a UDFB. For example, 30% less for a typical sized
program compared to a UDFB with one instance. The savings increases as the number of
UDFB instances increases.
• A UDFB can be executed within another UDFB, with a limit of five nested UDFBs. Avoid
creating UDFBs with references to other UDFBs, as executing these UDFBs too many times
may result in a compile error. This also applies to UDFs.
Example of Five Nested UDFBs

UDFB1

UDFB2

UDFB3

UDFB4

UDFB5

• Structured Text (ST) is much more efficient and easier to use than Ladder Logic, when used
for equations. If you are used to using the RSLogix 500® CPT Compute instruction, then a
great alternative is to use ST combined with either UDF or UDFB.
As an example, for an Astronomical Clock Calculation, Structured Text uses 40% less
instructions.

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 Chapter 6 Program Execution in Micro800

Display_Output LD:
Memory Usage (Code): 3148 steps
Memory Usage (Data): 3456 bytes
Display_Output ST:
Memory Usage (Code): 1824 steps
Memory Usage (Data): 3456 bytes
• You may encounter an Insufficient Reserved Memory error while
downloading and compiling a program over a certain size. One
workaround is to use arrays, especially if there are many variables.

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Notes:

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 Chapter 7
Controller Security
Micro800 security generally has two components:
• Exclusive Access that prevents simultaneous configuration of the controller by two users
• Controller Password Protection that secures the Intellectual Property contained within
the controller and prevents unauthorized access

Operation Mode To maintain the secure operation of your Micro800 controllers, operations that can disrupt
controller operations are restricted based on the controller operation mode.
Table 25 - Activities Allowed in Different Controller Operating Modes while Online
Activity
Ethernet Port
Current Controller (1) Serial and USB
Operation Firmware Update Configuration Setting Lost Password Password Controller Mode I/O Configuration
Request (through Connected Port Configuration Recovery Change Change Change
Components Workbench Changes
or RSLinx software)
Controller in Accepted Accepted Not Allowed Accepted Accepted Accepted Not Allowed
Program Mode
Controller without
Password Protection in Rejected Not Allowed Not Allowed Not Applicable Not Applicable Accepted Not Allowed
Remote Run Mode
Controller with
Password Protection in Rejected Not Allowed(2) Not Allowed Rejected Rejected Rejected Not Allowed
Remote Run Mode
(1) Ethernet configuration includes IP address, subnet mask, gateway, port speed/duplex, and so on.
(2) Difference between Not Allowed and Rejected is that Not Allowed activities can only be done during offline while Rejected activities can be performed but do not take effect.

Exclusive Access Exclusive access is enforced on the Micro800 controller regardless of whether the controller is
password-protected or not. This means that only one Connected Components Workbench session
is authorized at one time and only an authorized client has exclusive access to the controller
application. This ensures that only one software session has exclusive access to the Micro800
application-specific configuration.

Exclusive access is enforced on Micro800 firmware. When a Connected Components Workbench

user connects to a Micro800 controller, the controller is given exclusive access to that controller.

Password Protection By setting a password on the controller, a user effectively restricts access to the programming
software connection of the controller to software sessions that can supply the correct password.
Essentially, Connected Components Workbench operations such as upload and download are
prevented if the controller is secured with a password and the correct password is not provided.

Micro800 controllers are shipped with no password but a password can be set through the
Connected Components Workbench software (using controller firmware revision 2 or later).

In Connected Components Workbench software version 10 or later, a stronger password algorithm

is introduced to provide better security. To take full advantage of this enhancement, the Micro800
controller must have firmware revision 10 or later, and the project must also be version 10 or later.

The controller password is also backed up to the memory backup module (that is, 2080-MEMBAK-
RTC2 module for Micro850® and Micro870® controllers, 2080-LCD module for Micro810® controllers,
and microSD card for Micro820 controllers).
For instructions on how to set, change, and clear controller passwords,
see Configure Controller Password on page 125.

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Chapter 7 Controller Security

Compatibility The Controller Password feature is supported on:

• Connected Components Workbench software version 2 and later
• Micro800 controllers with at least revision 2 firmware

For users with earlier versions of the software and/or hardware, refer to the compatibility
scenarios below.
Connected Components Workbench software version 1 with Micro800 controller firmware
revision 2 and later

Connection to a Micro800 controller with firmware revision 2 using an earlier version of the
Connected Components Workbench software (version 1) is possible and connections will be
successful. However, the software will not be able to determine whether the controller is locked or
not.
If the controller is not locked, access to the user application will be allowed, provided the controller
is not busy with another session. If the controller is locked, access to the user application will fail.
Users will need to upgrade to version 2 of the Connected Components Workbench software.
Connected Components Workbench software version 2 and later with Micro800 controller
firmware revision 1

Connected Components Workbench software version 2 is capable of “discovering” and connecting

to Micro800 controllers with firmware revision earlier than revision 2 (that is, not supporting the
Controller Password feature). However, the Controller Password feature will not be available to
these controllers. The user will not be able see interfaces associated with the Controller Password
feature in the Connected Components Workbench session.

Users are advised to upgrade the firmware. See Update Your Micro800 Controller Firmware on
page 117 for instructions.

ATTENTION: Connected Components Workbench software version 9 or earlier

with Micro800 controller revision 10 or later.
If a Micro800 controller with firmware revision 10 or later is locked using the
new password algorithm introduced in Connected Components Workbench
software version 10 or later, it cannot be accessed using Components
Workbench software version 9 or earlier. Users are advised to upgrade to the
latest version of Connected Components Workbench software.

Work with a Locked The following workflows are supported on compatible Micro800 controllers (firmware revision 2)
and Connected Components Workbench software version 2.
Controller
Upload from a Password-Protected Controller
1. Launch the Connected Components Workbench software.
2. In the Project Organizer, expand Catalog by selecting the + sign.
3. Select the target controller.
4. Select Upload.
5. When requested, provide the controller password.

IMPORTANT When using Connected Components Workbench software version 9

or earlier:
• You cannot upload a version 10 or later project from the controller.
• You can upload a version 9 or earlier project from the controller if it was
downloaded to the controller using Connected Components Workbench
software version 10 or later, but you cannot go online.

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Debug a Password-Protected Controller

To debug a locked controller, you have to connect to the controller through the Connected
Components Workbench software and provide the password before you can proceed to debug.
1. Launch the Connected Components Workbench software.
2. In the Project Organizer, expand Catalog by selecting the + sign.
3. Select the catalog number of your controller.
4. When requested, provide the controller password.
5. Build and save your project.
6. Debug.

Download to a Password-Protected Controller

1. Launch the Connected Components Workbench software.
2. Select Connect.
3. Select the target controller.
4. When requested, provide the controller password.
5. Build and save the project, if needed.
6. Select Download.
7. Select Disconnect.

IMPORTANT If the controller has a password locked version 10 or later project, you
cannot access the controller using Connected Workbench software version 9
or earlier. If you use Connected Components Workbench software version 10
or later to download a version 9 or earlier project, the password in the
controller will be automatically converted to the old algorithm.

IMPORTANT If the controller has a password locked version 9 or earlier project and you
use Connected Components Workbench software version 10 or later, to
download a version 10 or later project, the password in the controller will be
automatically converted to the new algorithm.

IMPORTANT If communication is lost during the download, repeat the download and
verify that the controller is password protected.

Transfer Controller Program and Lock Receiving Controller

In this scenario, the user needs to transfer user application from controller1 (locked) to another
Micro800 controller with the same catalog number. The transfer of the user application is done
through the Connected Components Workbench software by uploading from controller1, then
changing the target controller in the Micro800 project, and then downloading to controller2. Finally,
controller2 will be locked.
1. In the Project Organizer, select the Discover icon.
The Browse Connections dialog appears.
2. Select target controller1.
3. When requested, enter the controller password for controller1.
4. Build and save the project.
5. Select Disconnect.
6. Power down controller1.
7. Swap controller1 hardware with controller2 hardware.
8. Power up controller2.
9. Select Connect.
10. Select target controller2.
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Chapter 7 Controller Security

11. Select Download.

12. Lock controller2. See Configure Controller Password on page 125.

Back Up and Restore a Password-Protected Controller

In this workflow, user application will be backed up from a Micro800 controller that is locked to a
memory plug-in device.
1. In the Project Organizer, select the Discover icon.
The Browse Connections dialog appears.
2. Select the target controller.
3. When requested, enter the controller password.
4. Back up controller contents to the memory module.
The project in the memory module is now password locked.
5. Remove the memory module from controller1 and insert into controller2.
6. Restore contents from the memory module to controller2.
This operation succeeds only if:
• The controller has no password – the project can be restored to the controller by
setting the “Load on power up” option for the memory module to Load Always.
• The controller’s password matches the project’s password.

IMPORTANT Even though the password matches, the restore operation will fail if either
one of the controller or project in the memory module is protected using the
old password algorithm, and the other is protected using the new password
algorithm. You can flash update the controller using the Reset option to clear
the password before restoring the project to the controller.

Configure Controller To set, change, and clear controller password, see the quickstart instructions Configure Controller
Password on page 125.
Password
Recover from a Lost If the controller is secured with a password and the password has been lost, then it is impossible to
access the controller using the Connected Components Workbench software.
Password
To recover, the controller must be set to Program Mode using the keyswitch for Micro850 and
Micro870 controllers, or the 2080-REMLCD module for Micro820 controllers. Then, ControlFLASH™
software can be used to update the controller firmware, which also clears the controller memory.
In Connected Components Workbench software version 10 or later, the Reset option must be
selected for the controller memory to be cleared during the firmware update. If the Upgrade or
Downgrade option is selected, the password is retained.

ATTENTION: The project in the controller will be lost but a new project can
be downloaded.

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 Chapter 8
Using the Micro800 Remote LCD
This chapter provides a description of how you can use the Micro800 Remote LCD with the
Micro820 controller.

Overview The 2080-REMLCD module serves as a simple IP65 text display that allows the configuration of
such controller settings as IP address. It connects to the Micro820 controller through the RS-232
port. The Remote LCD module has a dot matrix LCD with backlight and supports multilingual
characters. The display size is 3.5 inches with 192 x 64 pixel resolution.
It also has:
• Four arrow keys
• Six function keys
• ESC key
• OK key
• USB port for Connected Components Workbench connectivity

It supports:
• Small character set: 24 characters by 8 lines
• Large character set: 24 characters by 4 lines
• Extra large character set: displays 12 characters by 4 lines

The Remote LCD module supports English, French, Spanish, Italian, and Simplified Chinese
languages for the Main Menu.
Micro800 Remote LCD

3.5-inch LCD screen

Keypad
F1 F2 F3 ESC
USB port
F4 F5 F6 OK
MENU

RS-232 Serial port for

connectivity to the controller

The Remote LCD module is IP65-rated and can be mounted through the front panel or on the same
DIN rail as the Micro820 controller.

It has two modes of operation:

• USB Mode
• Text Display Mode

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Chapter 8 Using the Micro800 Remote LCD

- I/O Status and Main Menu operations (for example, change to Run mode)
- Optional user-defined screens (using the LCD_REM instructions)

USB Mode In USB mode, the Remote LCD module acts as a USB pass-through for Connected Components
Workbench software. The Remote LCD module automatically enters USB mode when traffic is
detected.
For example:
1. Remote LCD is in text display mode showing the I/O Status screen by default.
2. The user connects a USB cable between the PC and the Remote LCD.
3. Remote LCD is automatically detected by the PC as a USB device and the Remote LCD
automatically goes to USB mode.
4. I/O Status screen is no longer shown. The user is now able to download program over USB
using Connected Components Workbench software.
5. When the USB cable is disconnected and no traffic is detected for 30 seconds, the Remote
LCD automatically goes back to text display mode showing the I/O Status screen.

IMPORTANT Using the USB port is convenient when accessing the controller from the
front of the cabinet without opening the door and when the IP address is
unknown. For larger programs, it is recommended to use USB port through
the Remote LCD to set the IP address and then use Ethernet to download.
Ethernet is faster due to limitations of the USB to Serial conversion.

Text Display Mode In text display mode, you are either in I/O Status, Main Menu, or executing Remote LCD instructions.

Startup Screen

Default startup screen

Micro 820

On power-up, the Remote LCD module powers up with a splash screen that displays “Initializing”.
Then, it displays “Connecting to Controller” until the connection is established. The controller then
displays the startup screen for 3 seconds by default or user-defined duration after the connection
is established.

You can customize this startup screen in the Connected Components Workbench software. The
controller displays the default startup screen at power-up when the customized startup screen is
blank.

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After the startup message, the Remote LCD displays the I/O Status screen, if no LCD_REM
instructions are executing.

Navigate the Remote LCD

In text display mode, you can use the navigation keys (function keys, arrow keys, ESC and OK) to
navigate through the menus.

F1 F2 F3 ESC

F4 F5 F6 OK
MENU

The module has twelve keys with the operations shown in Table 26.

Table 26 - Function Keys Operation

Button Function
Move cursor
Select menu item
Arrow keys (cursor buttons)
Increment/Decrement number
Choose numbers, values, times, and so on
OK Next menu level, store your entry
Esc Previous menu level, cancel your entry.
F1 Variable (shortcut)
F2 ENET Cfg (shortcut)
F3 Mode Switch (shortcut)
F4 Fault Mode (shortcut)
F5 Security (shortcut)
F6 Backlight (shortcut)

Shortcut keys jump from the I/O Status screen to the specific main menu operation.

Main Menu
To access the Main Menu and available submenus, press F4 and F6 simultaneously. To exit the Main
Menu, press ESC.

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The Main Menu shows the following screen:

RUN
Mode Switch 14:18WED
Variables
I/O Status

The structure tree shown in Figure 39 takes you through the different menus available in the
Remote LCD module and their general description.
Figure 39 - 2080-REMLCD Menu Structure Tree

Mode Switch
Set the controller to Program mode
or Run mode from this screen.

Variable
Monitor or set values for program-
defined variables.

Use the arrow keys to move

the cursor up or down to the
item that you want to select. I/O Status
Monitor the I/O status from this
screen.

Advanced Set
View:
System Info Analog Calibration
Fault Code PwrUp Behavior
LCD Setup Memory Card
Clock Setup ENET Cfg
Language

Security
Activate, deactivate, and change
password.

Table 27 - Main Menu Items

Menu Item Description
I/O Status Shows the status of the local I/O
Mode switch Change the mode switch selection.
View and change the data value of a variable. Using Connected Components Workbench
software, you can specify which variables in the program can be viewed and edited through
Variables the 2080-REMLCD module.
See View and Edit Variable Values Through the Remote LCD on page 73.

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Table 27 - Main Menu Items (Continued)

Menu Item Description
Security Activate, deactivate, and change password protection.
View system information such as operating systems series
System Info and firmware revision.
Fault Code View controller fault code information.
LCD Setup Adjust LCD contrast, backlight color, and push button.
Clock Setup The real-time clock and daylight saving time
Change menu language to French, Italian, Spanish, and
Advanced Set Language Chinese.
Configure calibration parameter of embedded analog
Analog Calibration inputs.
PwrUp Behavior Configure controller mode on power-up.
Memory Card Access the microSD card.
ENET Cfg View and change the Ethernet port configuration.

The controller limits certain operations according to controller mode, as shown in Figure 28.

Table 28 - Operational Limit on 2080-REMLCD

Operation PROG Mode Run Mode
Variable Edit NO YES
Analog Calibration YES NO
Controller > Memory Card YES NO
Memory Card > Controller YES NO
Others YES YES

View and Edit Variable Values Through the Remote LCD

Go to the 2080-REMLCD configuration window in the Connected Components Workbench software.

Select LCD Variables and select which variables that you want to edit through the Remote LCD.

Shows how many bytes (out of

400 allowed) have been used
up

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User-defined Screens
To create user-defined screens through the Connected Components Workbench software, you can
program the Remote LCD module using the following function blocks.

Table 29 - 2080-REMLCD Function Blocks

Function Block Name Description
LCD_REM Used to display string or numbers on the Remote LCD
KEY_READ_REM Used to read keypad input on the Remote LCD
LCD_BKLT_REM Used to change the backlight color and mode of the Remote LCD screen

When the instructions are executing, the user-defined screen is shown, but when in the Main Menu,
the Remote LCD instructions are disabled. For example, the KEY_READ_REM instruction no longer
read keypad input.
LCD_REM

The LCD_REM function block is used to display user strings on the Remote LCD module when the
Remote LCD module is present and connected.
LCD_REM
Enable LCD_REM
Font Sts
Line 1

Line 2
Line 3
Line 4

Line 5

Line 6

Line 7

Line 8

LCD_BKLT_REM
LCD_BKLT_REM

Enable LCD_BKLT_REM

Color Sts

Mode

You can use this function block to configure backlight parameters on the Remote LCD module.

Execution of the LCD_BKLT_REM takes precedence over current backlight settings in the Main
Menu. When Enable, input becomes False and the instructions stop executing, the last Main Menu
setting of the backlight takes effect.

The LCD_BKLT_REM instruction is only effective when displaying user-defined screen or default I/O
Status screen. While in the Main Menu, backlight settings configured through the Main Menu take
effect.

IMPORTANT When in the Main Menu, the LCD_BKLT_REM instruction will be disabled or
ineffective.

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KEY_READ_REM
KEY_READ_REM

Enable KEY_READ_REM

Sts

KeyData

You can use this function block to read key status on the Remote LCD module when the user-
defined screen is active. When user-defined screen is not active, KEY_READ_REM instruction flags
an error.

The KEY_READ_REM instruction will always show key status as False if Push Button Key Read is
disabled in Connected Components Workbench software or the Remote LCD module.

Backup and Restore To initiate backup and restore through the Remote LCD module, access the memory card by going
to the Main Menu > Advanced Set > Memory Card.

For information on how to backup and restore a project on the microSD card, see Using microSD
Cards on page 79.

For installation, hardware features, and specifications of the Micro800 Remote LCD module, see the
Micro800 Remote LCD Installation Instructions, publication 2080-IN010.

ASCII Code for Special Figure 30 lists the special characters supported by the Remote LCD module.
Characters • Small (8 x 8 pixels)
• Medium (8 x 16 pixels)
• Large (16 x 16 pixels)
Table 30 - Special Characters
Character Character Description
Code (Hex)

01H Empty box (with border)

02H Filled box (with border)

08H Key sign (with border)

10H Filled box (without border)

11H Horizontal parallel lines (without border)

12H Vertical parallel lines (without border)

13H Horizontal line cap right (without border)

14H Horizontal line cap left (without border)

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Table 30 - Special Characters (Continued)

Character Character Description
Code (Hex)

15H Vertical line cap up (without border)

16H Vertical line cap down (without border)

18H Up arrow (with border)

19H Down arrow (with border)

1AH Right arrow (with border)

1BH Left arrow (with border)

80H 1/4 filled box left (without border)

81H 1/2 filled box left (without border)

82H 3/4 filled box left (without border)

83H 1/4 filled box right (without border)

84H 1/2 filled box right (without border)

85H 3/4 filled box right (without border)

86H 1/4 filled box upside down (without border)

87H 1/2 filled box upside down (without border)

88H 3/4 filled box upside down (without border)

89H 1/4 filled box upside (without border)

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Table 30 - Special Characters (Continued)

Character Character Description
Code (Hex)

8AH 1/2 filled box upside (without border)

8BH 3/4 filled box upside (without border)

8CH Centered vertical line (without border)

8DH Centered horizontal line (without border)

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Notes:

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 Chapter 9
Using microSD Cards
This chapter provides a description of microSD card support on Micro820 controllers.

The last section provides quickstart projects for the datalog and recipe functions.

Overview Micro820 controllers support microSD cards for the following purposes:
• Project backup and restore
• Datalog and Recipe

We recommend to use the Allen-Bradley 2080-SD-2GB microSD card.

IMPORTANT For optimum performance, the microSD card should not be more than 90%
full. Regularly check available space on your microSD card and ensure that
the card is exclusively used for the Micro800 controller and no unnecessary
files are present. Regularly delete old datalog files and directories.

IMPORTANT Do not remove the microSD card or power down while operations such as
upload, download, delete, search, backup, and restore are ongoing to
prevent data loss. A blinking SD status LED indicates that these operations
are ongoing.
Note the following:
• The SD status LED will not blink when updating the firmware from the
microSD card.
• The SD status LED does not blink continuously for the entire duration of the
restore operation.

IMPORTANT To prevent data loss, recipe and datalog function blocks must indicate Idle
status before microSD card is removed.

Project Backup and Restore Project backup and restore on Micro820 controllers are mainly supported through the microSD
card. Both backup and restore can be initiated or manually triggered and configured through the
Connected Components Workbench software, the 2080-REMLCD module, and the ConfigMeFirst.txt
file in the microSD card. These backup files are not the same as Connected Components
Workbench project files.

Backup and restore can only occur when the controller is in PROGRAM mode. On controller power-
up, restore automatically occurs if the Load Always or Load on Memory Error option has been
configured in Connected Components Workbench software.

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IMPORTANT To learn about restore and backup using the 2080-REMLCD module, see
Using the Micro800 Remote LCD on page 69.
To learn about restore and backup using the Connected Components
Workbench software, see the software Online Help.

IMPORTANT For Micro800 controllers that support microSD cards, IP protection of user
project can only be achieved through the POU password protection
mechanism in Connected Components Workbench software (Developer
Edition) and NOT via Controller Lock feature.

IMPORTANT If the Load Always setting is enabled and power is lost when restoring a
project from the micoSD card, the controller will attempt to load the project
using the default project name and directory after power is restored. If your
project is not using the default name and directory, the operation will fail and
a fault occurs, or the wrong project will be loaded.
The default project name is the name of the controller, for example
“Micro820”, and the default directory is “Micro820\USERPRJ”.
If you change the name of the controller from the default, you must
configure the UPD setting in the ConfigMeFirst.txt file.

The microSD card stores the controller password in encrypted format. When the password is
mismatched, the contents of the microSD card is not restored on the controller.

Backup and restore can be configured to trigger as shown in Table 31.

Table 31 - Backup and Restore Methods
Method Backup Restore
Online with Connected Components Yes Yes
Workbench
2080-REMLCD Yes Yes
Project configuration on memory card Load Always and/or Load on Memory
No
at power-up Error options
Yes Yes
ConfigMeFirst.txt at power-up (Through the [BKD] command) (Through the [RSD] command)

Backup and Restore Directory Structure

When a user project is backed up, a subdirectory named Micro820\USERPRJ is created on the
microSD card. The folder name takes the name of the project specified in the General Page in the
Connected Components Workbench software, which is Micro820 by default. However, if the
ConfigMeFirst.txt file specifies a different subdirectory (example: MyProject), the project is backed
up to that directory. See General Configuration Rules in ConfigMeFirst.txt on page 83.

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Project restore is done from the subdirectory specified in ConfigMeFirst.txt file or the Micro820/
USERPRJ default folder, if none is specified in the ConfigMeFirst.txt file. Ensure that the directory is
populated with correct contents before restoring.

The ConfigMeFirst.txt file is a configuration file that is stored on the microSD card that you can
optionally create to customize backup, restore, recipe, and datalog directories. The following
sections include information on how to configure the ConfigMeFirst.txt properly.

IMPORTANT The Micro800 controller reports a major fault when project backup does not
succeed because the memory card size is exceeded.

Power-up Settings in ConfigMeFirst.txt

On power-up, the Micro820 controller reads and implements configuration settings that are
described in the ConfigMeFirst.txt file. However, the UPD setting also takes effect when you insert
the microSD card. The configuration settings for the ConfigMeFirst.txt file are shown in Table 32.
Table 32 - ConfigMeFirst.txt Configuration Settings
Setting Takes effect on... Description
Firmware update settings
File path location of the firmware revision on the microSD card.
[FWFILE] Power-up The default location is in the following format:
firmware\<catalog number>\<filename of firmware>
Sets whether to upgrade or downgrade the controller firmware
from the current revision.
0 = Upgrade firmware; 1 = Downgrade firmware
[FWDOWN] Power-up IMPORTANT: Firmware Upgrade will happen if [FWFILE]
setting points to a newer version of firmware file compared to
current firmware in the controller, irrespective of [FWDOWN]
setting.
Controller settings
[PM] Power-up Power up and switch to PROGRAM mode.
[CF] Power-up Power up and attempt to clear fault.
Project settings
Power up and save the controller project into backup
[BKD = My Proj1] Power-up directory, My Proj1\USERPRJ. Requires extra power cycle to
clear existing fault first using [CF] setting or other means.
Power up and read the project from restore directory
MyProj2\USERPRJ into controller. Requires extra power cycle
[RSD = MyProj2] Power-up to clear existing fault first using [CF] setting or other means.
This setting overwrites UPD (or its default) load always or load
on error restore function.

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Table 32 - ConfigMeFirst.txt Configuration Settings (Continued)

Setting Takes effect on... Description
For normal usage of backup and restore (that is, through
Connected Components Workbench, 2080-REMLCD, Load
Power-up and Insertion Always, or Load on Memory Error settings), set the user project
[UPD = My Proj] directory name. For example, My Proj, during power-up or
when the microSD card is inserted.
This directory is also used by data logging and recipe function.
Network settings
Embedded Serial Factory Defaults.
[ESFD] Power-up Power up and revert embedded Serial comms to factory
defaults.
[IPA = xxx.xxx.xxx.xxx] Power-up Power up and set IP address to xxx (must be numbers only).
[SNM = xxx.xxx.xxx.xxx] Power-up Power up and set subnet mask to xxx (must be numbers only).
Power up and set gateway address to xxx (must be numbers
[GWA = xxx.xxx.xxx.xxx] Power-up only).
General settings
End of setting.
This setting is always required even when the
[END] Power-up ConfigMeFirst.txt file does not contain any other setting. The SD
LED goes off when this setting is not present.

IMPORTANT Update Settings

With Connected Components Workbench software version 8.0 or later, you
can update your Micro820 controller from the microSD card or by using
ControlFLASH. See Firmware Update From microSD Card on page 119 for
instructions.
• You must place [FWFILE] and [FWDOWN] settings at the beginning of the file.

IMPORTANT Directory Settings

• If you do not specify a directory in the ConfigMeFirst.txt file, then backup and
restore occurs in the controller name directory (Micro820/USERPRJ, by
default).
• If you configure [UPD] in the ConfigMeFirst.txt file, then backup and restore
occurs in the [UPD] directory specified.
• [BKD] setting implements even when the controller is locked or password
protected.
• [BKD] directory is created automatically if it does not already exist.

IMPORTANT Power-up Network Parameter Settings

• [IPA], [SNM] and [GWA] follow the general IP configuration rules.
• When you set [IPA] in ConfigMeFirst.txt, you must always configure it with a
valid [SNM] and vice versa.
• When you use the optional [GWA] setting, make sure that [IPA] and [SNM]
settings are also present in ConfigMeFirst.txt.
• The [ESFD], [IPA], [SNM], and [GWA] settings overwrite the respective
communication settings from project restore due to [RSD], Load Always or
Load on Memory Error.
Figure 40 - Sample ConfigMeFirst.txt File

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General Configuration Rules in ConfigMeFirst.txt

• All settings must be in upper case and enclosed in brackets [ ].
• Each line must contain only one setting.
• Settings must always appear first in a line.
• Comments are started with the # symbol.
• No action related to the setting will be carried out when the setting does not exist, or a #
symbol appears before the setting (example, #[PM]).

ConfigMeFirst.txt Errors
The SD status LED goes off when the microSD card is inserted during PROGRAM or Run mode (or on
power-up) and the ConfigMeFirst.txt file is either unreadable or invalid. The ConfigMeFirst.txt file
will be invalid when it has the following errors:
• Unrecognized setting (that is, the first three configuration rules have not been followed)
• The setting parameters after the = symbol is invalid, does not exist, or out of range
• The same setting exists twice or more
• One or more non-setting characters exist within the same bracket
• Space in between setting characters (example, [P M])
• Space in between IP address, subnet mask, and gateway address (for example, xxx. x
xx.xxx.xxx)
• Only one of the network parameter settings ([IPA], [SNM], or [GWA]) is assigned
• [END] setting does not exist (even if there are no other settings in the configuration file)

The microSD card becomes unusable until the ConfigMeFirst.txt file becomes readable or the errors
are corrected.

Deliver Project Updates to Customers Through Email

A benefit of using the project backup and restore feature is to allow you to deliver project updates
to customers through email. You can do so by following the example shown below.
Backup project to microSD card

The first step is to back up the project from the controller into the microSD card.
1. In the Connected Components Workbench software, verify that you have downloaded the
updated project to your Micro820 controller.
2. Insert a microSD card into the microSD card slot.
3. Set the controller to program mode.
4. Under the Memory Card option in your controller settings, select Backup to Memory Card.

IMPORTANT The Backup to Memory Card button is enabled when the controller is
in program mode and a microSD card is in the microSD card slot.
5. After the backup is completed, select OK.
The image files are stored in the default location on the microSD card Micro820\USERPRJ. This
location is where the controller loads from when the Load on power up setting is configured to
“Load Always” or “Load on Error”.

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Alternatively, if you do not want to use Connected Components Workbench software to create the
project backup, you can also use the ConfigMeFirst.txt file.
Figure 41 - Example Configuration for Project Backup

The ConfigMeFirst.txt file also allows you to restore from the backup if you want to configure the
Load on power up setting to “Disable”.
Send image files through email

The next step is to retrieve the image files from the microSD card and send them to your customer
through email.
1. Remove the microSD card from the controller and read the card using your computer.
2. Navigate to the location where the image files are stored (default is Micro820\USERPRJ).

3. Use a compression program to zip these image files and send them to your customer
through email.

The customer must unzip these image files into the root directory of their microSD card and verify
that the location is identical to the original (default is Micro820\USERPRJ).
Restore project from backup

The last step is to restore the project to your controller from the microSD card. There are two
methods to restore the backup, depending on the configuration of the controller.

Existing Controller - Load Always / Load on Error

For this example, the Load on power up setting was configured to “Load Always”. This means that
the controller loads the project from the memory card whenever it is powered on.
1. Insert the microSD card into the microSD card slot.
2. Cycle power to the controller.
3. When the SD status LED displays a steady green light, the project restore is complete.

Use this method for an existing controller that has been configured and you want to update the
program.

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New Controller

If your controller is new, you can use the ConfigMeFirst.txt file to restore the project backup.
Figure 42 - Example Configuration for Project Restore

In the example shown in Figure 42, the ConfigMeFirst.txt file configures the IP address, subnet
mask, and gateway of the controller, and restores the project from the location that is specified on
the microSD card.
You must place the ConfigMeFirst.txt file in the same root directory as the backup folder in the
microSD card.

1. Insert the microSD card into the microSD card slot.

2. Cycle power to the controller.
3. When the SD status LED displays a steady green light, the project restore is complete.

Datalog The data logging feature allows you to capture global and local variables with timestamp from the
Micro800 controller into the microSD card. You can retrieve the recorded datasets on the microSD
card by reading the contents of the microSD card through a card reader or by uploading through
the Connected Components Workbench software.

A maximum number of 10 datasets is supported for a Micro820 program. Each dataset can contain
up to 128 variables, with a maximum of four data string variables per dataset. String variables can
have a maximum of 252 characters. All datasets are written to the same file. For more information
on how to store datalogs on the microSD card, see the Datalog Directory Structure on page 86.

You can retrieve datalog files from the microSD card using a card reader or by uploading the
datalogs through the Connected Components Workbench software.

IMPORTANT For optimum performance and to prevent file access conflicts, we

recommend that you upload datalog files in PROGRAM mode. For example, if
the datalog instruction is executing, Connected Components Workbench
software does not upload the last datalog file.

See the sample quick start project to get you started on the Datalog feature, Use the Datalog
Feature on page 93.

IMPORTANT Datalog execution time depends on your application and its complexity. Do
not datalog faster than every two seconds for typical applications.
Housekeeping takes at least 5 ms per program scan. For more information
on program scan and execution rules and sequence, see Program Execution
in Micro800 on page 59.
See also Datalog – Data Payload vs. Performance Time on page 130.

IMPORTANT In cases where there are simultaneous RCP and DLG function block
executions or uploads/downloads/searches, the activities are queued, and
the program scan handles them one by one. You can observe a slowdown in
performance in these cases.

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Datalog Directory Structure

The DATALOG folder is created under the current project directory in the microSD card. In this
example, the current project directory is MYPROJECT. By default, the current project directory
name is taken from the downloaded project’s controller name or from the ConfigMeFirst.txt.
See ConfigMeFirst.txt Configuration Settings on page 81.

Subdirectories are also created following the controller RTC timestamp. This means that if
RTC date at the time of function block execution is February 02, 2013, the subfolder 2013 is
created under DATALOG. Under the 2013 folder, the subfolder 02 (which stands for the month
of February) is created. Under 02, another subfolder 02 is created, corresponding to the
These datalog files are for current date.
February 2, 2014.

Under the current working folder, the subfolder Grp01 is created. You can generate a
maximum of 50 Grpxxx folders on the microSD card per day.
Under the current Grpxxx working folder, the datalog file File01.txt is created. Once this file
reaches more than 4 KB, another file, File02.txt, is created automatically to store data. The
file size is kept small in order to minimize data loss in case the card is removed or when
there is unexpected power off.
Each Grpxx folder can accommodate up to 50 files. This means that, for example, when the
Grp01 folder already stores 50 files, a new folder Grp02 is created automatically to store the
next datalog files for that day. This automatic folder and file generation goes on until the
Grpxx folder reaches 50 for that day.
When you insert a microSD card, the DLG function block looks for the last Grpxx folder and
filexx.txt file, and proceeds to perform the data logging based on that information.

Table 33 summarizes data logging performance onMicro820 controllers.

Table 33 - Datalog Specifications
Attribute Value
Maximum datasets 10 All datasets are stored in the same file.
Configured in Connected Components Workbench
Maximum variables per dataset 128 software
Minimum size per file 4 KB
(1) When directory is full, a new directory is automatically
Maximum files per Grpxx folder 50 created in Run mode.
When file reaches maximum size, a new file is
Maximum files (Filexx.txt) per day 50 automatically created in Run mode.
Typical data per day 10 MB
(1) Once you reach the datalog limits (that is, 50 Grpxx folders per day) an error (ErrorID 3: DLG_ERR_DATAFILE_ACCESS) is returned.

Datalog Function (DLG) Block

The data logging function block lets a user program to write run-time global values into the data
logging file in microSD card.
DLG

Enable Status
TSEnable ErrorID

CfgId

Table 34 - DLG Input and Output Parameters

Parameter Parameter Type Data Type Description
Data logging write function enable.
On rising edge (that is, Enable value triggers from low to high),
Enable INPUT BOOL the function block executes. The precondition for execution is
that the last operation has completed.

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Table 34 - DLG Input and Output Parameters (Continued)

Parameter Parameter Type Data Type Description
TSEnable INPUT BOOL Date and timestamp logging enable flag
CfgId INPUT USINT Configured dataset (DSET) number (1…10)
Status OUTPUT USINT Data logging function block current status
ErrorID OUTPUT UDINT Error ID if DLG Write fails

Table 35 - DLG Function Block Status

Status Code Description
0 Data logging IDLE status
1 Data logging BUSY status
2 Data logging COMPLETE SUCCEED status
3 Data logging COMPLETE ERROR status

Table 36 - DLG Function Block Errors

Status Code Name Description
0 DLG_ERR_NONE No error
1 DLG_ERR_NO_SDCARD microSD card is missing.
2 DLG_ERR_RESERVED Reserved
3 DLG_ERR_DATAFILE_ACCESS Error accessing datalog file in microSD card
4 DLG_ERR_CFG_ABSENT Datalog configuration file is absent.
5 DLG_ERR_CFG_ID Configuration ID is missing in datalog configuration file.
Same Configuration ID is used with other datalog
6 DLG_ERR_RESOURCE_BUSY function block call at the same time.
7 DLG_ERR_CFG_FORMAT Datalog configuration file format is wrong
8 DLG_ERR_RTC Real time clock is invalid.
9 DLG_ERR_UNKNOWN Unspecified error has occurred.

IMPORTANT File access error will be returned during DLG function block execution when
card is full.
Figure 43 - Datalog Function Block Timing Diagram

Enable(1) Enable(1)

Enable(1)
Disable(0) Disable(0) Disable(0)

Error(3)
Succeed(2)

Busy(1) Busy(1)
Status(0)
Idle(0)
Idle(0) Idle(0)

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IMPORTANT Datalog Function Block Execution

• There are three possible states for the Datalog function block: Idle, Busy, and
Complete (which includes Complete with Succeed and Complete with Error).
• For one Datalog function block execution, the typical status starts from Idle,
then Busy and finishes with Complete. To trigger another function block
execution, the status must return to Idle first.
• Idle status changes to Busy status only when Enable input signal is in the
rising edge. Complete status enters Idle status when Enable input signal is
Disable status only.
• TSEnable and CfgId input parameters are only sampled at the Enable input
parameter’s rising edge when a new function block execution starts. During
function block execution, the input parameters of TSEnable and CfgId are
locked and any changes are ignored.
• When execution completes, the status changes from Busy to Complete. At
this stage, if the input Enable is False, status changes to Idle after indicating
Complete for exactly one scan time. Otherwise function block status is kept
as Complete until the input Enable changes to False.
• Only the DLG instruction block can create the datalog file. The Connected
Components Workbench software can only upload and delete the datalog
file.
• There are separators between every data variable in the data file that is
defined during configuration in the Connected Components Workbench
software.
See Supported Data Types for Datalog and Recipe Function Blocks on
page 88.
• Data variable values are sampled when data logging function block is in Busy
state. However, the data logging file is only created when data logging
function block is in the Complete state.

Table 37 - Supported Data Types for Datalog and Recipe Function Blocks
Data Type Description Example Format in Output Datalog File
0: FALSE
BOOL(1) Logical Boolean with values TRUE and FALSE 1: TRUe
-128
SINT Signed 8-bit integer value +127
-32,768
INT Signed 16-bit integer value +32,767
-2,147,483,648
DINT Signed 32-bit integer value +2,147,483,647
-9,223,372,036,854,775,808
LINT Signed 64-bit integer value +9,223,372,036,854,775,807
0
USINT(BYTE) Unsigned 8-bit integer value 255
0
UINT(WORD) Unsigned 16-bit integer value 65,535
0
UDINT(DWORD) Unsigned 32-bit integer value 4,294,967,295
0
ULINT(LWORD) Unsigned 64-bit integer value 18,446,744,073,709,551,615
-3.40282347E+38
REAL 32-bit floating point value +3.40282347E+38
-1.7976931348623157E+308
LREAL 64-bit floating point value +1.7976931348623157E+308

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Table 37 - Supported Data Types for Datalog and Recipe Function Blocks (Continued)
Data Type Description Example Format in Output Datalog File

STRING(2) character string (1 byte per character) '"Rotation Speed”

1234567
(1) (Date variables are stored as 32-bit words, a
DATE Unsigned 32-bit integer value positive number of seconds beginning at
1970-01-01 at midnight GMT)
1234567
TIME(1) Unsigned 32-bit integer value (Time variables are stored as 32-bit words,
positive number of milliseconds.)
(1) BOOL, DATE, TIME data variables are presented in decimal digital format in the microSD card. You can convert this format to a more
friendly format. For example, use ANY_TO_STRING function block to convert BOOL data type (0, 1) to FALSE or TRUE. You can
similarly do the same for DATE and TIME data types.
DATE data type is presented in differential decimal digital value between system baseline time (1970/01/01,00:00:00) and current
date value. Unit is millisecond.
Time should be absolute time value. Unit is second.
(2) STRING data variables are enclosed in double quotation marks in the datalog file.
The example below shows DSET1 using string variables and DSET2 using integers.

Datalog Performance
Table 38 - Datalog – Data Payload vs. Performance Time
Number of Characters
Parameter
28 502 518 1028 1493 3676
Average write time per datalog file including 541.77 ms 1043.75 ms 1086.67 ms 1632.36 ms 1972.9 ms 2696.22 ms
all overheads
Average write time excluding first sample 500.40 ms 963.86 ms 999.14 ms 1472.36 ms 1818.33 ms 2545.92 ms
Average write time excluding all overheads 479.10 ms 502.78 ms 493.03 ms 505.54 ms 519.91 ms 715.68 ms

Time (ms)
2692.22
2750

2545.918367

2250
Average write time per
1972.9 datalog including all
overheads
1750 1818.326531 Average write time
1632.36
excluding first sample
1472.367347
Average write time
1250
1086.67 excluding all overheads
1043.75
999.1414141
963.858859
750
541.75
502.7840909 715.68

502.7840909 493.0344828 505.5405405 519.9090909

250 Data Payload

0 500 1000 1500 2000 2500 3000 3500 4000

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Time (ms)
2900

2400
Average write time per
datalog including all
overheads
1900

Average write time

excluding first sample
1400

Average write time

excluding all overheads
900

400 Data Payload

28-characters 502-characters 518-characters 1028-characters 1493-characters 3676-characters

Recipe Micro820 controllers support the Recipe feature and allows users to store and load a list of data to
and/or from recipe data files using the RCP instruction. It also allows you to download, upload, and
delete Recipe data on the microSD card through the Connected Components Workbench software.
A Micro820 program supports a maximum of 10 recipe sets. Each recipe can contain up to 128
variables, with a maximum of four data string variables per recipe. String variables can have a
maximum of 252 characters. Variations of the recipe are stored in separate files with unique file
names. For more information on how to store recipes on the microSD card, see the Recipe Directory
Structure on page 90.
Table 39 - Recipe Specifications
Attribute Value
Maximum number of recipe sets 10 Recipe sets are stored in 10 directories
(Rcp_Id01...Rcp_Id10) with a maximum number of 50
Maximum number of recipes in each set 50 recipe files in each directory.
Configured in Connected Components Workbench
Maximum number of variables per recipe 128
software
Maximum bytes per recipe file 4 KB

Recipe Directory Structure

On first execution of RCP, it creates the RECIPE folder under the current project directory
on the microSD card.

It also creates 10 subdirectories for each recipe set with a name following the CfgID input
value (1…10). If the CfgID value is 1, then the subfolder Rcp_Id01 is created.

Recipe files are then created/written into the folder, with file names that correspond to
the input value of RcpName parameter for the RCP function block, as configured in
Connected Components Workbench. Each Recipe set can contain up to 50 recipe files or
variations. Filenames for recipe files should not exceed 30 characters.

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Recipe Configuration and Retrieval

You can retrieve recipe files from the microSD card using a card reader or by uploading and
downloading the recipe sets through Connected Components Workbench software.

Recipe Function (RCP) Block

The RCP function block allows a user program to read variable values from an existing recipe data
file that is in the recipe folder of the microSD card and update run-time global or local variable
values in the controller. The RCP function block also allows the user program to write run-time
global or local variable values from smaller controller into the recipe data file in the microSD card.
RCP

Enable Status
RWFlag ErrorID

CfgId

RcpName

Table 40 - RCP Input and Output Parameters

Parameter Parameter Type Data Type Description
Recipe read/write function enable. If Rising Edge (Enable is
Enable INPUT BOOL triggered from "low" to "high"), starts the recipe function block
and the precondition is that last operation is completed.
TRUE: Recipe write data variables to recipe files into the
microSD card.
RWFlag INPUT BOOL
FALSE: Recipe reads saved data variables from the microSD
card and update these variables accordingly.
CfgId INPUT USINT Recipe set number (1…10)
RcpName INPUT STRING Recipe data filename (maximum 30 characters)
Status OUTPUT USINT Current state of Recipe function block
ErrorID OUTPUT UDINT Detailed error ID information if RCP read/write fails

Table 41 - RCP Function Block Status

Status Code Description
0 Recipe Idle status
1 Recipe Busy status
2 Recipe Complete Succeed status
3 Recipe Complete Error status

Table 42 - RCP Function Block Errors

Error ID Error Name Description
0 RCP_ERR_NONE No error
1 RCP_ERR_NO_SDCARD microSD card is absent.
2 RCP_ERR_DATAFILE_FULL Recipe files exceed maximum number of files per recipe set folder.
3 RCP_ERR_DATAFILE_ACCESS Error to access recipe data file in microSD card
4 RCP_ERR_CFG_ABSENT Recipe configuration file is absent.
5 RCP_ERR_CFG_ID Configure ID is absent in recipe configuration file.
The Recipe operation resource linked to this Recipe ID is used by
6 RCP_ERR_RESOURCE_BUSY another function block operation.
7 RCP_ERR_CFG_FORMAT Recipe configuration file format is invalid.
8 RCP_ERR_RESERVED Reserved
9 RCP_ERR_UNKNOWN Unspecified error has occurred.

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Table 42 - RCP Function Block Errors (Continued)

Error ID Error Name Description
10 RCP_ERR_DATAFILE_NAME Recipe data file name is invalid.
11 RCP_ERR_DATAFOLDER_INVALID Recipe dataset folder is invalid.
12 RCP_ERR_DATAFILE_ABSENT Recipe data file is absent.
13 RCP_ERR_DATAFILE_FORMAT Recipe data file contents are wrong.
14 RCP_ERR_DATAFILE_SIZE Recipe data file size is too large (>4K).

IMPORTANT File access error is returned during RCP function block execution when card
is full.
Figure 44 - Recipe Function Block Timing Diagram

Enable(1) Enable(1)

Enable(1)
Disable(0) Disable(0) Disable(0)

Error(3)
Succeed(2)

Status(0) Busy(1) Busy(1)

Idle(0)
Idle(0) Idle(0)

IMPORTANT RCP Function Block Execution

• There are three possible states for Recipe function block: Idle, Busy, and
Complete (Complete with Succeed and Complete with Error).
• For one Recipe function block execution, the typical status starts from Idle
then Busy and finishes with Complete. To trigger another function block
execution, the status needs to go back to Idle first.
• Idle status changes to Busy status only when Enable input signal is in rising
edge. Complete status enters Idle status when Enable input signal is on
Disable status.
• RWFlag, CfgId, and RcpName input parameters are only sampled at Enable
input parameter's rising edge when a new function block execution starts.
During function block execution, input parameters of RWFlag, CfgId, and
RcpName are locked and any changes are ignored.
• When the function block execution finishes, the function block status
changes from Busy to Complete. At this stage, if input Enable is False,
function block status changes to Idle after staying as Complete for exactly
one scan time. Otherwise, function block status remains Complete until
input Enable changes to False.
• Recipe function block file name supports a maximum of 30 bytes in length,
and only supports upper and lower case letters Aa…Zz, numbers 0…9, and
underscore (_).
• The RcpName input parameter does not allow file extension (for example,
.txt) to be added to its value. The recipe data file is written to the microSD
card with the .txt extension.
• There are separators in between every data variable in the recipe data file
which is defined during configuration in Connected Components Workbench
software. Redundant tab, space, carriage return, and line feed characters
are strictly not allowed. See Supported Data Types for Datalog and Recipe
Function Blocks on page 88.
• Double quotes are not allowed within a string in a recipe file.

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Quick Start Projects for The sample quick start projects shown in Figure 45 provide step-by-step instructions on how to
use the Datalog and Recipe function blocks in Connected Components Workbench software to
Datalog and Recipe Function generate and manage your recipe files and datalogs.
Blocks
Figure 45 - Use the Datalog Feature

Configure datalog

Create Datalog Ladder Program

Build and Download

Execute DLG Function Block

Upload Datalog File

Configure datalog
1. In the Connected Components Workbench software, go to the Properties pane to configure
your datalog.
2. Select Data Log. Select Add Data Set to add a dataset. Each dataset is stored in the same
file. You can add up to 10 datasets per configuration.
3. Select Add Variable to add variables to the dataset. You can add up to 128 variables to each
dataset.
For this quick start sample project, add the variables shown in Table 43 that you have
previously created to Dataset 1.
Table 43 - Local Variables
Variable Name Data Type
data_bool BOOL
data_int8 INT
data_string STRING

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Create Datalog Ladder Program

1. Launch the Connected Components Workbench software. Create a user program for your
Micro820 controller.
2. Right-click Programs. Select Add New LD: Ladder Diagram. Name the Program (for example,
Prog1).
3. From the Toolbox, select Direct Contact to add it to the rung.

4. From the Toolbox, double-click Block to add it to the rung.

5. On the Block Selector window that appears, type DLG to filter the DLG function block from
the list of available function blocks. Select OK.

6. Create the local variables shown in Table 44 for your project.

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Table 44 - Local Variables

Variable Name Data Type
EnDlg BOOL
cfg_id USINT
data_time_enable BOOL
error UDINT
status USINT
data_bool BOOL
data_int8 INT
data_string STRING
7. Assign the variables to the DLG input and output parameters as follows:

For CfgID input parameter, you can choose a predefined variable by choosing from the Defined
Words in Connected Components Workbench software. To do so, select the CfgID input box. From
the Variable Selector window that appears, select the Defined Words tab and choose from the list of
defined words. See Figure 46.
Figure 46 - Choose a Predefined Variable

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Build and Download

After configuring datalog properties, build the program and download to the controller.
Execute DLG Function Block

Execute the DLG function block. Notice the Status output go from 0 (Idle) to 1 (Enable), and then
2 (Succeed).

Upload Datalog File

You can retrieve datalog files from the microSD card with a card reader or by uploading the
datalogs through Connected Components Workbench software.
1. To use the Upload feature, go to the Properties section of your project in the Connected
Components Workbench software.
2. Select Data Log. Select Manage and then choose Upload.

IMPORTANT The Manage button is not available in DEBUG mode. You need to stop DEBUG
mode to use the Manage button to upload datalog files. Uploading datalog
files in PROGRAM mode is recommended for performance and file locking
reasons.
3. From the Upload window that appears, select the date of the datalog files that you want to
upload. You can upload datalogs for the entire month by selecting the Whole Month option.

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4. If the file exists in your destination folder, select whether you would like to Overwrite file,
Skip file, or Preserve both files.
5. Select Upload. The progress bar indicates whether the upload is successful or not.

IMPORTANT Do not remove the microSD card from the slot while data is being written or
retrieved from the card. Ongoing write and retrieval operations are indicated
by a flashing SD status LED.

IMPORTANT For better datalog file management, you can use a third-party tool or DOS
CMD to merge all your datalog files into a single file and import as a CSV file
in Excel®.

Use the Recipe Feature

Configure Recipe

Create Recipe Ladder Program

Build and Download

Execute RCP Function Block

Upload Recipe Files

Configure Recipe
1. In the Connected Components Workbench software, go to the Properties pane to configure
Recipe.
2. Select Recipe. Select Add Recipe to add a recipe. Each recipe is stored in separate files. You
can add up to 10 recipes per configuration.
3. Select Add Variable to add variables to the recipe. You can add up to 128 variables to each
recipe.
For this quick start sample project, add the variables shown in Figure 45 that you have
previously created to RCP 1:

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Table 45 - Local Variables

Variable Name Data Type
data_bool BOOL
data_int8 INT

Create Recipe Ladder Program

4. Launch the Connected Components Workbench software. Create a user program for your
Micro820 controller.
5. Right-click Programs. Select Add New LD: Ladder Diagram. Name the Program (for example,
Prog2).
6. From the Toolbox, select Direct Contact to add it to the first rung.

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7. From the Toolbox, select Block to add it to the rung.

8. On the Block Selector window that appears, type RCP to filter the Recipe function block from
the list of available function blocks. Select OK.

9. From the Toolbox, select rung to add another rung.

10. Add a Direct Contact and RCP function block to this second rung by following steps 3…5.
11. Create the following local variables shown in Figure 46 for your program, in addition to the
ones that you have already created for datalog.

Table 46 - Local Variables

Variable Name Data Type
recipe_file STRING
recipe_file2 STRING
cfg_id2 USINT
read BOOL
write BOOL

12. Assign the variables to the RCP input and output parameters as shown in Figure 47:
Figure 47 - Assign Variables

Rung 1

Rung 2

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For CfgID input parameter, you can choose a predefined variable from the Defined Words in the
Connected Components Workbench software. To do so, select the CfgID input box. From the
Variable Selector window that appears, select the Defined Words tab and choose from the list of
defined words. For example, RCP1 that corresponds to RCP1 in your recipe configuration. See
Figure 48.
Figure 48 - Defined Words

Build and Download

After configuring Recipe, build the program and download to the controller.
Execute RCP Function Block

Execute the RCP function block. Notice the Status output go from 0 (Idle) to 1 (Enable), and then
2 (Succeed).

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Upload Recipe Files

You can retrieve recipe files from the microSD card with a card reader or by uploading the recipe
files through Connected Components Workbench software.
1. To use the Upload feature, go to the Properties section of your project in the Connected
Components Workbench software.
2. Select Recipe. Select Manage and then choose Upload.
Through Manage, you can also choose to Download and Delete recipe files.
3. From the Upload window that appears, select the batch of recipe files that you want to
upload.

4. If the file exists in your destination folder, select whether you would like to Overwrite file,
Skip file, or Preserve both Files.
5. Select Upload. The progress bar indicates whether the upload is successful or not.

IMPORTANT Do not remove the microSD card from the slot while data is being written or
retrieved from the card. Ongoing write and retrieval operations are indicated
by a flashing SD status LED.
A recipe header file is saved with the uploaded recipes.

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Notes:

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Modbus Mapping for Micro800 Controllers
Modbus Mapping Micro820 controllers support Modbus RTU over a Serial port through the embedded, non-isolated
Serial port. The 2080-SERIALISOL isolated Serial port plug-in module also supports Modbus RTU.
Both Modbus RTU master and slave are supported. Although performance may be affected by the
program scan time, the 48-point controllers can support up to six Serial ports (one embedded and
five plug-ins), and so consequently, six separate Modbus networks.

Endian Configuration
Modbus protocol is big-endian in that the most significant byte of a 16-bit word is transmitted first.
Micro800 controllers are also big-endian, so byte ordering does not have to be reversed. For
Micro800 data types larger than 16 bits (for example, DINT, LINT, REAL, LREAL), multiple Modbus
addresses may be required but the most significant byte is always the first.

Mapping Address Space and supported Data Types

Since Micro800 controllers use symbolic variable names instead of physical memory addresses, a
mapping from symbolic variable name to physical Modbus addressing is supported in Connected
Components Workbench software. For example, InputSensorA is mapped to Modbus address
100001.

By default Micro800 controllers follow the six-digit addressing specified in the latest Modbus
specification. For convenience, conceptually the Modbus address is mapped with the following
address ranges. The Connected Components Workbench mapping screen follows this convention.
Table 47 - Mapping Table
0 - Coils 1 - Discrete Inputs 3 - Input Registers 4 - Holding Registers
000001…065536 100001…165536 300001…365536 400001…465536
Variable Data Type
Supported Modbus Address Supported Modbus Address Supported Modbus Address Supported Modbus Address
Used Used Used Used
BOOL Y 1 Y 1
SINT Y 8 Y 8
BYTE Y 8 Y 8
USINT Y 8 Y 8
INT Y 16 Y 16 Y 1 Y 1
UINT Y 16 Y 16 Y 1 Y 1
WORD Y 16 Y 16 Y 1 Y 1
REAL Y 32 Y 32 Y 2 Y 2
DINT Y 32 Y 32 Y 2 Y 2
UDINT Y 32 Y 32 Y 2 Y 2
DWORD Y 32 Y 32 Y 2 Y 2
LWORD Y 64 Y 64 Y 4 Y 4
ULINT Y 64 Y 64 Y 4 Y 4
LINT Y 64 Y 64 Y 4 Y 4
LREAL Y 64 Y 64 Y 4 Y 4

NOTE: Strings are not supported.

To make it easier to map variables to five-digit Modbus addresses, the Connected Components
Workbench mapping tool checks the number of characters that are entered for the Modbus
Address. If only five-digits are entered, the address is treated as a five-digit Modbus address.

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This means that the Coils are mapped from 00001…09999, Discrete Inputs are mapped from
10001…19999, Input Registers are mapped from 30001…39999, and Holding Registers are mapping
from 40001…49999.

Example 1, PanelView Component HMI (Master) to Micro800 (Slave)

The embedded Serial port is targeted for use with HMIs using Modbus RTU. The maximum
recommended cable distance is 3 meters (10 feet). Use the 2080-SERIALISOL Serial port plug-in
module if longer distances or more noise immunity is needed.

The HMI is typically configured for Master and the Micro800 embedded Serial port is configured for
Slave.

From the default Communications Settings for a PanelView 800 HMI (PV800), there are three items
that must be checked or modified in order to set up communications from PV800 to Micro800.
1. Change the Protocol from DF1 to Modbus.

2. Set the Address of Micro800 slave to match the Serial port configuration for the controller.

3. Deactivate Tags on Error. This is to prevent the requirement of power cycling PanelView 800
when new Modbus Mappings are downloaded from the Connected Components Workbench
software to the Micro800 controller.

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Example 2, Micro800 (Master) to PowerFlex 4M Drive (Slave)

The following is the overview of the steps to take to configure a PowerFlex 4M drive.
Parameter numbers listed in this section are for a PowerFlex 4M drive and will be different if you
are using another PowerFlex 4-class drive.
Table 48 - Parameters in PowerFlex 4-class Drives
Parameter Number
Parameter Name
4M 4 40 40P 400 400N 400P
Start Source P106 P36
Speed Reference P108 P38
Comm Data Rate C302 A103 C103
Comm Node Addr C303 A104 C104
Comm Loss Action C304 A105 C105
Comm Loss Time C305 A106 C106
Comm Format C306 A107 C102

• Connect the 1203-USB to the PowerFlex drive and to the computer.

• Launch Connected Components Workbench software, connect to the drive, and set
parameters.

To configure a PowerFlex 4M drive, perform the following steps:

1. Double-click the PowerFlex 4M drive if it is not already open in Connected Components
Workbench software.
2. Select Connect.
3. In the Connection Browser, expand the AB_DF1 DH+™ Driver.
Select the AB DSI (PF4 Port) and select OK.
4. Once the Drive has connected and been read in, select the Start up wizard and change the
following items. Select Finish to save the changes to the drive.
- Select the Comm Port as the Speed Reference. Set P108 [Speed Reference] to 5 (Comm
Port).
- Set Start Source to Comm Port. Set P106 [Start Source] to 5 (Comm Port).
- Accept defaults for the remaining Inputs.
- Accept defaults for the remainder and select Finish.
5. Select Parameters from the Connected Components Workbench window.

6. The Parameter window opens. Resize it to view the parameters. From this window, you can
view and set data values of Parameters.

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7. From the Parameter window, change the following Parameters to set the communications
for Modbus RTU so that the PowerFlex 4M drive will communicate with Micro820 via Modbus
RTU communication.
Table 49 - Modbus RTU Parameters
Parameter Description Setting
C302 Communication Data Rate (Baud Rate) 4 = 19200 bps 4
C303 Communication Node Address (Address range is 1…127) 2
Communication Loss Action (Action taken when loss communication) 0 = Fault
C304 0
with coast stop
Communication Loss Time (Time remain in communication before taking action
C305 5
set in C304) 5 sec (max 60)
C306 Communication Format (Data/Parity/Stop) RTU:8 Data Bit, Parity None, 1 Stop bit 0
8. Disconnect the Communications and save your project.

9. Turn off the power to the drive until the PowerFlex 4M display blanks out completely, then
restore power to the PowerFlex 4M drive.
The drive is now ready to be controlled by Modbus RTU communication commands initiated
from the Micro820 controller.

Modbus devices can be 0-based (registers are numbered starting at 0), or 1-based (registers are
numbered starting at 1). When PowerFlex 4-class drives are used with Micro800 family controllers,
the register addresses listed in the PowerFlex 4M User Manual need to be offset by n+1.
For example, the Logic Command word is at address 8192, but your Micro800 program must use
8193 (8192+1) to access it.

EXAMPLE: Modbus Address (n+1 value shown)

EXAMPLE:
8193 Logic Command word (Stop, Start, Jog, and so on.)
8194 Speed Reference word
xxx.x format for 4/4M/40, where "123" = 12.3 Hz
xxx.xx format for 40P/400/400N/400P, where "123" = 1.23 Hz
8449 Logic Status word (Read, Active, Fault, and so on.)
8452 Speed Feedback word (uses same format as Speed Reference)
8450 Error Code word
(n+1) To access Parameter 'n'

• If the respective PowerFlex drive supports Modbus Function Code 16 Preset

(Write) Multiple Registers, use a single write message with a length of "2" to
write the Logic Command (8193) and Speed Reference (8194) at the same
time.
• Use a single Function Code 03 Read Holding Registers with a length of "4" to
read the Logic status (8449), Error Code (8450), and Speed Feedback (8452)
at the same time.
See the PowerFlex 4M Adjustable Frequency AC Drive User Manual FRN 1.xx - 2.xx, publication 22F-
UM001 for additional information about Modbus addressing. (See the appendix – Modbus RTU
Protocol, in PowerFlex 400 Adjustable Frequency AC Drive for Fan & Pump Applications User
Manual, publication 22C-UM001).

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Performance
The performance of MSG_MODBUS (Micro800 is master) is affected by the Program Scan because
messages are serviced when the message instruction is executed in a program. For example, if the
program scan is 100 ms and six Serial ports are used, then the theoretical maximum for Serial
ports is 60 messages/second total. This theoretical maximum may not be possible since
MSG_MODBUS is a master/slave request/response protocol, so performance is affected by several
variables such as message size, baud rate, and slave response time.

The performance of Micro800 when receiving Modbus request messages (Micro800 is slave) is also
affected by the Program Scan. Each Serial port is serviced only once per program scan.

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Notes:

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 Appendix B
Troubleshooting
Status Indicators on the Status indication on the Micro820 controller is as shown in Figure 49.
Controller Figure 49 - Status Indicators

Input status

Run status Fault status

Force status Comm status
ENET status SD status

Output status

Table 50 - Status Indicator Description

Description State Indicates
Off Input is low.
1 Input status
On Input is energized (terminal status).
Off No fault detected
2 Fault status Red Non-recoverable fault that requires a power cycle
Flashing red Recoverable fault
Green Executing the user program in run mode
3 Run status The controller is in program mode or performing a
Flashing green (1 Hz) restore operation.
Off No traffic for RS-232/RS-485
4 Serial comm status Traffic through RS-232/RS-485.
Green The indicator only blinks when transmitting data. It does
not blink when receiving data.
Off No force conditions are active.
5 Force status
Amber Force conditions are active.
• microSD card is not inserted.
Off • microSD card is inserted but medium is bad.
Uninitialized state
• microSD card is inserted but file system is bad.
• microSD card read/write failure
Off • Failure to read Configmefirst.txt in the root directory
Error state • Errors are detected in ConfigMeFirst.txt. See
6 SD status ConfigMeFirst.txt Errors on page 83 for list of errors.
• microSD card is initialized completely without read/
On write on SD card.
Idle state
• microSD card read/write is complete.
microSD card is being read/written.
Blinking The status indicator does not blink continuously for the
Operating state entire duration of the restore operation.

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Table 50 - Status Indicator Description (Continued)

Description State Indicates
Not powered, no connection.
Steady off The device is powered off, or is powered on but no
Ethernet link established.
No IP address.
The device is powered on with Ethernet link established
but no IP address is assigned yet.
Duplicate IP.
7 ENET status Flashing green The device has detected that its IP address is being
used by another device in the network. This status is
applicable only if the device’s duplicate IP address
detection (ACD) feature is enabled.
Operational.
Steady green Ethernet ink is active and the device has valid IP
address.
Off Output is not energized.
8 Output status
On Output is energized (logic status).

Normal Operation
The Run status indicator is on or flashing. If a force condition is active, the Force status indicator
turns on and remains on until all forces are removed.

Error Codes This section lists possible error codes for your controller, as well as recommended actions for
recovery. Information about the fault is stored in a fault log, which can be accessed from the
Diagnostics page in the Connected Components Workbench software. The fault log contains brief
information about the last fault, and detailed information about the last 10 non-recoverable faults
that occurred.
If an error persists after performing the recommended action, contact your local Rockwell
Automation technical support representative. For contact information, go to rok.auto/support.

Fault Types
There are two basic types of faults that can occur:
• Recoverable — You can clear a recoverable fault without having to power cycle the
controller. The fault status indicator flashes red when a recoverable fault occurs.
• Non-recoverable — You must power cycle the controller to clear a non-recoverable fault.
After you power cycle or reset the controller, check the fault log in the Diagnostic page of
the Connected Components Workbench software, then clear the fault. The fault status
indicator is solid red when a non-recoverable fault occurs.
Table 51 - List of Error Codes for Micro800 controllers
Error Code Fault Type Description Recommended Action
The controller was unexpectedly reset due to a noisy
environment or an internal hardware failure. Perform one of the following:
If the system variable _SYSVA_USER_DATA_LOST is set, the • See Corrective Actions for Recoverable Faults on page 115.
0xF000 Recoverable controller is able to recover the user program but the user • Check wiring to eliminate any noise, see Wiring Requirements and
data is cleared. If not, the Micro800 controller program is Recommendation on page 33.
cleared.
The controller program has been cleared. This happened
because:
• A power-down occurred during program download or Perform one of the following:
0xF001 Recoverable data transfer from the memory module. • See Corrective Actions for Recoverable Faults on page 115.
• The cable was removed from the controller during • Transfer the program using the memory module restore utility.
program download.
• The RAM integrity test failed.

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 Appendix B Troubleshooting

Table 51 - List of Error Codes for Micro800 controllers (Continued)

Error Code Fault Type Description Recommended Action
The controller hardware watchdog was activated. The
controller hardware watchdog timeout happens if program
scan is more than three seconds.
0xF002 Non-recoverable If the system variable _SYSVA_USER_DATA_LOST is set, the See Corrective Actions for Non-recoverable Faults on page 115.
controller is able to recover the user program but the user
data is cleared. If not, the Micro800 controller program is
cleared.
Perform one of the following:
One of the following occurred: • Remove the memory module and plug it in again.
• The memory module hardware faulted. • Obtain a new memory module.
0xF003 Recoverable • The memory module connection faulted. • See Corrective Actions for Recoverable Faults on page 115.
• The memory module was incompatible with the • Upgrade the Micro800 controller’s firmware revision to be compatible with
Micro800 controller’s firmware revision. the memory module. For information on firmware revision compatibility, go
to rok.auto/pcdc.
Perform one of the following:
• See Corrective Actions for Recoverable Faults on page 115.
A failure occurred during the memory module data
0xF004 Recoverable • Attempt the data transfer again. If the error persists, replace the memory
transfer.
module.
• For Embedded RTC failure, restart the controller.
Perform one of the following:
The user program failed an integrity check while the
0xF005 Recoverable • See Corrective Actions for Recoverable Faults on page 115.
Micro800 controller was in Run mode.
• See Wire Your Controller on page 33.
Perform one of the following:
The user program is incompatible with the Micro800
0xF006 Recoverable • See Corrective Actions for Recoverable Faults on page 115.
controller’s firmware revision.
• Contact your local Rockwell Automation technical support representative.
Perform one of the following:
The user program contains a function/function block that • See Corrective Actions for Recoverable Faults on page 115.
0xF010 Recoverable is not supported by the Micro800 controller.
• Contact your local Rockwell Automation technical support representative.
• See Corrective Actions for Recoverable Faults on page 115.
0xF014 Recoverable A memory module memory error occurred. • Reprogram the memory module. If the error persists, replace the memory
module.
Perform one of the following:
0xF015 Non-recoverable An unexpected software error occurred. • See Corrective Actions for Non-recoverable Faults on page 115.
• Refer to Wiring Requirements and Recommendation on page 33.
Perform one of the following:
0xF016 Non-recoverable An unexpected hardware error occurred. • See Corrective Actions for Non-recoverable Faults on page 115.
• Refer to Wiring Requirements and Recommendation on page 33.
An unexpected software error occurred due to unexpected
hardware interrupt. Perform one of the following:
If the system variable _SYSVA_USER_DATA_LOST is set, the • See Corrective Actions for Non-recoverable Faults on page 115.
0xF017 Non-recoverable controller is able to recover the user program but the user
data is cleared. If not, the Micro800 controller program is • See Wiring Requirements and Recommendation on page 33.
cleared.
An unexpected software error occurred due to SPI
communication failure. Perform one of the following:
If the system variable _SYSVA_USER_DATA_LOST is set, the • See Corrective Actions for Non-recoverable Faults on page 115.
0xF018 Non-recoverable controller is able to recover the user program but the user
data is cleared. If not, the Micro800 controller program is • See Wiring Requirements and Recommendation on page 33.
cleared.
An unexpected software error occurred due to memory or See Corrective Actions for Non-recoverable Faults on page 115.
0xF019 Non-recoverable other controller resource issue.
The controller was unexpectedly reset during Run Mode
Change (RMC) due to a noisy environment or an internal
hardware failure.
0xF01A Recoverable If the system variable _SYSVA_USER_DATA_LOST is set, the See Corrective Actions for Recoverable Faults on page 115.
controller is able to recover the user program but the user
data is cleared. If not, the Micro800 controller program is
cleared.
The base hardware faulted or is incompatible with the
0xF020 Recoverable See Corrective Actions for Recoverable Faults on page 115.
Micro800 controller’s firmware revision.
The I/O configuration in the user program is invalid or does See Corrective Actions for Recoverable Faults on page 115.
0xF021 Recoverable not exist in the Micro800 controller.
Perform one of the following:
The user program in the memory module is incompatible • See Corrective Actions for Recoverable Faults on page 115.
0xF022 Recoverable with the Micro800 controller’s firmware revision.
• Replace the memory module.

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Table 51 - List of Error Codes for Micro800 controllers (Continued)

Error Code Fault Type Description Recommended Action
The controller program has been cleared. This happened
because: Perform one of the following:
0xF023 Non-recoverable • A power down occurred during program download or • See Corrective Actions for Non-recoverable Faults on page 115.
transfer from the memory module. • Download or transfer the program.
• The Flash Integrity Test failed (Micro810 only).
Power down information in persistent memory may not be
written properly due to a noisy environment or an internal
0xF030 hardware failure.
0xF031 Recoverable If the system variable _SYSVA_USER_DATA_LOST is set, the See Corrective Actions for Recoverable Faults on page 115.
0xF032 controller is able to recover the user program but the user
0xF033 data is cleared. If not, the Micro800 controller program is
cleared.
The embedded I/O configuration in the user program is
0xF050 Recoverable See Corrective Actions for Recoverable Faults on page 115.
invalid.
There is general configuration error detected in the motion Perform the following:
configuration downloaded from the Connected
0xF100 Recoverable • See Corrective Actions for Recoverable Faults on page 115.
Components Workbench software, such as number of axis,
or motion execution interval being configured out of range. • Correct the axes configuration in the user program.
Perform the following:
There is motion resource missing, such as Motion_DIAG
0xF110 Recoverable • See Corrective Actions for Recoverable Faults on page 115.
variable not defined.
• Correct the axes configuration in the user program.
Motion configuration for axis z cannot be supported by this Perform the following:
controller model, or the axis configuration has some • See Corrective Actions for Recoverable Faults on page 115.
0xF12z(1) Recoverable resource conflict with some other motion axis, which has • Remove all axes and re-configure motion with the guidance from the User
been configured earlier. Manual.
There is a motion engine logic error (firmware logic issue
or memory crash) for one axis detected during motion
0xF15z(1) Recoverable engine cyclic operation. One possible reason can be See Corrective Actions for Recoverable Faults on page 115.
motion engine data/memory crash.
Perform the following:
1. Power off the controller.
0xF210 Recoverable The expansion I/O terminator is missing. 2. Attach the expansion I/O terminator on the last expansion I/O module on the
system.
3. Power on the controller.
4. See Corrective Actions for Recoverable Faults on page 115.
Perform the following:
1. Power off the controller.
The maximum number of expansion I/O modules has been
0xF230 Recoverable 2. Verify that the number of expansion I/O modules is not more than four.
exceeded.
3. Power on the controller.
4. See Corrective Actions for Recoverable Faults on page 115.
There is a non-recoverable error and the expansion I/O
0xF250 Recoverable See Corrective Actions for Recoverable Faults on page 115.
module(s) could not be detected.
0xF26z(2) Recoverable An expansion I/O master fault is detected on the system. See Corrective Actions for Recoverable Faults on page 115.
Perform one of the following:
A non-recoverable communication fault has occurred on • See Corrective Actions for Recoverable Faults on page 115.
0xF27z(2) Recoverable the expansion I/O module.
• Replace the slot number z module.
Perform one of the following:
0xF28z(2) Recoverable Expansion I/O communication rate error • See Corrective Actions for Recoverable Faults on page 115.
• Replace the slot number z module.
Perform one of the following:
0xF29z(2) Recoverable A module fault is detected on your expansion I/O module. • See Corrective Actions for Recoverable Faults on page 115.
• Replace the slot number z module.
Perform one of the following:
0xF2Az(2) Recoverable Expansion I/O power failure • See Corrective Actions for Recoverable Faults on page 115.
• Replace the slot number z module.
Perform one of the following:
• See Corrective Actions for Recoverable Faults on page 115.
• Correct the expansion I/O module configuration in the user program to match
0xF2Bz(2) Recoverable Expansion I/O configuration fault
that of the actual hardware configuration.
• Check the expansion I/O module operation and condition.
• Replace the expansion I/O module.

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Table 51 - List of Error Codes for Micro800 controllers (Continued)

Error Code Fault Type Description Recommended Action
Perform the following:
• See Corrective Actions for Recoverable Faults on page 115.
The memory module is present but memory module is
0xF300 Recoverable • Check to make sure there is a valid project in the memory module.
empty and restore operation is requested.
• Download a user program and use the backup function to the memory
module.
Perform one of the following:
• See Corrective Actions for Recoverable Faults on page 115.
The memory module’s project is not compatible with the • Check to make sure there is a user program with a controller that has the
0xF301 Recoverable controller. correct controller catalog configured.
• Download a user program and use the backup function to the memory
module.
Perform one of the following:
• See Corrective Actions for Recoverable Faults on page 115.
The password is mismatched between memory module • Check to make sure that the user program in the memory module has the
and controller. Only applies to Micro820 controller when correct password.
0xF302 Recoverable Remote LCD performs the restore operation.
This fault does not apply to Micro800 controller firmware • Download a user program with a password and use the backup function to
revision 10 or later. the memory module.
• Use the Connected Components Workbench software to enter the correct
password into the controller and perform the restore operation again.
The memory module is not present and restore operation Verify that the memory module is present.
0xF303 Recoverable is requested.
Perform the following:
The plug-in I/O module experienced an error during
0xF0Az(3) Recoverable operation. • Check the condition and operation of the plug-in I/O module.
• See Corrective Actions for Recoverable Faults on page 115.
Perform one of the following:
• See Corrective Actions for Recoverable Faults on page 115.
The plug-in I/O module configuration does not match the • Correct the plug-in I/O module configuration in the user program to match
0xF0Bz(3) Recoverable actual I/O configuration detected. that of the actual hardware configuration.
• Check the condition and operation of the plug-in I/O module.
• Replace the plug-in I/O module.
Perform the following:
1. See Corrective Actions for Recoverable Faults on page 115.
When power was applied to the plug-in I/O module or the
2. Correct the plug-in I/O module configuration in the user program.
0xF0Dz(3) Recoverable plug-in I/O module was removed, a hardware error
occurred. 3. Build and download the program using Connected Components Workbench
software.
4. Put the Micro800 controller into Run mode.
Perform the following:
1. See Corrective Actions for Recoverable Faults on page 115.
The plug-in I/O module configuration does not match the 2. Correct the plug-in I/O module configuration in the user program.
0xF0Ez(3) Recoverable actual I/O configuration detected. 3. Build and download the program using Connected Components Workbench
software.
4. Put the Micro800 controller into Run mode.
Perform the following:
• See Corrective Actions for Recoverable Faults on page 115.
0xF830 Recoverable An error occurred in the EII configuration.
• Review and change the EII configuration in the Micro800 controller
properties.
Perform the following:
• See Corrective Actions for Recoverable Faults on page 115.
0xF840 Recoverable An error occurred in the HSC configuration.
• Review and change the EII configuration in the Micro800 controller
properties.
Perform the following:
• See Corrective Actions for Recoverable Faults on page 115.
0xF850 Recoverable An error occurred in the STI configuration.
• Review and change the EII configuration in the Micro800 controller
properties.
Perform the following:
A data overflow occurred. 1. See Corrective Actions for Recoverable Faults on page 115.
A data overflow error is generated when the ladder, 2. Correct the program to ensure that there is no data overflow.
0xF860 Recoverable structured text or function block diagram execution 3. Build and download the program using Connected Components Workbench
encounters a divide-by-zero. software.
4. Put the Micro800 controller into Run mode.

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Table 51 - List of Error Codes for Micro800 controllers (Continued)

Error Code Fault Type Description Recommended Action
Perform the following:
1. See Corrective Actions for Recoverable Faults on page 115.
2. Correct the program to ensure that there is no index used to access an array
0xF870 Recoverable An index address was out of data space. element beyond the array boundaries.
3. Build and download the program using Connected Components Workbench
software.
4. Put the Micro800 controller into Run mode.
Perform the following:
1. See Corrective Actions for Recoverable Faults on page 115.
An index used to access a bit is beyond the boundaries of 2. Correct the program to ensure that there is no index used to access a bit
0xF0878 Recoverable beyond the boundaries of the data type.
the data type it is used on.
3. Build and download the program using Connected Components Workbench
software.
4. Put the Micro800 controller into Run mode.
Perform the following:
1. See Corrective Actions for Recoverable Faults on page 115.
2. Correct the program to ensure that there is no data conversion error.
0xF880 Recoverable A data conversion error occurred.
3. Build and download the program using Connected Components Workbench
software.
4. Put the Micro800 controller into Run mode.
Perform the following:
The call stack of the controller cannot support the
0xF888 Recoverable sequence of calls to function blocks in the current project. • See Corrective Actions for Recoverable Faults on page 115.
Too many blocks are within another block. • Change the project to reduce the quantity of blocks being called within a
block.
Perform the following:
An error occurred in the user interrupt configuration for • See Corrective Actions for Recoverable Faults on page 115.
0xF898 Recoverable the plug-in I/O module. • Correct the user interrupt configuration for plug-in I/O module in the user
program to match that of the actual hardware configuration.
Perform the following:
1. See Corrective Actions for Recoverable Faults on page 115.
0xF8A0 Recoverable The TOW parameters are invalid. 2. Correct the program to ensure that there are no invalid parameters.
3. Build and download the program using Connected Components Workbench
software.
4. Put the Micro800 controller into Run mode.
Perform the following:
1. See Corrective Actions for Recoverable Faults on page 115.
0xF8A1 Recoverable The DOY parameters are invalid. 2. Correct the program to ensure that there are no invalid parameters.
3. Build and download the program using Connected Components Workbench
software.
4. Put the Micro800 controller into Run mode.
A user-created fault from the Connected Components
0xFFzz(4) Recoverable Workbench software has occurred. See Corrective Actions for Recoverable Faults on page 115.
A particular hardware type (for example, embedded I/O)
0xD00F Recoverable was selected in the user program configuration, but did See Corrective Actions for Recoverable Faults on page 115.
not match the actual hardware base.
Perform the following:
• See Corrective Actions for Recoverable Faults on page 115.
• Determine if the program is caught in a loop and correct the problem.
Fault may occur if your Structured Text program contains a “For loop” with the
upper limit set to the maximum value of the variable. For example, the variable
is a USINT and the limit is set to 255, or the variable is a UINT and the limit is set
to 65,535.
The program scan time exceeded the watchdog timeout To correct the fault, perform the following:
0xD011 Recoverable value. 1. Correct the program to ensure that the upper limit is not reached. One
method is to use a data type with a larger maximum value.
2. Build and download the program using Connected Components Workbench.
3. Put the Micro800 controller into Run mode.
4. If your program is designed to have a scan time of longer than three
seconds, in the user program, increase the watchdog timeout value that is
set in the system variable _SYSVA_TCYWDG and then build and download the
program using Connected Components Workbench software.
(1) z indicates the logic axis ID. (0...3)
(2) z indicates the slot number of the expansion I/O. If z=0, then the slot number cannot be identified.
(3) z is the slot number of the plug-in module. If z = 0, then the slot number cannot be identified.
(4) zz indicates the last byte of the program number. Only program numbers up to 0xFF can display. For program numbers 01x00 to 0xFFFF, only the last byte displays.

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Corrective Action for Recoverable and Non-recoverable Faults

Corrective Actions for Recoverable Faults

Perform the following:

1. Optionally save the fault log from Connected Components Workbench software. For more
information, see Retrieve a Fault Log on page 115.
2. Clear the recoverable fault using Connected Components Workbench software.
3. If problem persists, contact technical support with the fault log.
Corrective Actions for Non-recoverable Faults

Perform the following:

1. Power cycle your Micro800 controller.
2. Controller will go to recoverable fault. Optionally save the fault log from Connected
Components Workbench software.
3. Clear the recoverable fault using Connected Components Workbench software.
4. If program is lost, build and download your program using Connected Components
Workbench software.
5. If problem persists, contact technical support with the fault log.

Retrieve a Fault Log You can retrieve a fault log for your controller by using the Connected Components Workbench
software, version 9 or later.
Perform the following:
1. Launch the Connected Component Workbench software.
2. Connect to your Micro800 controller.
3. In Project Organizer, right-click the Micro800 controller.
4. Select Diagnose > Fault.
The Fault Diagnostics tab displays.
5. Select the Get Fault Log button.
6. Save the fault log (.txt) file.

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Controller Error Recovery Use the error recovery model shown in Figure 50 to help you diagnose software and hardware
problems in the micro controller. The model provides common questions you might ask to help
Model troubleshoot your system. See the recommended pages within the model for further help.
Figure 50 - Error Recovery Model

Start

Is the Power No
status indicator Check the wiring.
on?

Yes

Check the Fault status indicator.

Flashing red = Recoverable
Solid red = Non-recoverable

No
Is fault recoverable? Power cycle the controller.

Yes

Diagnose fault in Connected Components Workbench

software and see page 110 for probable cause and
recommended action.

Clear the fault.

Correct the condition

causing the fault.

Test and verify system

operation.

End

Calling Rockwell Automation If you need to contact Rockwell Automation or local distributor for assistance, it is helpful to obtain
the following (before calling):
for Assistance
• Controller type, series letter, revision letter, and firmware (FRN) number of the controller
• Controller indicator status

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 Appendix C
Quick Starts
This chapter covers some common tasks and quickstart instructions that are aimed to make you
familiar with the Connected Component Workbench software.

Update Your Micro800 The quick start shows you how to update the firmware for a Micro800 controller using Connected
Components Workbench software version 10 or later.
Controller Firmware
From Connected Components Workbench software release 10 onwards, there are two options you
can select to update the firmware:
• Upgrade or Downgrade – This option retains the controller’s existing configuration, Ethernet
settings, and password.
• Reset – This option clears the controller’s existing configuration, Ethernet settings, and
password.
The procedure to update the controller is similar for both options.

ATTENTION: Retention of the controller’s existing configuration, Ethernet

settings, and password is only available when updating from firmware
revision 10 to the same or later revision. If updating from firmware revision
10 to 9 or earlier, or updating to firmware revision 10 from an earlier revision,
the controller’s existing configuration, Ethernet settings, and password are
cleared.

IMPORTANT If you have forgotten the password for the controller, use the Reset option to
clear the password.

On Micro820 controllers, you can update your controllers through the Ethernet port and the USB of
the 2080-REMLCD plug-in module.

IMPORTANT To update your controller over USB successfully, connect only one controller
to your computer, and do not perform the update in a virtual machine such
as VMware.

To begin, launch the Connected Components Workbench software:

1. In the menu, select Device -> Update Firmware -> Upgrade or Downgrade...
Alternatively, in the Project Organizer, right-click the controller and select Update Firmware
-> Upgrade or Downgrade...

2. If your project does not have a connection path to the controller, the Connection Browser
dialog appears. Select your controller, then select OK.

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3. In the Upgrade or Downgrade Firmware dialog box, select the desired Target Revision to
update the controller.

If you do not see the desired firmware revision in the drop-down list, you can download that
firmware revision by selecting the “Get the firmware files online” link.
You can also change the Connection Path by selecting the “Change” link.
4. When you have confirmed the settings, select Update to begin updating the controller.
The update progress is shown in the dialog box.

5. After the update is completed, the status is shown in the dialog box.

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IMPORTANT After updating the controller, some microSD cards may not be detected.
Remove and insert the microSD card, or power cycle the controller if you
encounter this issue.

Firmware Update From microSD Card

With Connected Components Workbench software version 8.0 or later, you can update your
Micro820 controller from the microSD card and with ControlFLASH. This is two-step process: First
you transfer the firmware to the microSD card using the SD Card Utility, then you edit the
ConfigMeFirst.txt file to initiate the update process. See the following instructions for performing
the firmware update from the microSD card.
Step 1 – Transfer the Firmware to the microSD Card
1. Launch the Connected Components Workbench software.
2. Select Tools -> SD Card Utility.

The SD Card Utility window appears.

3. Select the drive letter that points to the microSD card on your computer from the dropdown
list.
You can check the drive letter by looking in Windows® Explorer. For this example, the
microSD card is using the drive letter “G”.

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4. Select the catalog number of your Micro820 controller.

5. Select the firmware revision you want to update your Micro820 controller with.

The list of firmware revisions are installed together with the Connected Components
Workbench software. If you require a revision that is not listed, download the firmware from
the Product Compatibility and Download Center (PCDC) at rok.auto/pcdc and install the
included ControlFLASH kit.

IMPORTANT You must sign in to the Rockwell Automation website before

downloading a firmware revision.
Close and relaunch the Connected Components Workbench software, then open the SD Card
Utility again. The revision should now appear in the list.
6. Select Transfer.
The file is copied to the microSD card.

7. Close the SD Card Utility and proceed to the next step to edit the ConfigMeFirst.txt file.

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Step 2 – Edit the ConfigMeFirst.txt File

To update the controller with the firmware that you have transferred to the microSD card, you must
edit the ConfigMeFirst.txt file with the settings listed in Table 52. You must add these settings at the
beginning of the file.
Table 52 - New ConfigMeFirst.txt Configuration Settings for Flash Upgrade
Setting Takes Effect On... Description
Firmware update settings
File path location of the firmware revision on the microSD card.
[FWFILE] Power-up The default location is in the following format:
firmware\<catalog number>\<filename of firmware>
Sets whether to upgrade or downgrade the controller firmware
from the current revision.
0 = Upgrade firmware; 1 = Downgrade firmware
[FWDOWN] Power-up IMPORTANT: Firmware Upgrade occurs if the [FWFILE] setting
points to a newer version of firmware file compared to the
current firmware in the controller, irrespective of [FWDOWN]
setting.

Figure 51 - Example of ConfigMeFirst.txt File for Flash Upgrade

After you have edited the file, insert the microSD card into the controller. Power cycle the controller
and the update process begins. The SD status LED does not blink when updating the firmware from
the microSD card is in progress.

When upgrading a Micro820 controller using the microSD card with a firmware revision that is not
compatible with the series, the controller hard faults. There is no error code reported after you
have cycled power to the controller. The controller retains the old firmware.

Fault Status Indicator Description

State Indicates
Steady Red Fault
Flashing Green Run

For a list of firmware and series compatibility, see the release notes for firmware revision 11.011 or
later, on the Product Compatibility and Download Center (PCDC) at rok.auto/pcdc.

Establish Communications This quick start shows you how to get RSLinx® RSWho to communicate with a Micro820 controller
through USB. Micro820 controller uses the 2080_REMLCD_xxxx driver.
between RSLinx and a
Micro820 Controller Through RSLinx® Classic is installed as part of the Connected Components Workbench software installation
process. The minimum version of RSLinx Classic with full Micro820 controller support is 3.60.01
USB (released on December 2013).
1. Power up the Micro820 controller.
2. Connect the USB A/B cable directly between your PC and the USB port on the 2080-REMLCD
plug-in module.
3. Windows should discover the new hardware. Select No, not this time and then select Next.

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4. Select Install the software automatically (Recommended), and then select Next.

The Wizard searches for new hardware.

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5. Open RSLinx Classic and run RSWho by selecting the icon.

6. On the EDS Wizard that appears, select Next to continue.

7. Follow the prompts to upload and install the EDS file.

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8. Select Finish to complete.

Configure Controller Set, change, and clear the password on a target controller through the Connected Components
Workbench software.
Password
IMPORTANT The following instructions are supported in Connected Components
Workbench software version 2 and Micro800 controllers with firmware
revision 2.
For more information about the controller password feature on Micro800
controllers, see Controller Security on page 65.

Set Controller Password

IMPORTANT After creating or changing the controller password, you must power down
the controller in order for the password to be saved.

In the following instructions, the Connected Components Workbench software is connected to the
Micro800 controller.
1. In the Connected Components Workbench software, open the project for the target
controller.
2. Select Connect to connect to the target controller.
On the Device Details toolbar, the Secure tooltip message “Set, Change, or Clear Micro800
Controller Password Protection” is displayed.

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3. Select Secure. Select Set Password.

4. The Set Controller Password dialog appears. Provide a password. Confirm the password by
providing it again in the Confirm field.

Passwords must have at least eight characters to be valid.

5. Select OK.
Once a password is created, any new sessions that try to connect to the controller must
supply the password to gain exclusive access to the target controller.

Change Password
With an authorized session, you can change the password on a target controller through the
Connected Components Workbench software. The target controller must be in Connected status.
1. On the Device Details toolbar, select Secure. Select Change Password.

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2. The Change Controller Password dialog appears. Enter Old Password, New Password and
confirm the new password.

3. Select OK.

The controller requires the new password to grant access to any new session.

Clear Password
With an authorized session, you can clear the password on a target controller through the
Connected Components Workbench software.
1. On the Device Details toolbar, select Secure button. Select Clear Password.

2. The Clear Password dialog appears. Enter Password.

3. Select OK to clear the password.

The controller requires no password on any new session.

Forcing I/Os
IMPORTANT This section generally talks about forcing I/O in Micro800 controllers. Some
elements may not apply to certain models (for example, Micro810 and
Micro820 controllers do not support PTO motion).
Inputs are logically forced. LED status indicators do not show forced values, but the inputs in the
user program are forced.
Forcing is only possible with I/O and does not apply to user defined variables and non-I/O variables,
and special functions such as HSC which execute independently from the User Program scan. For
example, for motion, Drive Ready input cannot be forced.

Unlike inputs, outputs are physically forced. LED status indicators do show forced values and the
user program does not use forced values.

The following diagram illustrates forcing behavior.

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HSC

User program

Physical Logical Logical Physical

Force Force
inputs inputs outputs outputs

Normal
variables

Motion

• Status indicators always match the physical value of I/O.

• Normal, non-physical internal variables cannot be forced.
• Special functions such as HSC and Motion cannot be forced.

ATTENTION: Forcing variable can result in sudden machine

movement, possibly injuring personnel or equipment. Use extreme
caution when forcing variables.

Checking if Forces (locks) are Enabled

If the Connected Components Workbench software is available, check the Variable Monitor while
debugging online. Forcing is performed by first locking an I/O variable and then setting the Logical
Value for Inputs and Physical Value for Outputs. Remember you cannot force a Physical Input and
cannot force a Logical Output.

In many cases, the front of the controller is not visible to the operator and the Connected
Components Workbench software is not online with the controller. If you want the force status to be
visible to the operator, then the User Program must read the force status using the SYS_INFO
function block and then display the force status on something that the operator can see, such as
the human machine interface (HMI), or stack light. The following is an example program in
Structured Text.

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I/O Forces After a Power Cycle

After a controller is power cycled, all I/O forces are cleared from memory.

Using Run Mode Change Run Mode Change allows the user to make small changes to the logic of a running project and
immediately testing it out on the controller, without having to go into Program mode or
disconnecting from the controller.

IMPORTANT The following requirements must be met to use Run Mode Change:
• Micro820 controller firmware revision 8.0 or later, and
• Connected Components Workbench Developer Edition software, version 8.0
or later.

The following sample project guides you through the creation of a simple application for a Micro820
controller without any plug-in modules, and how to use the Run Mode Change feature.

Create the Project

1. Create a new project for a Micro820 controller without any plug-ins.
Observe that the controller is disconnected.

2. Right-click Programs and select Add -> New LD: Ladder Diagram.
3. From the Toolbox, double-click Direct Coil to add it to the rung, or drag and drop Direct Coil
onto the rung.

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4. Double -click the newly added Direct Coil to bring up the Variable Selector dialog and select
“_IO_EM_DO_00”.

5. Build the project.

6. Download the project to the controller.

In the Connection Browser dialog, select the Micro820 controller.

7. Select Download current project to the controller.

8. Select Download to confirm.

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9. When the project is downloaded to the controller, a prompt asking to change the controller
to Remote Run mode appears. Select Yes.

10. Observe that the controller is now in Debug mode.

IMPORTANT From Connected Components Workbench version 8.0 onwards,

selecting “Yes” to change the controller to Remote Run mode after a
downloading a project automatically switches it to Debug mode.

Edit the Project Using Run Mode Change

Run Mode Change Toolbar

Run Mode Change Test Logic Changes Accept Changes Undo Changes

1. Select the Run Mode Change icon.

Observe that the controller goes into Edit mode and is still connected.

If you add a new variable during RMC, external data access and changing the access type
(default is Read/Write) of this new variable is not available until you choose to Accept or
Undo the Test Logic changes.
2. From the Toolbox, double-click Instruction Block to add it to the rung, or drag and drop
Instruction Block onto the rung.

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3. Double-click the newly added Instruction Block and select “Timer On/Off“ (TONOFF).

Configure the Instruction Block to trigger every one second.

4. From the Toolbox, double-click Reverse Contact to add it to the rung, or drag and drop
Reverse Contact onto the run. Place it to left of the recently added Instruction Block.

5. Click the Test Logic Changes icon to build the project and download it to the controller.

IMPORTANT When you perform a Test Logic, or undo changes after the Test Logic
is completed, any active communication instructions are aborted
while the changes download to the controller.

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6. The controller automatically goes into Debug mode and display the updated project.

7. You can now choose either to Undo or Accept the changes to the project.
To Undo the Changes
1. Select the Undo Changes icon.
2. The changes are discarded and the original project is restored to the controller.

IMPORTANT When you perform a Test Logic, or undo changes after the Test Logic
is completed, any active communication instructions are aborted
while the changes download to the controller.
Observe that original project is shown and the controller is in Debug mode.

To Accept the Changes

1. Click the Accept Changes icon.
2. Observe that only the Run Mode Change icon is now enabled and the controller remains in
Debug mode.

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Notes:

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 Appendix D
PID Function Blocks
The PID function block has parameter naming similar to RSLogix 500® and is recommended if you
are already familiar with programming in RSLogix 500. The IPIDCONTROLLER function block has the
advantage of supporting auto tune.
Table 53 - Comparison Between IPIDCONTROLLER and PID
IPIDCONTROLLER PID Description
Common parameters
Process PV Process Variable feedback
Setpoint SP Setpoint input
Output CV CV output
Gains.DirectActing Control Control direction of process (cooling versus heating)
Gains.ProportionalGain Gains.Kc Controller gain for both P and I
Gains.TimeIntegral Gains.Ti Time integral value for I
Gains.TimeDerivative Gains.Td Time derivative value for D
A higher filter constant makes CV output more
Gains.DerivativeGain Gains.FC responsive to error. Acts like a derivative gain.
AbsoluteError AbsoluteError Absolute value of error
PID specific parameters
CVMin For limiting CV
CVMax For limiting CV
TRUE = Normal operation of PID
AutoManual FALSE = Manual operation using CVManual
CVManual CV when in manual mode
– TRUE = Start execution with current input parameters.
Enable FALSE = CV equals zero.
TRUE = PID state is running.
Active FALSE = PID state is stopped.
TRUE = PID has an error.
Error FALSE = PID has no errors.
ErrorID PID Error ID
IPIDCONTROLLER specific parameters
TRUE = Normal operation of PID
Auto FALSE = Output tracks Feedback.
Feedback of the control being applied to the process.
Feedback – Usually it’s the PID’s CV after any limits or manual control
is applied.
TRUE = Auto tune
AutoTune FALSE = No Auto tune
ATParameters Auto tune parameters
ATWarning Auto tune warning
–
OutGains Gains from Auto tune
Initialize Used for Auto tune

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PID Function Block This function block diagram shows the arguments in the PID function block.

PID
Enable Active
PV CV
SP AbsoluteError
AutoManual Error
CVManual Error ID
CVMax
CVMin
Gains
Control
Llnit

Table 54 explains the arguments that are used in this function block.
Table 54 - PID Arguments
Parameter
Parameter Data Type Description
Type
Enable instruction
Enable Input BOOL TRUE = Start execution with current input parameters.
FALSE = CV equals zero.
Process Value. This value is typically read from an analog input
PV Input REAL module.
The SI unit must be the same as Setpoint.
SP Input REAL The set point value for the process
Auto or manual mode selection:
AutoManual Input BOOL TRUE = Normal operation of PID
FALSE = Manual operation using CVManual
Control value input defined for manual mode operation. The valid
CVManual Input REAL range for CVManual is:
CVMin < CVManual < CVMax
Control value minimum limit.
CVMin Input REAL If CV < CVMin, then CV = CVMin.
If CVMin > CVMax, an error occurs.
Control value maximum limit.
CVMax Input REAL If CV > CVMax, then CV = CVMax.
If CVMax < CVMin, an error occurs.
Gains of PID for controller
Gains Input PID_GAINS Use the PID_GAINS data type to configure the Gains parameter.
Control direction of the process:
Control Input BOOL TRUE = Direct acting, such as Cooling
FALSE = Reverse acting, such as Heating
Llnit Input BOOL Reserved for future use
Status of the PID controller:
Active Output BOOL TRUE = PID state is running.
FALSE = PID state is stopped.
The control value output.
CV Output REAL If any error occurred, CV is 0.
Absolute error is the difference between process value (PV) and
AbsoluteError Output REAL setpoint (SV) value.
Indicates the existence of an error condition
Error Output BOOL TRUE = PID has an error.
FALSE = PID has no errors.
A unique numeric that identifies the error. The errors are defined
ErrorID Output USINT in PID error codes.

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GAIN_PID Data Type

Parameter
Parameter Data Type Description
Type
Controller gain for PID.
Proportional and Integral are dependent on this gain
(≥ 0.0001).
Kc Input REAL Increasing Kc improves response time but also increases
overshoot and oscillation of the PID.
If Kc is invalid, an error occurs.
Time integral constant in seconds (≥ 0.0001).
Ti Input REAL Increasing Ti decreases overshoot and oscillation of the PID.
If Ti is invalid, an error occurs.
Time derivative constant in seconds (≥ 0.0).
When Td equals 0, then there is no derivative action and PID
becomes a PI controller.
Td Input REAL Increasing Td reduces the overshot and removes the oscillation
of the PID controller.
If Td is invalid, an error occurs.
Filter constant (≥ 0.0).
Recommended range for FC is 0...20.
FC Input REAL Increasing FC smooths the response of the PID controller.
If FC is invalid, an error occurs.

Table 55 - PID Error Codes

Error Code Description
0 PID is working normally.
1 Kc is invalid.
2 Ti is invalid.
3 Td is invalid.
4 FC is invalid.
5 CVMin > CVMax, or CVMax < CVMin
CVManual < CVMin
6 CVManaul is invalid.
CVManual > CVMax
7 CVManual is invalid.

IPIDCONTROLLER Function This function block diagram shows the arguments in the IPIDCONTROLLER function block.
Block IPIDCONTROLLER
EN ENO
Process Output
SetPoint AbsoluteError
FeedBack ATWarning
Auto OutGains
Initialize
Gains
AutoTune
ATParameters

Table 56 explains the arguments used in this function block.

Table 56 - IPIDCONTROLLER Arguments
Parameter
Parameter Data Type Description
Type
Function block enable.
TRUE = Execute function.
EN Input BOOL FALSE = Do not execute function.
Applicable to Ladder Diagram programs.
Process value, which is the value measured from the process
Process Input REAL output.

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Table 56 - IPIDCONTROLLER Arguments (Continued)

Parameter
Parameter Data Type Description
Type
SetPoint Input REAL The set point value for the process
Feedback signal, which is the value of the control variable
Feedback Input REAL applied to the process.
For example, the feedback can be IPIDCONTROLLER output.
Operating modes of PID controller:
Auto Input BOOL TRUE = Normal operation of PID
FALSE = Output tracks Feedback.
A change in value (TRUE to FALSE or FALSE to TRUE) causes the
Initialize Input BOOL controller to eliminate any proportional gain during that cycle. It
also initializes Auto tune sequences.
Gains PID for IPIDCONTROLLER.
Gains Input GAIN_PID Use the GAIN_PID data type to define the parameters for the
Gains input.
TRUE = When AutoTune is TRUE, and Auto and Initialize are FALSE,
AutoTune Input BOOL the AutoTune sequence is started.
FALSE = Do not start AutoTune.
Auto tune parameters
ATParameters Input AT_Param Use AT_Param data type to define the parameters for the
ATParameters input.
Output Output Real Output value from the controller
AbsoluteError Output Real Absolute error (Process - SetPoint) from the controller
Warning for the AutoTune sequence. Possible value are:
0 = No auto tune done
1 = In auto tune mode
ATWarnings Output DINT 2 = Auto tune done
-1 = Error 1: Input automatically set to TRUE, no auto tune
possible.
-2 = Error 2: Auto tune error, the ATDynamSet expired.
Gains calculated from AutoTune Sequences.
OutGains Output GAIN_PID Use GAIN_PID data type to define the OutGains output.
Enable out.
ENO Output BOOL Applicable to Ladder Diagram programs.

Table 57 - GAIN_PID Data Type

Parameter Type Description
Types of acting:
TRUE = Direct acting, output moves same direction as error. That is, the actual
process value is greater than the SetPoint and the appropriate controller action is
DirectActing BOOL to increase the output. For example, Chilling.
FALSE = Reverse acting, output moves opposite direction as error. That is, the
actual process value is greater than the Setpoint and the appropriate controller
action is to decrease the output. For example, Heating.
Proportional gain for PID (>= 0.0001)
Proportional gain for PID (P_Gain)
A higher proportional gain causes a larger change in the output based upon the
difference between the PV (measured process value) and SV (set point value). The
ProportionalGain REAL higher the gain, the faster the error is decreased, but this may result in instability
such as oscillations. The lower the gain, the slower the error is decreased, but the
system is more stable and less sensitive to large errors. The P_Gain usually is the
most important gain to adjust and the first gain to adjust while tuning.
Time integral value for PID (>= 0.0001)
Time integral value for PID
A smaller integral time constant causes a faster change in the output based upon
the difference between the PV (measured process value) and SV (set point value)
TimeIntegral REAL integrated over this time. A smaller integral time constant decreases the steady
state error (error when SV is not being changed) but increases the chances of
instability such as oscillations. A larger integral time constant slows down the
response of the system and make it more stable, but PV approaches the SV at a
slower rate.

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Table 57 - GAIN_PID Data Type (Continued)

Parameter Type Description
Time derivative value for PID (> 0.0)
Time derivative value for PID (Td)
A smaller derivative time constant causes a faster change in the output based
upon the rate of change of the difference between PV (measured process value)
and SV (set point value). A smaller derivative time constant makes a system more
TimeDerivative REAL responsive to sudden changes in error (SV is changed) but increases the chances
of instability such as oscillations. A larger time constant makes a system less
responsive to sudden changes in error and the system is less susceptible to noise
and step changes in PV. TimeDerivative (Td) is related to the derivative gain but
allows the derivative contribution to PID to be tuned using time so the sample time
must be taken into consideration.
Derivative gain for PID (>= 0.0)
Derivative gain for PID (D_Gain)
A higher derivative gain causes a larger change in the output based upon the rate
of change of the difference between the PV (measured process value) and SV (set
DerivativeGain REAL point value). A higher gain makes a system more responsive to sudden changes in
error but increases the chances of instability such as oscillations. A lower gain
makes a system less responsive to sudden changes in error and makes the
system less susceptible to noise and step changes in the PV.
If derivative gain is set to zero, it disables the derivative portion of the PID.

Table 58 - AT_Param Data Type

Parameter Type Description
Load REAL Load parameter for auto tuning. This is the output value when starting AutoTune.
Deviation for auto tuning. This is the standard deviation used to evaluate the noise
Deviation REAL
band needed for AutoTune (noise band = 3* Deviation)(1).
Step REAL Step value for AutoTune. Must be greater than noise band and less than ½ load.
ATDynamSet REAL Waiting time in seconds before abandoning auto tune
Determines whether the output value is reset to zero after an AutoTune sequence:
ATReset BOOL TRUE = Resets output to zero
FALSE = Leaves output at Load value
(1) The application engineer can estimate the value of ATParams.Deviation by observing the value of Process input. For example, in a
project that involves the control of temperature, if the temperature stabilizes around 22 °C (72 °F), and a fluctuation of 21.7…22.5 °C
(71…72.5 °F) is observed, the value of ATParams.Deviation will be (22.5-21.7)/2=0.4.

How to Auto Tune Before you auto tune, you need to:
• Verify that your system is constant when there is no control. For example, for temperature
control, process value should remain at room temperature when there is no control output.
• Configure the setpoint to 0.
• Set Auto Input to False.
• Set the Gain parameter as shown in Table 59:
Table 59 - GAIN Parameter Values
GAIN Parameter Value
According to operation:
DirectActing TRUE (for example, Cooling), or
FALSE (for example, Heating)
DerivativeGain 0.5
ProportionalGain 0.0001
TimeIntegral 0.0001
TimeDerivative 0.0
• Set the AT_Parameter as shown in Table 60:

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Table 60 - AT_Parameter Values

AT Parameter Recommendation
Every ‘Load’ provides a saturated process value over a period of time. Adjust the load to the
value for the saturated process value you want.
Load
IMPORTANT: If a load of 40 gives you a process value of 30 °C (86 °F) over a period of time,
and you want to tune your system to 30 °C (86 °F), you should set the load to 40.
This parameter plays a significant role in the auto tune process. The method of deriving this
Deviation value is explained later in this section. It is not necessary to set this parameter prior to auto
tuning. However, if you already know the deviation, it is fine to set it first.
Step value should be between 3*Deviation and ½ load. The step provides an offset for the
Step load during auto tuning. It should be set to a value high enough to create a significant change
in process value.
Set this value to a reasonably long time for the auto tune process. Every system is different,
ATDynamSet so allow more time to a system with a process value that takes longer to react to change.
Set this parameter to TRUE to reset the output to zero after the auto tune process completes.
ATReset Set this parameter to FALSE to leave the output at load value after the auto tune process
completes.

To auto tune, perform the following steps:

1. Set the Initialize input to TRUE.
2. Set the AutoTune input to TRUE.
3. Wait for the Process input to stabilize or reach a steady state.
4. Note the temperature fluctuation of the process value.
5. Calculate deviation value with reference to the fluctuation. For example, if the temperature
stabilizes around 22 °C (72 °F) with a fluctuation of 21.7…22.5 °C (71…72.5 °F), the value of
‘ATParams.Deviation’ is:

22.5 - 21.7 72.5 - 71

For °C: = 0.4 For °F: = 0.75
2 2

6. Set the deviation value, if you have not set it yet.

7. Change the initialize input to FALSE.
8. Wait until the ‘AT_Warning’ shows 2. The auto tune process is successful.
9. Get the tuned value from the ‘OutGains’.

How Auto Tune Works

The auto tune process begins when the ‘Initialize’ is set to FALSE (Step 7.) At this moment, the
control output increases by the amount of ‘Step’ and the process waits for the process value to
reach or exceeds ‘first peak’.
First peak is defined as:

For Direct Operation: First peak = PV1 - (12 x Deviation)

For Reverse Operation: First peak = PV1 + (12 x Deviation)
Where PV1 is the process value when Initialize is set to FALSE.

Once the process value reaches first peak, the control output reduces by the amount of Step and
waits for the process value to drop to the second peak.
Second peak is defined as:

For Direct Operation: Second peak = PV1 - (3 x Deviation)

For Reverse Operation: Second peak = PV1 + (3 x Deviation)
Once the process value reaches or falls below second peak, calculations commence and a set of
gain will be generated to parameter OutGains.

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Troubleshooting an Auto You can tell what is going on behind the auto tune process from the sequences of control output.
Here are some known sequences of control output and what it means if auto tune fails. For the
Tune Process ease of illustrating the sequence of control output, we define:

Load: 50
Step: 20
Table 61 - Output Sequence 1: 50 -> 70 -> 30
Sequence Condition Autotune Result Action for AutoTune Fail
Process value reached first peak and second Likely successful NA
peak in time

Table 62 - Output Sequence 2: 50 -> 70 -> 50

Sequence Condition Autotune Result Action for AutoTune Fail
Process value not able to reach first peak Likely unsuccessful Reduce Deviation or increase Step

Table 63 - Output Sequence 3: 50 -> 70 -> 30 -> 50

Sequence Condition Autotune Result Action for AutoTune Fail
Process value not able to reach second peak Likely unsuccessful Increase Deviation or increase Step

Table 64 - Output Sequence 4: 50 -> 70

Sequence Condition Autotune Result Action for AutoTune Fail
Process value not able to reach first peak in Likely unsuccessful Increase ATDynamSet
time

PID Application Example Figure 52 - Example of a PID Application

Water in

Water level

Tank Water out

Figure 52 shows a basic water level control system, to maintain a preset water level in the tank. A
solenoid valve is used to control incoming water, filling the tank at a preset rate. Similarly,
outflowing water is controlled at a measurable rate.
IPID Auto Tuning for First and Second Order Systems

Auto tune of IPID can only work on first and second order systems.

A first order system can be described by a single independent energy storage element. Examples
of first order systems are the cooling of a fluid tank, the flow of fluid from a tank, a motor with
constant torque driving a disk flywheel or an electric RC lead network. The energy storage element
for these systems are heat energy, potential energy, rotational kinetic energy, and capacitive
storage energy, respectively.

This may be written in a standard form such as f(t) = τdy/dt + y(t), where τ is the system time
constant, f is the forcing function and y is the system state variable.

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In the cooling of a fluid tank example, it can be modeled by the thermal capacitance C of the fluid
and thermal resistance R of the walls of the tank. The system time constant will be RC, the forcing
function will be the ambient temperature and the system state variable will be the fluid
temperature.

A second order system can be described by two independent energy storage elements which
exchange stored energy. Examples of second order systems are a motor driving a disk flywheel
with the motor coupled to the flywheel via a shaft with torsional stiffness or an electric circuit
composed of a current source driving a series LR (inductor and resistor) with a shunt C (capacitor).
The energy storage elements for these systems are the rotational kinetic energy and torsion spring
energy for the former and the inductive and capacitive storage energy for the latter. Motor drive
systems and heating systems can be typically modeled by the LR and C electric circuit.
Figure 53 - PID Code Sample

Figure 53 shows sample code for controlling the PID application example (Figure 52). The sample
code, developed using Function Block Diagrams, consists of a pre-defined function block,
IPIDCONTROLLER, and four user-defined function blocks. The four user-defined function blocks are:
• PID_OutputRegulator
Regulates the output of IPIDCONTROLLER within a safe range to verify that there is no
damage to the hardware used in the process.

IF RMIN ≤ RIN ≤ RMAX, then ROUT = RIN,

IF RIN < RMIN, then ROUT = RMIN,
IF RIN > RMAX, then ROUT = RMAX.

• PID_Feedback
Acts as a multiplexer.

IF "FB_RST" is false, FB_OUT=FB_IN;

If "FB_RST" is true, then FB_OUT=FB_PREVAL.

• PID_PWM
Provides a PWM function, which converts a real value to a time related ON/OFF output.
• SIM_WATERLVL
Simulates the process that is shown in the PID application example (Figure 52).

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IMPORTANT User Program Scan Time

The auto tuning method must cause the output of the control loop to
oscillate. To identify the oscillation period, the IPID must be called frequently
enough to sample the oscillation adequately. The scan time of the user
program must be less than half the oscillation period. In essence, you must
adhere to the Shannon, or Nyquist-Shannon, or the sampling theorem.
Also, you must trigger the function block at a relatively constant time
interval.

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Notes:

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 Index

Symbols CIP Client Messaging 50

CIP communications pass-thru 50
__SYSVA_CYCLECNT 59
CIP Generic 50
__SYSVA_TCYCURRENT 59
CIP Serial 49, 52
__SYSVA_TCYMAXIMUM 59
Client/Server 47, 48
CIP Serial Driver
Numerics
parameters 53
2080-MEMBAK-RTC 9 configure 53
2080-PS120-240VAC 29 CIP Symbolic 49, 50
2080-REMLCD 9, 31, 68, 69 Addressing 49
advanced set 72 Client/Server 47, 49
analog calibration 73 supported data types 49
backlight parameters 74 communication
customization 70 connections 47
edit variables 73 protocols 47
function blocks 74 communication rate 11
I/O Status 72 communications
main menu 71 ports 47
memory card 73
CompactLogix 49
mode switch 72
modes of operation 69 ConfigMeFirst.txt 11
operational limit 73 errors 83
rating 69 Connected Components Workbench 13, 56, 59,
resolution 69 62, 65, 66, 68, 70, 74, 85, 90
security 72 Online 48
startup screen 70 connection limits 47
text display mode 69
control line 53
USB Mode 69
user-defined screens 74 ControlFlash 68
variable 72 controller
variable edit 73 grounding 35
I/O wiring 41
minimizing electrical noise 41
A preventing excessive heat 24
About Your Controller 13 Controller Error Recovery Model 116
analog cable grounding 42 controller load 60
analog channel wiring guidelines 42 controller lock 66
analog input controller password 65, 66
from transmitters 46 ControlLogix 49
analog inputs
analog channel wiring guidelines 42
analog output 46 D
array of strings 49 data types 49
arrays 49 datalog 9, 85
ASCII 47, 48, 50, 52 data types 88
configuration 55 directory structure 86
ASCII devices 48 execution rules 88
specifications 86
AutoTune 139
timing diagram 87
datasets 85, 86
B DATE 50
DF1 mode 53
backup 9, 11 DF1 point-to-point connection 51
baud rate 53
DHCP Client 47
BOOL 49
DIN rail mounting 29
DINT 49
C disconnecting main power 23
discover 66
calibration 45
Checking if Forces (locks) are Enabled 128

Rockwell Automation Publication 2080-UM005G-EN-E - December 2023 145

Index

DLG Installing Your Controller 29

function block status 87 INT 49
function error ID list 87 IP address
input and output parameters 86 exclusions 57
DLG_ERR_DATAFILE_ACCESS 86 rules 57
duplicate packet detection 54 IP65 69
IPIDCONTROLLER 137
parameters 136, 137
E isolation transformers
embedded responses 54 power considerations 23
Embedded Serial Port Cables 12
Endian Configuration 103
ENQ retries 54 K
error codes 110 KEY_READ_REM 74, 75
error detection 54
error recovery model 116
Ethernet 48, 49, 70
L
LCD_BKLT_REM 74
configuration settings 56 LCD_REM 74
transfer rate 47 LINT 49
Ethernet support 12 Literature Library 31
EtherNet/IP 49 LREAL 50
EtherNet/IP Client 49
EtherNet/IP Client/Server 47
EtherNet/IP Server 49 M
exclusive access 65
Mapping Address Space and supported Data
Execution Rules 60
Types 103
execution rules 85
master control relay 24
emergency-stop switches 25
F using ANSI/CSA symbols schematic 27
using IEC symbols schematic 26
force status 109 master control relay circuit
Forcing I/Os 127 periodic tests 23
Micro800 cycle or scan 59
Micro800 Remote LCD 69
G Micro820 Controllers 10
grounding the controller 35 microSD 11, 65
Guidelines and Limitations for Advanced Users card slot 11
62 Class 6 and 10 SDSC and SDHC 11
microSD card 86
installation 31
H minimizing electrical noise 41
hardware on analog channels 42
features 9 Modbus 48
Hardware Features 9 Modbus Mapping 103
Hardware Overview 9 Modbus Mapping for Micro800 103
heat protection 24 Modbus RTU 47, 48, 52
housekeeping 59, 85
advanced parameters 55
configuration 54
I parameters 55
Modbus TCP Client 48
I/O Status 70, 71 Modbus TCP Client/Server 47, 48
input states on power down 24 Modbus/TCP Server 48
inputs Modbus/TCP server 48
embedded 9 module spacing 29
installation
motor starters (bulletin 509)
DIN rail mounting 29
Micro820 controller 29 surge suppressors 35
module spacing 29 MSG_CIPGENERIC 50
mounting dimensions 29 MSG_CIPSYMBOLIC 50
panel mounting 30 MSG_MODBUS 48
dimensions 30 MSG_MODBUS2 49
146 Rockwell Automation Publication 2080-UM005G-EN-E - December 2023
 Index

N resistance input 45
restore 9, 11
NAK retries 54
RJ45 connector
Normal Operation 110
location 30
RJ45 Ethernet cable 12
O RJ45 Ethernet port 47
RJ45 ethernet port 12
outputs
embedded 9 RS232 11
Overview of Program Execution 59 RS232/RS485 11, 35
pin definition 11
RS-232/RS-485 combo port 47
P RS-232/RS-485 Serial port 11, 47
panel mounting 30 RSLinx 49
PanelView Component 49 Run Mode Change (RMC) 13
parity 53 benefits 14
limitations 16
password 65
RMC memory 15
password recovery 68 uncommitted changes 15
Performance, MSG_MODBUS 107 using 129
PID 136 Run Mode Configuration Change (RMCC) 17
PID Application Example 141 using EtherNet/IP 20
PID Code Sample 142 using Modbus RTU 19
verify IP address change 22
PID Function Blocks 135
verify node address change 20
POU (Program Organizational Unit) 60
power considerations
input states on power down 24 S
isolation transformers 23 safety circuits 23
loss of power source 24
Safety Considerations 22
other line conditions 24
overview 23 safety considerations 22
power supply inrush 23 disconnecting main power 23
power distribution 23 master control relay circuit
power source periodic tests 23
loss of 24 periodic tests of master control relay circuit
power supply 23
power distribution 23
requirement 9 safety circuits 23
power supply inrush security 65
power considerations 23 Serial communications status 109
power-up settings 11
Serial port
preventing excessive heat 24
configure 52
program mode 85 Serial port cables 11
program scan 85 Shutdown 52
program scan cycle 60 SINT 49
Sockets Client/Server 47, 50
Q station address 53
status indicator 10
Quickstarts 117
fault status 109
input status 109
network status 110
R run status 109
REAL 50 Serial communications 109
recipe 9, 90 status indicators 10
data types 88 Status Indicators on the Controller 109
directory structure 90 STRING 50
function block errors 91 surge suppression 34
function block parameters 91 surge suppressors
function block status 91 for motor starters 35
specifications 90
recommended 35
recipe sets 90
using 34
Remote LCD
configuration 52
Remote LCD module 9, 31

Rockwell Automation Publication 2080-UM005G-EN-E - December 2023 147

Index

T
thermistor resistance 44, 45
TIME 50
transmit retries 54
troubleshooting 109

U
UDINT 50
UINT 50
ULINT 50
USB mode 70
USB port 69, 70
User Defined Function (UDF) 62
user defined function (UDF) 59
User Defined Function Block (UDFB) 62
user defined function block (UDFB) 59
using emergency-stop switches 25
USINT 49

V
validate IP address 57
variable retainment 61
voltage input 45

W
wiring 33
fixed terminal blocks 33
removable terminal blocks 33
RS232/RS485 terminal block 33
wiring diagrams 36
Wiring Examples 43
wiring recommendation 33
Wiring Your Controller 33

148 Rockwell Automation Publication 2080-UM005G-EN-E - December 2023

 Micro820 Programmable Controllers User Manual

Rockwell Automation Publication 2080-UM005G-EN-E - December 2023 149

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