Allen-Bradley MicroLogix 1200 User manual

MicroLogix™ 1200

Programmable

Controllers

Bulletin 1762 Controllers and

Expansion I/O

User Manual

Important User Information

Solid state equipment has operational characteristics differing from those of

electromechanical equipment. Safety Guidelines for the Application,

Installation and Maintenance of Solid State Controls (Publication SGI-1.1

available from your local Rockwell Automation sales office or online at

http://www.ab.com/manuals/gi) describes some important differences

between solid state equipment and hard-wired electromechanical devices.

Because of this difference, and also because of the wide variety of uses for

solid state equipment, all persons responsible for applying this equipment

must satisfy themselves that each intended application of this equipment is

acceptable.

In no event will Rockwell Automation, Inc. be responsible or liable for

indirect or consequential damages resulting from the use or application of

this equipment.

The examples and diagrams in this manual are included solely for illustrative

purposes. Because of the many variables and requirements associated with

any particular installation, Rockwell Automation, Inc. cannot assume

responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to

use of information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without

written permission of Rockwell Automation, Inc. is prohibited.

Throughout this manual 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.

IMPORTANT Identifies information that is critical for successful

application and understanding of the product.

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

•recognize the consequence

SHOCK HAZARD Labels may be located on or inside the drive to alert

people that dangerous voltage may be present.

BURN HAZARD Labels may be located on or inside the drive to alert

people that surfaces may be dangerous temperatures.

1Publication 1762-UM001D-EN-P - March 2004

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

MicroLogix 1200 controllers with the

additional communications port

(Programmer/HMI Port)

•hardware features

•firmware revision history

•description

•new 6 catalog numbers

•application example

•specifications

page(s):

•1-1

•1-5

•1-6

•4-1

•A-1

Programmer/HMI Port

•location

•configuration

•supported protocol

•no LED indicator provided

page(s):

•1-1

•4-2

•C-1

Publication 1762-UM001D-EN-P - March 2004

Summary of Changes 2

iPublication 1762-UM001D-EN-P - March 2004

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-2

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

Firmware Revision History . . . . . . . . . . . . . . . . . . . . . . 1-4

Communication Options . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Chapter 2

Installing Your Controller

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

Compliance to European Union Directives . . . . . . . . . . . . . 2-1

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

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

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

Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Hazardous Location Considerations . . . . . . . . . . . . . . . 2-3

Disconnecting Main Power. . . . . . . . . . . . . . . . . . . . . . 2-4

Safety Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

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

Periodic Tests of Master Control Relay Circuit . . . . . . . . 2-5

Power Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Isolation Transformers . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

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

Loss of Power Source. . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

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

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

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

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

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

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Table of Contents ii

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 . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

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

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

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

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

1762-L24AWA, 1762-L24BWA, 1762-L24BXB, 1762-L24AWAR,

1762-L24BWAR and 1762-L24BXBR Wiring Diagrams. . . 3-11

1762-L40AWA, 1762-L40BWA, 1762-L40BXB ,

1762-L40AWAR, 1762-L40BWAR and 1762-L40BXBR Wiring

Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Controller I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Minimizing Electrical Noise. . . . . . . . . . . . . . . . . . . . . . 3-17

Expansion I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Discrete Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . 3-17

Analog Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Chapter 4

Communication Connections

Supported Communication Protocols . . . . . . . . . . . . . . . . . 4-1

Default Communication Configuration . . . . . . . . . . . . . . . . 4-2

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

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

Making a DF1 Point-to-Point Connection . . . . . . . . . . . 4-5

Using a Modem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Isolated Modem Connection. . . . . . . . . . . . . . . . . . . . . 4-6

Connecting to a DF1 Half-Duplex Network. . . . . . . . . . 4-8

Connecting to a DH-485 Network . . . . . . . . . . . . . . . . . . . 4-9

Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

DH-485 Communication Cable . . . . . . . . . . . . . . . . . . . 4-9

Connecting the Communication Cable to the DH-485

Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Grounding and Terminating the DH-485 Network . . . . . 4-12

Connecting the AIC+. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Cable Selection Guide . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Recommended User-Supplied Components. . . . . . . . . . 4-16

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Table of Contents iii

Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Installing and Attaching the AIC+ . . . . . . . . . . . . . . . . . 4-18

Powering the AIC+. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

DeviceNet Communications. . . . . . . . . . . . . . . . . . . . . . . . 4-20

Cable Selection Guide . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Chapter 5

Using Trim Pots

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

Trim Pot Information Function File . . . . . . . . . . . . . . . . 5-2

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

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-6

Discrete I/O Modules. . . . . . . . . . . . . . . . . . . . . . . . . . A-6

Analog Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-12

Appendix B

Replacement Parts

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

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

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

Appendix C

Troubleshooting Your System

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

Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

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

Publication 1762-UM001D-EN-P - March 2004

Table of Contents iv

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

Critical and Non-Critical Errors . . . . . . . . . . . . . . . . . . . C-5

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

Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-7

Calling Rockwell Automation for Assistance . . . . . . . . . . . . C-8

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-2

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

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

Appendix E

Connecting to Networks via

RS-232 Interface

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

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

DF1 Half-Duplex Protocol . . . . . . . . . . . . . . . . . . . . . . . . . E-2

Using Modems with MicroLogix 1200 Programmable

Controllers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3

DH-485 Communication Protocol. . . . . . . . . . . . . . . . . . . . E-5

Devices that use the DH-485 Network . . . . . . . . . . . . . E-5

Important DH-485 Network Planning Considerations. . . E-6

Example DH-485 Connections . . . . . . . . . . . . . . . . . . . E-9

Modbus Communication Protocol . . . . . . . . . . . . . . . . . . E-12

ASCII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-12

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-4

System Loading Example Calculations (40-Point Controller) .

F-5

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

Current Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-7

Calculating Heat Dissipation . . . . . . . . . . . . . . . . . . . . . . . F-9

Glossary

Index

Rockwell Automation Support . . . . . . . . . . . . . . . . . . . . . . 1-9

Installation Assistance . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

New Product Satisfaction Return. . . . . . . . . . . . . . . . . . 1-9

1Publication 1762-UM001D-EN-P - March 2004

Preface

Read this preface to familiarize yourself with the rest of the manual. It

provides information concerning:

•who should use this manual

•the purpose of this manual

•related documentation

•conventions used in this manual

•Rockwell Automation support

Who Should Use this

Manual

Use this manual if you are responsible for designing, installing,

programming, or troubleshooting control systems that use

MicroLogix™ 1200 controllers.

You should have a basic understanding of electrical circuitry and

familiarity with relay logic. If you do not, obtain the proper training

before using this product.

Purpose of this Manual

This manual is a reference guide for MicroLogix 1200 controllers and

expansion I/O. 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 MicroLogix 1200 controller system

Refer to Publication 1762-RM001, MicroLogix 1200 and 1500

Programmable Controllers Instruction Set Reference Manual for the

MicroLogix 1200 and 1500 instruction set and for application examples

to show the instruction set in use. Refer to your RSLogix 500

programming software user documentation for more information on

programming your MicroLogix 1200 controller.

Publication 1762-UM001D-EN-P - March 2004

P-2 Preface

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