Allen-Bradley MicroLogix 1200 User manual

MicroLogix™ 1200

Programmable

Controllers

Bulletin 1762 Controllers and

Expansion I/O

User Manual

Allen-Bradley PLCs

Important User Information

Because of the variety of uses for the products described in this

publication, those responsible for the application and use of this

control equipment must satisfy themselves that all necessary steps

have been taken to assure that each application and use meets all

performance and safety requirements, including any applicable laws,

regulations, codes and standards.

The illustrations, charts, sample programs and layout examples shown

in this guide are intended solely for purposes of example. Since there

are many variables and requirements associated with any particular

installation, Rockwell Automation does not assume responsibility or

liability (to include intellectual property liability) for actual use based

upon the examples shown in this publication.

Rockwell Automation publication SGI-1.1, Safety Guidelines for the

Application, Installation and Maintenance of Solid-State Control

(available from your local Rockwell Automation office), describes

some important differences between solid-state equipment and

electromechanical devices that should be taken into consideration

when applying products such as those described in this publication.

Reproduction of the contents of this copyrighted publication, in whole

or part, without written permission of Rockwell Automation, is

prohibited.

Throughout this manual we use notes to make you aware of safety

considerations:

Attention statements help you to:

•identify a hazard

•avoid a hazard

•recognize the consequences

MicroLogix, ControlFlash, RSLogix, and RSLinx are trademarks of Rockwell Automation.

PLC-5 is a registered trademark of Rockwell Automation.

Belden is a trademark of Belden, Inc.

DeviceNet is a trademark of The Open DeviceNet Vendors Association.

Modbus is a trademark of Modicon, Inc.

ATTENTION

Identifies information about practices or

circumstances that can lead to personal injury or

death, property damage or economic loss

IMPORTANT Identifies information that is critical for successful

application and understanding of the product.

iii Publication 1762-UM001B-EN-P

Summary of Changes

The information below summarizes the changes to this manual since

the last printing.

To help you find new and updated information in this release of the

manual, we have included change bars as shown to the right of this

paragraph.

The table below lists the sections that document new features and

additional or updated information about existing features.

For this information See

1762-L24BXB, 1762-L40BXB controllers

description

wiring

specifications

page 1-2

pages 3-8 and 3-8, 3-12 through 3-15

Appendix A

Expansion I/O

new module descriptions

wiring diagrams for new modules

expanded specifications

page 1-3

pages 3-17 through 3-20, and 3-24

Appendix A

Analog expansion I/O module error codes Appendix C

Simplified controller wiring diagrams Chapter 3

Expanded system loading and heat dissipation

worksheets to cover BXB controllers and new

I/O modules

Appendix F

ASCII protocol page E-17

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Publication 1762-UM001B-EN-P

Summary of Changes iv

iPublication 1762-UM001B-EN-P

Table of Contents

Table of Contents Preface

Who Should Use this Manual. . . . . . . . . . . . . . . . . . . . . . . P-1

Purpose of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1

Related Documentation . . . . . . . . . . . . . . . . . . . . . . . . P-2

Common Techniques Used in this Manual . . . . . . . . . . . . . P-3

Rockwell Automation Support . . . . . . . . . . . . . . . . . . . . . . P-3

Local Product Support . . . . . . . . . . . . . . . . . . . . . . . . . P-3

Technical Product Assistance . . . . . . . . . . . . . . . . . . . . P-3

Your Questions or Comments on this Manual . . . . . . . . P-3

Chapter 1

Hardware Overview

Hardware Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Component Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

MicroLogix 1200 Memory Module and/or

Real-Time Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1762 Expansion I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Communication Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Communication Options . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Chapter 2

Installing Your Controller

Agency Certifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Compliance to European Union Directives . . . . . . . . . . . . . 2-2

EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Installation Considerations. . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Hazardous Location Considerations . . . . . . . . . . . . . . . 2-4

Disconnecting Main Power. . . . . . . . . . . . . . . . . . . . . . 2-5

Safety Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Power Distribution. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Periodic Tests of Master Control Relay Circuit . . . . . . . . 2-6

Power Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Isolation Transformers . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Power Supply Inrush . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Loss of Power Source. . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Input States on Power Down . . . . . . . . . . . . . . . . . . . . 2-7

Other Types of Line Conditions . . . . . . . . . . . . . . . . . . 2-7

Preventing Excessive Heat. . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Master Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Using Emergency-Stop Switches . . . . . . . . . . . . . . . . . . 2-9

Schematic (Using IEC Symbols) . . . . . . . . . . . . . . . . . . 2-10

Schematic (Using ANSI/CSA Symbols). . . . . . . . . . . . . . 2-11

Installing a Memory Module and/or Real-Time Clock . . . . . 2-12

Controller Mounting Dimensions . . . . . . . . . . . . . . . . . . . . 2-13

Controller and Expansion I/O Spacing . . . . . . . . . . . . . . . . 2-13

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Table of Contents ii

Mounting the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

DIN Rail Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Panel Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

1762 Expansion I/O Dimensions . . . . . . . . . . . . . . . . . . . . 2-17

Mounting 1762 Expansion I/O . . . . . . . . . . . . . . . . . . . . . . 2-17

DIN Rail Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Panel Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Connecting Expansion I/O . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Chapter 3

Wiring Your Controller

Wiring Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Wiring Recommendation . . . . . . . . . . . . . . . . . . . . . . . 3-1

Using Surge Suppressors . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Recommended Surge Suppressors . . . . . . . . . . . . . . . . 3-5

Grounding the Controller . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Terminal Block Layouts . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Terminal Groupings . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Sinking and Sourcing Wiring Diagrams . . . . . . . . . . . . . . . 3-10

1762-L24AWA, 1762-L24BWA and 1762-L24BXB Wiring

Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

1762-L40AWA, 1762-L40BWA and 1762-L40BXB Wiring

Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Controller I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Minimizing Electrical Noise. . . . . . . . . . . . . . . . . . . . . . 3-16

Expansion I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Discrete Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . 3-16

Analog Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Chapter 4

Communication Connections

Default Communication Configuration . . . . . . . . . . . . . . . . 4-1

Using the Communications Toggle Push Button . . . . . . . . . 4-2

Connecting to the RS-232 Port . . . . . . . . . . . . . . . . . . . . . . 4-2

Making a DF1 Point-to-Point Connection . . . . . . . . . . . 4-3

Using a Modem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Isolated Modem Connection. . . . . . . . . . . . . . . . . . . . . 4-4

Connecting to a DF1 Half-Duplex Network. . . . . . . . . . 4-6

Connecting to a DH485 Network . . . . . . . . . . . . . . . . . . . . 4-7

Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

DH485 Communication Cable. . . . . . . . . . . . . . . . . . . . 4-8

Connecting the Communication Cable to the DH485

Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Grounding and Terminating the DH485 Network . . . . . 4-10

Connecting the AIC+. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Cable Selection Guide . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

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Table of Contents iii

Recommended User-Supplied Components. . . . . . . . . . 4-14

Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Installing and Attaching the AIC+ . . . . . . . . . . . . . . . . . 4-15

Powering the AIC+. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

DeviceNet Communications. . . . . . . . . . . . . . . . . . . . . . . . 4-17

Cable Selection Guide . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Chapter 5

Using Trim Pots

Trim Pot Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Trim Pot Information Function File . . . . . . . . . . . . . . . . 5-1

Error Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Chapter 6

Using Real-Time Clock and

Memory Modules

Real-Time Clock Operation . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Removal/Insertion Under Power. . . . . . . . . . . . . . . . . . 6-1

Writing Data to the Real-Time Clock. . . . . . . . . . . . . . . 6-2

RTC Battery Operation . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Memory Module Operation . . . . . . . . . . . . . . . . . . . . . . . . 6-3

User Program and Data Back-up. . . . . . . . . . . . . . . . . . 6-3

Program Compare . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Data File Download Protection. . . . . . . . . . . . . . . . . . . 6-4

Memory Module Write Protection . . . . . . . . . . . . . . . . . 6-4

Removal/Insertion Under Power. . . . . . . . . . . . . . . . . . 6-4

Appendix A

Specifications

Controller Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Expansion I/O Specifications . . . . . . . . . . . . . . . . . . . . . . . A-7

Discrete I/O Modules. . . . . . . . . . . . . . . . . . . . . . . . . . A-7

Analog Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11

Controller Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . A-14

Expansion I/O Dimensions . . . . . . . . . . . . . . . . . . . . . . . A-14

Appendix B

Replacement Parts

MicroLogix 1200 Replacement Kits. . . . . . . . . . . . . . . . . . . B-1

Controllers Replacement Doors . . . . . . . . . . . . . . . . . . B-1

Controller Replacement Door Labels. . . . . . . . . . . . . . . B-1

Controller Replacement DIN Latches. . . . . . . . . . . . . . . B-1

Controller 40-Point Replacement Terminal Blocks . . . . . B-1

Controller 24-Point Terminal Doors . . . . . . . . . . . . . . . B-2

Controller 40-Point Terminal Doors . . . . . . . . . . . . . . . B-2

1762 Expansion I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Expansion I/O Replacement Doors. . . . . . . . . . . . . . . . B-2

Expansion I/O Replacement DIN Latches . . . . . . . . . . . B-2

Expansion I/O Replacement Door Labels . . . . . . . . . . . B-2

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Table of Contents iv

Appendix C

Troubleshooting Your System

Understanding the Controller LED Status . . . . . . . . . . . . . . C-1

Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

Error Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

Controller Error Recovery Model . . . . . . . . . . . . . . . . . . . . C-3

Analog Expansion I/O Diagnostics and Troubleshooting. . . C-4

Module Operation and Channel Operation . . . . . . . . . . C-4

Power-up Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . C-4

Critical and Non-Critical Errors . . . . . . . . . . . . . . . . . . . C-4

Module Error Definition Table . . . . . . . . . . . . . . . . . . . C-5

Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6

Calling Rockwell Automation for Assistance . . . . . . . . . . . . C-7

Appendix D

Using Control Flash to Upgrade

Your Operating System

Preparing for Upgrade. . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

Install ControlFlash Software . . . . . . . . . . . . . . . . . . . . D-1

Prepare the Controller for Updating . . . . . . . . . . . . . . . D-1

Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2

Missing/Corrupt OS LED Pattern . . . . . . . . . . . . . . . . . . . . D-2

Appendix E

Understanding the

Communication Protocols

RS-232 Communication Interface . . . . . . . . . . . . . . . . . . . . E-1

DF1 Full-Duplex Protocol . . . . . . . . . . . . . . . . . . . . . . . . . E-1

DF1 Full-Duplex Operation . . . . . . . . . . . . . . . . . . . . . E-2

DF1 Half-Duplex Protocol . . . . . . . . . . . . . . . . . . . . . . . . . E-3

DF1 Half-Duplex Operation . . . . . . . . . . . . . . . . . . . . . E-3

Considerations When Communicating as a

DF1 Slave on a Multi-drop Link . . . . . . . . . . . . . . . . . . E-5

Using Modems with MicroLogix 1200

Programmable Controllers . . . . . . . . . . . . . . . . . . . . . . E-6

DH485 Communication Protocol . . . . . . . . . . . . . . . . . . . . E-8

DH485 Network Description. . . . . . . . . . . . . . . . . . . . . E-8

DH485 Token Rotation. . . . . . . . . . . . . . . . . . . . . . . . . E-8

DH485 Configuration Parameters . . . . . . . . . . . . . . . . . E-9

Devices that use the DH485 Network . . . . . . . . . . . . . . E-9

Important DH485 Network Planning Considerations . . E-10

Example DH485 Connections . . . . . . . . . . . . . . . . . . . E-13

Modbus Communication Protocol . . . . . . . . . . . . . . . . . . E-16

ASCII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-17

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Table of Contents v

Appendix F

System Loading and Heat

Dissipation

System Loading Limitations . . . . . . . . . . . . . . . . . . . . . . . . F-1

System Loading Example Calculations

(24-Point Controller) . . . . . . . . . . . . . . . . . . . . . . . . . . F-1

System Loading Worksheet . . . . . . . . . . . . . . . . . . . . . . . . F-3

Current Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-3

System Loading Example Calculations

(40-Point Controller) . . . . . . . . . . . . . . . . . . . . . . . . . . F-5

System Loading Worksheet . . . . . . . . . . . . . . . . . . . . . . . . F-7

Calculating Heat Dissipation . . . . . . . . . . . . . . . . . . . . . . F-10

Glossary

Index

Allen-Bradley PLCs

Publication 1762-UM001B-EN-P

Table of Contents vi

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