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MicroLogix™ 1200 Programmable Controllers

1. Werecommend using an AIC catalog number 1761 N ET AIC as your optical isolator See page 4 11 for specific AIC cabling information Isolated Modem Connection Using an AIC to isolate the modem is illustrated below M icroLogix 1200 24V dc cu M icroLogix 1200 provides power to the an external power supply may be used 1761 CBL AM 00 or 1761 CBL HM 02 User supplied modem cable For additional information on connections using the AIC refer to the Advanced Interface Converter AIC User M anual publication 1761 6 4 NOTE Series C or higher cables are required Constructing Your Ow n Cable Communication Connections 4 5 If you construct your own modem cable the maximum cable length is 15 24 m 50 ft with a 25 pin or 9 pin connector Refer to the following typical pinout for constructing a amp raight through cable AIC Optical Isolator 9 Pin 3 TXD 2 RXD 5 GND 1 CD 4 DTR 6 DSR 8 CTS 7 RTS Constructing Your Own Null M odem Cable Modem 25 Pin 9 TXD 2 3 RXD 3 2 gt GND 7 5 CD 8 1 gt DIR 20 4 DSR 6 6 CTS 5 8 gt RTS 4 7 If you construct your own null modem cable the maximum cable length is 15 24 m
2. Catalog Number n A B nxA nxB Number of Device Current Requirements max Calculated Current M odules at5V dc mA at24V mA at5Vdc mA at24V dc mA 1762 1A8 2 50 0 100 0 1762 0W8 3 80 90 240 270 1762 108 1 50 0 50 0 1762 IF20F2 40 105 Total Modules 6 maximum 6 Subtotal 2 390 270 1 Refer to your expansion 1 0 Installation Instructions for Current Requi rements not listed in this table Publication 1762 UM 001A US P F 6 System Loading and Heat Dissipation Validating the System T he example systems shown in thetables below are verified to be acceptable configurations T he systems are valid because e Calculated Current Values lt Maximum Allowable Current Values e Calculated System Loading lt Maximum Allowable System Loading Table F 11 Validating Systems using 1762 40AWA Maximum Allowable Values Calculated Values Current Current Subtotal 1 Subtotal 2 from page 1 600 mA at 5V dc 500 mA at 24V dc 0 mA 390 mA 390 mA at 5V dc 120 mA 270 mA 390 mA at 24V dc System Loading System Loading 390 mA x 5V 390 mA x 24V 1950 mW 9360 mW 11 310 mW 15 Watts 11 31 Watts Table F 12 Validating Systems using 1762 40BW A Maximum Allow able Values Calculated Values Current for Devices Connected to the 24V dc Sum of all current sensors and or 1761 NET AIC connected to the 24V dc user supply User Supply AIC selector switch in the down position
3. B 3 Appendix C Understanding the Controller LED Status C 1 Controller Error Recovery C 3 Analog Expansion 1 0 Diagnostics and Troubleshooting C 4 Calling Rockwell Automation for C 7 Appendix D Preparing for D 1 Sequence of O peration D 2 Missing Corrupt OS LED Pattern D 2 Appendix E RS 232 Communication Interface E 1 DF1 Full D uplex Protocol 1 DF1 E 3 DH485 Communication Protocol E 8 M odbus Communication E 17 Appendix F System Loading 1 lt F 1 System Loading W F 3 System Loading W F 7 Calculating H eat Dissipation F 9 Glossary Index Hardw are Features Hardw are Overview Chapter 1 TheBulletin 1762 icroLogix 1200 programmable controller contains power supply input and output circuits and a processor T he controller is available 24 1 0 and 40 I O configurations Thehardware features of the controller are
4. Bottom lt m Publication 1762 UM 001A US P Mounting the Controller Installing Your Controller 2 15 MicroLogix 1200 Controllers are suitable for use in an industrial environment when installed in accordance with these instructions Specifically this equipment is intended for use in clean dry environments Pollution degree 2 1 and to circuits not exceeding ver Voltage Category 11 IEC 60664 1 D o not remove the protective debris shield until after the ATTENTION controller and all other equipment in the panel near the controller are mounted and wiring is complete O nce wiring is complete remove protective debris shield Failure to remove shield before operating can cause overheating debris shield Electrostatic discharge can damage semiconductor device ATTENTION inside the controller D o not touch the connector pins or other sensitive area 1 Pollution Degree 2 is an environment where normally only non conductive pollution occurs except that occasionally a temporary conductivity caused by condensation shall be expected 2 Over Voltage Category Il is the load level section of the electrical distribution system At this level transient voltages are controlled and do not exceed the impulse voltage capability of the product s insulation 3 Pollution Degree 2 and Over Voltage Category Il are International Electrotechnical Commission designations Publication 1762
5. 3 6 Wiring altis a PLA C Rod 3 7 Sinking and Sourcing Wiring Diagrams 3 10 Controller WO Wiring 3 14 Expansion 1 0 3 14 Chapter 4 Default Communication Configuration 4 1 U sing the Communications T oggle Push Button 4 2 Connecting to the RS 232 4 2 Connecting to a DH 485 Network 4 7 4 10 D eviceN amp Communications 4 17 Publication 1762 UM 001A US P ii Table of Contents Using Trim Pots Using Real Time Clock and Memory Modules Specifications Replacement Parts Troubleshooting Your System Using Control Flash to Upgrade Your Operating System Understanding the Communication Protocols System Loading and Heat Dissipation Publication 1762 UM 001A US P Chapter 5 Trim Pot Operation aig ro e yeas wares aes 5 1 Chapter 6 Real Time Clock O peration 6 1 Memory ModuleOperation 6 3 Appendix A Controller 1 50 5 6 Expansion I O 1 lt A 6 Appendix B icroLogix 1200 Replacement B 1 1 62 Expansion I O X 14 x he
6. Poll Timeout x20 ms 0 to 65535 can be set in 20 ms increments Poll Timeout only applies when a slave device initiates a M SG instruction It is the amount of time that the slave device waits for a poll from the master device If the slave device does not receive a poll within the Poll Timeout a M SG instruction error is generated and the ladder program needs to requeue the M SG instruction If you are us used Poll Timeout is disabled when set to zero ng a M SG instruction it is recommended that Poll Timeout value of zero not be RTS Off Delay x20 ms 0 to 65535 can be set in 20 ms increments Specifies the delay time between when the last serial character is sent to the modem and when RTS is deactivated Gives the modem extra time to transmit the last character of a packet RTS Send Delay x20 ms 0 to 65535 can be set in Specifies the time delay 20 ms increments between setting RTS until checking for the CTS response For use with modems that are not ready to respond with CTS immediately upon receipt of RTS M essage Retries 0 to 255 Specifies the number of receive an ACK from the times a slave device attempts to resend a message packet when it does not master device For use in noisy environments where message packets may become corrupted in transmission Pre Transmit Delay X1 ms 0 to 65535 can be set in e When the Contr
7. 400 mA at 5V dc 350 System Loading mA at 24V dc System Loading 10 4 Watts Table F 8 Validating Systems using 1762 24BWA Maximum Allow able Values Current for Devices Connected to the 24V dc User Calculated Values Sum of all sensor currents and or 1761 NET AIC connected to the 24 dc user Supply supply AIC selector switch in the down position 350 mA at 24V dc mA at 24V dc Current for M icroLogix Accessories and Expansion Current Values Subtotal 1 Subtotal 2 from page F 1 400 mA at 5V dc 350 mA at 24V dc mA at 5 V dc mA at 24V dc System Loading System Loading z mMAX24V mAX5V mA x 24V c dede US ee fon 1 mWt mW __________ mW 12 Watts W 1 No current is consumed from the controller when the AIC is powered by an external source Publication 1762 UM 001A US P System Loading and Heat Dissipation 5 System Loading Example Calculations 40 Point Controller Current Loading Table F 9 Calculating the Current for M icroLogix Accessories Catalog Number 1761 NET AIC when powered by the base unit communications port selector switch in the up position Device Current Requirements Calculated Current at 5V dc mA 1 This is an optional accessory Current is consumed only if the accessory is installed Table F 10 Calculating the Current for Expansion 1 0 at 24V dc mA at 5V dc mA at 24V dc mA
8. 500 mA at 24V dc 150 mA at 24V dc example sensor value Current for M icroLogix Accessories and Current Values Subtotal 1 Subtotal 2 from page F 1 Expansion 1 0 600 mA at 5V dc 500 mA at 24V dc 0 mA 390 mA 2390 mA at 5V dc 120 mA 270 mA 390 at 24V dc System Loading System Loading 150 mA x 24V 390 mA x 5V 390 mA x 24V 3600 mW 1950 mW 9360 mW 14 910 mW 16 Watts 14 91 Watts 1 No current is consumed from the controller when the AIC is powered by an external source Publication 1762 UM 001A US P System Loading and Heat Dissipation 7 System Loading Worksheet 7 hetables below are provided for system loading validation See System Loading Example Calculations 24 Point Controller on page F 1 Current Loading Table F 13 Calculating the Current for MicroLogix Accessories Catalog Number Device Current Requirements Calculated Current at5V dc mA jat24Vdc mA 5 dc mA at24V dc mA 1761 NET AIC when powered by the base unit communications port selector switch in the up position 1 This is an optional accessory Current is consumed only if the accessory is installed Table F 14 Calculating the Current for Expansion 1 0 Catalog Number n A B nxA nxB Number of Device Current Requirements Calculated Current Modules at5Vdc mA jat24Vdc at5Vdc mA at 24V dc mA 1762 1A8 50 0 1762 OW 8 80 90 1762 1Q8 50
9. Understanding the Communication Protocols DH485 Configuration Parameters E 9 W hen M icroLogix communications are configured for D H 485 thefollowing parameters can be changed Table E 3 DF1 Full Duplex Configuration Parameters Parameter Options Baud Rate 9600 19 2K Node Address 1 to 31 decimal Token Hold Factor 1to4 Refer to Software Considerations on page E 12 for tips on setting the parameters listed above Devices that use the DH485 Netw ork In addition to the M icroLogix 1200 controllers the devices shown in the following table also support the D H 485 network Table E 4 Allen Bradley Devices that Support DH485 Communication Catalog Number Description Installation Function Publication Bulletin 1761 MicroLogix 1000 Series Cor These controllers support DH485 communications 1761 6 3 Controllers higher Bulletin 1764 M icroLogix 1500 SeriesA or These controllers support DH485 communications 1764 6 1 higher Bulletin 1747 SLC 500 SLC Chassis These processors support a variety of I O requirements and 1741 62 Processors Processors functionality 1746 BAS BASIC M odule SLC Chassis Provides an interface for SLC 500 devices to foreign devices 1746 6 1 Program in BASIC to interface the 3 channels 2 5232 and 1 1746 6 2 DH485 to printers modems or the DH485 network for data 1746 6 3 collection 1785 KA5 DH DH485 771 PLC Provides communication between stations on
10. Leased Line M odems Leased line modems are used with dedicated phone lines that aretypically leased from the local phone company T he dedicated lines may bein a point to point topology supporting Full D uplex communications between two modems or in a multi drop topology supporting H alf D uplex communications between three or more modems Radio M odems Radio modems may be implemented in a point to point topology supporting either H alf D uplex or Full D uplex communications or in a multi drop topology supporting H alf D uplex communications between three or more modems Line Drivers Line drivers also called short haul modems do not actually modulate serial data but rather condition the electrical signalsto operate reliably over long transmission distances up to several miles Line drivers are available in Full D uplex and H alf D uplex models Allen Bradley s AIC Advanced Interface Converter is a alf D uplex line driver that converts an RS 232 electrical signal into an RS 485 electrical signal increasing the signal transmission distance from 50 to 4000 feet 8000 feet when bridged Publication 1762 UM 001A US P E 8 Understanding the Communication Protocols DH485 Communication Protocol Publication 1762 UM 001A US P The information in this section describes the D 485 network functions network architecture and performance characteristics It will also help you plan and operate a M icroLogix on aD H 485 net
11. Schematic Using IEC Symbols L1 L2 230V ac Disconnect Fuse MCR 230V ac t 1 0 Circuits Isolation Operation of either ofthese contacts will Transformer remove power from the external 1 0 M aster Control Relay M CR i 15V ac circuits stopping machine motion Cat No 700 PK400A1 Lor 230V ac Emergency Stop Start Suppressor Push Button Overtravel stop 2 Cat No 700 N24 rm Limit Switch feu MCR XE WE PE Suppr MCR e MCR e e 115V ac or r 230V ac 1 0 Circuits dc Power Supply Use IEC 950 EN 60950 MCR 3 24V dc Lo Hi f 1 0 Line Terminals Connect to terminals of Circuits Power Supply 1762 24AWA and Line Terminals Connect to 24V dc 1762 24BWA terminals of Power Supply Publication 1762 UM 001A US P 2 12 Installing Your Controller Schematic Using ANSI CSA Symbols xi ac op Circuits stopping machine motion 230V ac lt gt Disconnect MCR IBS 230 e i 1 Output e Circuits Isolation Operation of either ofthese contacts will Transformer remove power from the external 1 0 M aster Control Relay MCR X Cat No 700 PK400A1 230V ac Emergency Stop Suppressor Push Button Overtravel Stop Start Cat No
12. 0 1762 IF20F2 40 105 Total Modules 6 maximum Subtotal 2 1 Refer to your expansion 1 0 Installation Instructions for Current Requirements not listed in this table Publication 1762 UM 001A US P F 8 System Loading and Heat Dissipation Validating the System T he example systems shown in thetables below are verified to be acceptable configurations T he systems are valid because e Calculated Current Values lt Maximum Allowable Current Values e Calculated System Loading lt Maximum Allowable System Loading Table F 15 Validating Systems using 1762 40AWA Maximum Allowable Values Calculated Values Current Current Subtotal 1 Subtotal 2 from page F 1 600 mA at 5V de 500 mA at 24V de System Loading System Loading 15 Watts Table F 16 Validating Systems using 1762 40BWA Maximum Allow able Values Calculated Values Current for Devices Connected to the 24V dc User Sum of all sensor currents and or 1761 NET AIC connected to the 24V dc user Supply supply AIC selector switch in the down position 400 mA at 24V dc mA at 24V dc Current for M icroLogix Accessories and Expansion Current Values Subtotal 1 Subtotal 2 from page F 1 0 500 mA at 5V dc 500 mA at 24V dc mA at 5 V dc mA at 24V dc System Loading System Loading z mMAX24V mAX5V mA x 24V fon 1 mWt mW __________ mW 16 Watts W 1 No current is consumed from the controller when the AIC is powered by an ext
13. 50 ft with a 25 pin or 9 pin connector Refer to the following typical pinout Optical Isolator 9 Pin 3 TXD 2 RXD 5 GND 4 1 CD 4 4 DTR 6 DSR 8 CTS 7 RS Modem 25 Pin 9 Pin TXD 2 3 RXD 3 2 GND 7 5 CD 8 1 20 4 DSR 6 6 CTS 5 8 RTS 4 7 Publication 1762 UM 001A US P 4 6 Communication Connections Publication 1762 UM 001A US P Connecting to a DF1 Half Duplex Network Use this diagram for D F1 alf D uplex M aster Slave protocol without hardware handshaking SLC 2 ne 120 FE j is f aster 1761 CBL AM 00 or 1761 CBL HM 02 1761 CBL APOO or 1761 CBL PM 02 DFI Slave radio modem or lease line JJ straight 9 25 pin cable straight 9 25 pin cable M icroLogix 1200 2 S 1761 CBL PM 02 to controller controller 1761 00 or 1761 CBL PM 02 to controller 1761 CBL AM 00 or 1761 CBL HM 02 to controller DH485 DH485 NOTE Series C or higher cables are required 1 DB 9 RS 232 port 2 mini DIN 8 RS 232 port 3 RS 485 port Connecting to a DH485 Communication Connections 4 7 T hefollowing illustration shows how to connect to a DH 485 network M icroLogix DH485 Network M icroLogix 1200 Gr
14. Applicable Specifications 3 Table A 3 Output Specifications Maximum Continuous Current Specification 1762 L24AW A 1762 L24BW A 1762 L40AW A 1762 L40BW Current per Common 8A 8A Current per Controller at 150V max 23A 30A at 240V max 20A 20A 1 15A above 40 2 24A above 40 Table A 4 AC Input Filter Requirements Nominal Filter Maximum OFF Setting ms Delay ms Delay ms Delay ms Delay ms 8 2 20 10 20 Table A 5 Fast DC Input Filter Requirements Settings 0 to 3 Maximum Counter Nominal Filter Minimum ON Maximum ON Minimum OFF Maximum OFF Frequency Hz Setting ms Delay ms Delay ms Delay ms Delay ms 50 Duty Cycle 20 0 kHz 0 025 0 005 0 025 0 005 0 025 6 7 kHz 0 075 0 040 0 075 0 045 0 075 5 0 kHz 0 100 0 050 0 100 0 060 0 100 2 0 kHz 0 250 0 170 0 250 0 210 0 250 1 0 kHz 0 500 0 370 0 500 0 330 0 500 0 5 kHz 1 00 0 700 1 000 0 800 1 000 200 Hz 2 000 1 700 2 000 1 600 2 000 125 Hz 4 000 3 400 4 000 3 600 4 000 63 Hz 8 0000 6 700 8 000 7 300 8 000 31Hz 16 000 14 000 16 000 14 000 16 000 1 This is the default setti g Publication 1762 UM 001A US P A 4 Specifications Table A 6 Normal DC Input Filter Requirements Settings 4 and higher Maximum Counter Nominal Filter Minimum ON Maximum ON Minimum OFF Maximum OFF Frequency Hz Setting ms Delay ms Delay ms Delay m
15. Blue 3106 or Blue with White Drain Wire Stripes 49842 5 d 4B 3 Common 2 Shield 1 Chassis Ground Shrink Tubing Recommended Multiple Cable Connection W hen connecting multiple cables to the D H 485 connector use the following diagram to Previous Device to Next Device Table 4 4 Connections using Belden 3106A Cable For this Wire Pair Connect this Wire To this Terminal Shield Drain Non jacketed Terminal 2 Shield Blue Blue Terminal 3 Common White Orange W hite with Orange Stripe Terminal 4 Data B Orange with W hite Stripe Terminal 5 Data A Table 4 5 Connections using Belden 9842 Cable Connect this Wire To this Terminal For this Wire Pair Shield Drain Non jacketed Terminal 2 Shield Blue W hite W hite with Blue Stripe Cut back no connection Blue with White Stripe Terminal 3 Common White Orange White with Orange Stripe Terminal 4 Data B Orange with W hite Stripe Terminal 5 Data A 1 To prevent confusion when installing the com unication cable cut back the white with blue stripe wire immediately after the insulation jacket is removed This wire is not used by DH485 Publication 1762 UM 001A US P 4 10 Communication Connections Connecting the AIC Publication 1762 UM 001A US P Grounding and Terminating the DH485 Network Only one connector at the end of the lin
16. D uplex communication takes place in one direction at a time You can use the S 232 port on the M icroLogix 1200 as both aH alf D uplex programming port and aH alf D uplex peer to peer messaging port DF1 Half Duplex Operation T he master device initiates all communication by polling each slave device T he slave device may only transmit message packets when it is polled by the master It isthe master s responsibility to poll each slave on a regular and sequential basisto allow slave devices an opportunity to communicate D uring a polling sequence the master polls a slave either repeatedly until the slave indicates that it has no more message packets to transmit or just onetime per polling sequence depending on how the master is configured An additional feature of the D F1 H alf D uplex protocol isthat it is possiblefor a slave device to enable a M SG instruction in its ladder program to send or request data to from another slave W hen the initiating slave is polled the M SG instruction is sent to the master T he master recognizes that the message isnot intended for it but for another slave so the master immediately forwards the message to the intended slave T he master does this automatically you do not need to program the master to move data between slave nodes T his slave to slave transfer can also be used by programming software to allow slave to slave upload and download programs to processors including the master on t
17. Second Power Source 24V User Power Figure 3 7 1762 L24BWA Sourcing Input Wiring Diagram DC DC Publication 1762 UM 001A US P 3 12 Wiring Your Controller Figure 3 8 1762 L24AW A and 1762 L24BWA Output Wiring Diagram 1762 L40AWA and 1762 L40B WA Wiring Diagrams Figure 3 9 1762 40AWA Input Wiring Diagram INS 7 IN8 IN 10 IN 12 IN 14 IN 16 IN 18 IN20 IN 22 NC IN1 IN3 41 6 A A 12 L1 e e e e e e e e e e Publication 1762 UM 001A US P Wiring Your Controller 3 13 Figure 3 10 1762 L40BWA Sinking Input Wiring Diagram Figure 3 11 1762 L40BWA Sourcing Input Wiring Diagram Dc DC vbt INO IN2 IN5 IN7 IN8 IN10 IN12 IN 14 IN 16 IN 18 IN20 IN22 24 COM wil ina ina ine 13 IN 15 IN 19 IN21 23 COM 4 L2 L1 7 OUT OUT VAC OUT OUT OUT L1 NEUT OUT VAC OUT OUT 1 2 10631 5 7 8 10 005 13 15 VAC VAC VAC OUT OUT OUT VAC OUT OUT O
18. UM 001A US P 2 16 Installing Your Controller Publication 1762 UM 001A US P DIN Rail Mounting Themaximum extension of thelatch is 14 mm 0 55 in in theopen position A flat blade screwdriver is required for removal of the controller T he controller can be mounted to EN 50022 35x7 5 or EN 50022 35x15 DIN rails DIN rail mounting dimensions are shown below Table 2 2 Controller Dimensions Dimension Height 90 mm 3 5 in B 27 5 mm 1 08 in C 27 5 mm 1 08 in To install your controller on the DIN rail 1 Mount your DIN rail M ake sure that the placement of the controller on the DIN rail meets the recommended spacing requirements see Controller and Expansion 1 0 Spacing on page 2 14 Refer to the mounting template inside the back cover of this document 2 Closethe DIN latch if it isopen 3 Hook thetop slot over theDIN rail 4 While pressing the controller down against the top of the rail snap the bottom of the controller into position 5 Leavethe protective debris shield attached until you are finished wiring the controller and any other devices Installing Your Controller 2 17 To remove your controller from the DIN rail 1 Place flat blade screwdriver in the DIN rail latch at the bottom of the controller Holding the controller pry downward on the latch until the latch locks in the open position Repeat steps 1 and 2 for the seco
19. cable distance from the first nodeto the last node in a segment However two segments can be used to extend the DH485 network to 2438m 8000 ft For additional information on connections using the AIC refer to the Advanced Interface Converter AIC User Manual publication 1761 6 4 Planning Cable Routes Follow these guidelinesto help protect the communication cable from electrical interference Keep the communication cable at least 1 52m 5 ft from any electric motors transformers rectifiers generators arc welders induction furnaces or sources of microwave radiation f you must run the cable across power feed lines run the cable at right angles to the lines f you do not run the cable through a contiguous metallic wireway or conduit keep the communication cable at least 0 15m 6 in from ac power lines of less than 20A 0 30m 1 ft from lines greater than 20A but only up to 100K VA and 0 60m 2 ft from lines of 100K VA or more e f you run the cable through a contiguous metallic wireway or conduit keep the communication cable at least 0 08m 3 in from ac power lines of lessthan 20A 0 15m 6 in from lines greater than 20A but only up to 100K VA and 0 30m 1 ft from lines of 100K VA or more Publication 1762 UM 001A US P E 12 Understanding the Communication Protocols Publication 1762 UM 001A US P Running the communication cable through conduit provides extra protection from physical damage and
20. electrical interference If you route the cable through conduit follow these additional recommendations Use ferromagnetic conduit near critical sources of electrical interference You can use aluminum conduit in non critical areas Useplastic connectors to couple between aluminum and ferromagnetic conduit M akean electrical connection around the plastic connector use pipe clamps and the heavy gauge wire or wire braid to hold both sections at the same potential Ground the entire length of conduit by attaching it to the building earth ground Do not le the conduit touch the plug on the cable Arrangethe cables loosely within the conduit The conduit should contain only serial communication cables nstall the conduit so that it meets all applicable codes and environmental specifications For more information on planning cable routes seeIndustrial Automation Wiring and Grounding Guidelines publication N umber 1770 4 1 Software Considerations Software considerations include the configuration of the network and the parameters that can be set to the specific requirements of the network The following are major configuration factors that have a significant effect on network performance e number of nodes on the network e addresses of those nodes e baud rate The following sections explain network considerations and describe ways to select parameters for optimum network performance speed See your programming sof
21. galvanic gun 1 0 2 kV CM common mode 1 kV DM differential mode Power Supply 4 kV CM common mode 2 kV DM differential mode IEC1000 4 6 10V communications cable 3V Terminal Screw 0 791 Nm 7 in Ib rated Torque 1 The total load watts of the 5V 24V and user power output shall not exceed 12W 2 The total load watts of the 5V 24V and user power output shall not exceed 16W 3 Conducted Immunity frequency range may be 150 kHz to 30 M Hz if the Radiated Immunity frequency range is 30 M Hzto 1000 M Hz Table A 2 Input Specifications Description 1762 L24AW A 1762 L24BW A and 1762 L40BWA LEER MA Inputs 0 through 3 Inputs 4 and higher On State Voltage 79 to 132V ac 14 to 26 4V dc at 10 to 26 4V dc at Range 55 C 131 F 55 C 131 F 14 to 30 0V dc at 10 to 30 0V dc at 30 C 86 F 30 C 86 F Off State Voltage 0 to 20V ac 0 to 5V dc Range Operating 47 Hz to 63 Hz 0 Hz to 20 kHz 0 Hz to 1 kHz scan Frequency time dependent On State Current e50 mA at e2 5 mA 141 2 0 mA at 10V dc 79V dc min min min e12mA at120Vdc 8 8 24 e8 5 mA at 24V dc nom nom nom 6 0 mA at e 12 0 mA at 30V 12 0 mA at 30V dc 132V dc max max max Off State Leakage 2 5 mA max 15 mA min Current Nominal l2Kohmsat50Hz 2 5K ohms 2 6K ohms Impedance 10K ohms at 60 Hz Inrush Current max at 120V ac 250 mA Not
22. nce set write protection cannot be removed A change cannot be madeto the control program stored in a write protected memory module If a changeis required use a different memory module Removal Insertion Under Power The memory module can beinstalled or removed at any time without risk of damage to either the memory module or the controller f a memory module is installed whilethe M icroLogix 1200 is executing the memory moduleis not recognized until either a power cycle occurs or until the controller is placed in a non executing mode program mode suspend mode or fault condition Specifications Table A 1 General Specifications Appendix A Description 1762 L24AWA 1762 L24BWA 1762 L40AWA 1762 LA0BW A Dimensions Height 90 mm 3 55 in Height 90 mm 3 55 in 104 mm 4 10 in 104 mm 4 10 in with DIN latch open with DIN latch open W idth 110 mm 4 33 in Width 160 mm 6 30 in Depth 87 mm 3 43 in Depth 87 mm 3 43 in Shipping 0 9 kg 2 0 Ib 1 1 kg 2 4 Ib Weight Number of I O 14 inputs 14 inputs 24 inputs 24 inputs 10 outputs 10 outputs 16 outputs 16 outputs Line Power 85 to 265 85to 265Vacat 85to 265 85 to 265V ac at at 47 to 63 Hz 47 to 63 Hz at 47 0 63 Hz 47 to 63 Hz Power Supply 100 120V ac Nominal 200 240 V ac Power Supply 68 VA 70 VA 80 VA 82 VA Usage Power Supply 120V ac 225A for 8 ms Inrush 240V ac 40A for 4 ms Heat Refe
23. to install and connect an AIC This manual Advanced Interface Converter AIC 1761 6 4 also contains information on network wiring User M anual Information on how to install configure and commission a DNI DeviceNet Interface User Manual 1761 6 5 Information on DF1 open protocol DF1 Protocol and Command Set 1770 6 5 16 Information about the M odbus Slave protocol M odbus Protocol Specifications Available from Schneider Automation Inc In depth information on grounding and wiring Allen Bradley Allen Bradley Programmable 1770 4 1 programmable controllers Controller Grounding and Wiring Guidelines A description of important differences betw een solid state Application Considerations for 561 1 1 programmable controller products and hard wired electromechanical devices Solid State Controls An article on wire sizes and types for grounding electrical equipment National Electrical Code Published by Protection Association of Boston M A the National Fire A complete listing of current documentation including ordering Allen Bradley Publication Index 50499 instructions Also indicates whether the documents are available on CD ROM or in multi languages A glossary of industrial automation terms and abbreviations Allen Bradley Industrial Automation AG 7 1 Glossary Publication 1762 UM 001A US P Common Techniques Used in this Manual Rockw ell Automation Support Preface
24. used by a programmable controller to control devices least significant bit LSB T he digit or bit in a binary word code that carries the smallest value of weight LED Light Emitting Diode U sed as status indicator for processor functions and inputs and outputs LIFO Last In First Out T he order that data is entered into and retrieved from a file low byte Bits 0 7 of a word logic A process of solving complex problems through the repeated use of simple functions that can be either true or false G eneral term for digital circuits and programmed instructionsto perform required decision making and computational functions Master Control Relay M CR A mandatory hard wired relay that can be de energized by any series connected emergency stop switch W henever the M CR is de energized its contacts open to de energize all application 1 0 devices mnemonic A simple and easy to remember term that is used to represent a complex or lengthy set of information modem M odulator demodulator Equipment that connects data terminal equipment to a communication line modes Selected methods of operation Example run test or program negative logic The use of binary logic in such a way that 0 represents the voltage level normally associated with logic 1 for example 0 5 1 0 Positive is more conventional for example 1 45V 0 2 OV Glossary 5 netw ork A series of stations nodes connected by some ty
25. when the switch isin the off state T his current is referred to as the off state leakage current To ensure reliable operation the off state leakage current rating of a switch should be less than the minimum operating current rating of the load that is connected to the switch on delay time TheON delay timeis a measure of thetime required for the controller logic to recognize that a signal has been presented at the input terminal of the controller one shot A programming technique that sets a bit for only one program scan Publication 1762 UM 001A US P 6 Glossary Publication 1762 UM 001A US P online D escribes devices under direct communication For example when RSLogix 500 is monitoring the program file in a controller operating voltage For inputs the voltage range needed for the input to bein the On state For outputs the allowable range of user supplied voltage output device A device such asa pilot light or a motor starter coil that receives data from the controller processor A Central Processing Unit See C PU processor file The set of program and data files used by the controller to control output devices nly one processor file may be stored in the controller at a time program file Thearea within a processor file that contains the ladder logic program program mode W hen the controller is not executing the processor file and all outputs are de energized program scan A part of the controller
26. 020 SUO to port 2 on another AIC port2 yes external 1 External power supply required unless the AIC is powered by the device connected to port 2 then the selection switch should be set to cable 2 Series C or higher cables are required t iD 1761 CBL ACOO Cable Length Connections from to AIC External Power Power Supply Selection Required Switch Setting 1747 CP3 3m 9 8 ft SLC 5 03 or SLC 5 04 processor channel 0 port1 yes externa CBL 1 45 cm 17 7 in 1761 CBL ACO0 VE PC COM port portl yes externa PanelView 550 through NULL modem portl yes externa adapter DTAM Plus Micro portl yes externa Port 1 on another AIC portl yes externa 1 External power supply required unless the AIC is powered by the device connected to port 2 then the selection switch should be set to cable pw M E m NN cud creta T E Le User supplied cable iJ Cable Length Connections from to AIC External Power Power Supply Selection Required Switch Setting straight 9 25 modem or other communication device external 1 External power supply required unless the AIC is powered by the device connected to port 2 then the selection switch should be set to cable Publication
27. 1762 UM 001A US P Cable 1761 CBL AS03 1761 CBL AS09 Length 3m 9 8 ft 9 5m 31 17 ft Communication C SS RENE SSS BL AS09 N onnections 4 13 999999 1761 CBL AS03 Connections from to AIC External Power Power Supply Selection Setting SLC 500 Fixed port3 yes external SLC 5 01 SLC 5 02 and SLC 5 03 processors PanelView 550 RJ 45 port port3 yes external 1 External power supply requ ired unless the AIC is powered by the device connected to port 2 then the selection switch should be set to cable 1761 CBL PM 02 Series C or equivalent Cable W iring Diagram Programming Controller Device 9 Pin D Shell 8 Pin Mini Din 9 RI 24V 1 8 CIS gt GND 2 7 RTS Mia RTS 3 6 DSR gt 4 5 GND DCD 5 4 DTR CTS 6 3 TXD TXD 7 2 RXD 4 sd GND 8 1 DCD 1761 CBL PM 02 Series C or later Cable 91095 NT 8 9 6 Tee 8 pin Mini Din O EJ 9 pin D shell 678 3 16 o 5 i 12 Publication 1762 UM 001A US P 4 14 X Communication Connections Recommended User Supplied Components T hese components can be purc
28. 1A U S P Error Conditions Error conditions of PI Function File are described in the M icroL ogix 1200 and 1500 Programmable Controllers nstruction Set Reference M anual publication 1762 RM 001A U S P Real Time Clock Operation Chapter 6 Using Real Time Clock and Memory Modules NOTE For moreinformation on Real TimeClock Function File and emory M Information File please refer to the M icroLogix 1200 and 1500 Programmable C ontrollers Instruction Se Reference M anual publication 1762 RM 001A U S P Three modules with different levels of functionality are available for use with the M icroLogix 1200 controller Catalog Number Function 1762 RTC Real Time Clock 1762 MM1 M emory M odule 1762 M M IRTC M emory M odule and Real Time Clock Removal Insertion Under Power At power up and when the controller enters a run or test mode the controller determines if a real time clock module RT C is present If an RTC is present its values date time and status are written to the RTC Function Filein the controller TheRTC module can be installed or removed at any time without risk of damage to either the module or the controller If an isinstalled while the M icroLogix 1200 isin a run or test mode the module is not recognized until either a power cycle occurs or until the controller is placed in a non executing mode program mode suspend mode or fault condition Removal of theR
29. 1A US P 4 18 Communication Connections Publication 1762 UM 001A US P Trim Pot Operation Chapter 5 Using Trim Pots T he processor has two trimming potentiometers trim pots which allow modification of data within the controller Adjustments to the trim pots change the value in the corresponding Trim Pot Information T PI register T hedata value of each trim pot can be used throughout the control program as timer counter or analog presets depending upon the requirements of the application T hetrim pots are located below the memory module port cover and the right of the communications port as shown below Trim Pot 0 Trim Pot 1 U se a small flathead screwdriver to turn thetrim pots Adjusting their value causes data to change within a range of 0 to 250 fully clockwise T he maximum rotation of each trim pot is three quarters as shown below Trim pot stability over time and temperature is typically 2 counts 2 M inimum fully counterclockwise M aximum fully clockwise 2 7 Trim pot file data is updated continuously whenever the controller is powered up Publication 1762 UM 001A US P 5 2 Using Trim Pots Publication 1762 UM 001A US P Trim Pot Information Function File Thecomposition of the Trim Pot Information T PI Function File is described in the M icroLogix 1200 and 1500 Programmable Controllers Ingruction Set Reference M anual publication 1762 RM 00
30. 2 6 periodic tests of master control relay circuit 2 6 power distribution 2 6 safety circuits 2 5 save G 7 scan time G 7 sinking G 7 sinking and sourcing wiring diagrams 3 10 sinking wiring diagram 1762 24BWA 3 11 sourcing G 7 sourcing wiring diagram 1762 24BWA 3 11 specifications A 1 relay contact rating table A 4 status G 7 Publication 1762 UM 001A US P surge suppressors for contactor 3 5 for motor starters 3 5 for relays 3 5 recommended 3 5 using 3 3 system configuration DF1 Full Duplex examples E 2 DF1 Half Duplex examples E 4 DH485 connection examples E 13 system loading example calculations F 1 limitations F 1 worksheet F 3 system loading and heat dissipation F 1 T terminal G 7 terminal block layouts 3 7 terminal groupings 3 9 terminal groupings 3 9 throughput G 8 Trim Pot Information Function File 5 2 trim pot operation 5 1 trim pots 5 1 adjustment 5 1 error conditions 5 2 location 5 1 troubleshooting C 1 contacting Rockwell Automation for assistance P 3 true G 8 U upload G 8 using communications toggle push button 4 2 using emergency stop switches 2 10 using memory modules 6 1 using real time clock 6 1 using trim pots 5 1 W wiring diagrams 3 7 terminal block layouts 3 7 wiring recommendation 3 1 wiring your controller 3 1 workspace G 8 write G 8 Reach us now at www rockwellautomation com Wherever you need us Rockwell Automation brings together leading brands in industrial aut
31. 3 T he following conventions are used throughout this manual Bulleted lists such asthis one provide information not procedural steps e Numbered lists provide sequential steps or hierarchical information e talictype is used for emphasis Rockwell Automation offers support services worldwide with over 75 Sales Support O ffices 512 authorized D istributors and 260 authorized Systems Integrators located throughout the U nited States alone plus Rockwell Automation representatives in every major country in the world Local Product Support Contact your local Rockwell Automation representative for sales and order support product technical training warranty support e support service agreements Technical Product Assistance If you need to contact Rockwell Automation for technical assistance please review the information in the Troubleshooting appendix first Then call your local Rockwell Automation representative Your Questions or Comments on this Manual If you find a problem with this manual or you have any suggestions for how this manual could be made more useful to you please contact us at the address below Rockwell Automation Control and Information Group Technical Communication D ept A602V Box 2086 M ilwaukee WI 53201 2086 or visit our internet page at http www ab com micrologix Publication 1762 UM 001A US P 4 Preface Publication 1762 UM 001A US P Hardw are Overview In
32. 3 to 255 bits 0 to 4095 10001 to 14096 Read Only odbus Contact Data space Bit B or Integer N 3to 255 bits 0 to 4095 30001 to 30256 Read Only M odbus Input Register space Bit or Integer 3 to 255 words 0 to 255 30501 to 30532 M odbus Communication Parameters Communication 2 words 0 to 31 Status Files 31501 to 31566 Read Only System Status File space Status S 2 words 32 to 65 40001 to 40256 Read W rite odbus Holding Register Bit B or Integer N 3 to 255 words 0 to 255 Space 41501 to 41566 Read W rite System Status File space Status 5 2 words 0 to 65 Publication 1762 UM 001A US P E 18 Understanding the Communication Protocols Publication 1762 UM 001A US P System Loading Limitations Appendix F System Loading and Heat Dissipation W hen you connect M icroLogix accessories and expansion 1 0 an electrical load is placed on the controller power supply T his section shows how to calculate the load and validate that the system will not exceed the capacity of the controller power supply Thefollowing example is provided to illustrate system loading validation T he system validation procedure accounts for the amount of 5V dc and 24V dc current consumed by controller expansion 1 0 and user supplied equipment Refer to System Loading Worksheet on page F 3 to validate your specific configuration Current consumed by the processor memory modules and thereal time clock modules has a
33. 485 network connecting to AIC DeviceN et communications TheM icroLogix 1200 hasthefollowing default communication configuration NOTE T he default configuration is present when e The controller is powered up for the first time e The communications toggle push button specifies default communications the DCOMM LED ison An OS upgradeis completed Refer to U nderstanding the Communication Protocols on page E 1 for more information about communicating Table 4 1 DF1 Full Duplex Default Configuration Parameters Parameter Default Baud Rate 19 2K Parity none Source ID Node Address 1 Control Line no handshaking Stop Bits 1 Publication 1762 UM 001A US P 4 2 Communication Connections Using the Communications 1 heCommunications Toggle Push Button is located the processor under the processor door if installed as Shown below Toggle Push Button Connecting to the RS 232 Port Publication 1762 UM 001A US P U sethe Communications Toggle Push Button to change from the user defined communication configuration to the default communications mode and back TheD efault Communications D C O M M LED operates to show when the controller is in the default communications mode settings shown on page 4 1 E gt D Zi Communications Toggle Push Button NOTE TheCommunication Toggle Push Button must be
34. 5 off state leakage current G 5 one shot G 5 online G 6 operating voltage G 6 output device G 6 P planning considerations for a network E 10 power considerations input states on power down 2 7 isolation transformers 2 6 loss of power source 2 7 other line conditions 2 7 overview 2 6 power supply inrush 2 6 power distribution 2 6 power source loss of 2 7 power supply inrush power considerations 2 6 preparing for upgrade D 1 preventing excessive heat 2 8 processor G 6 processor file G 6 program file G 6 program mode G 6 program scan G 6 programming 1 3 programming device G 6 protocol G 6 publications related P 2 purpose of this manual P 1 R read G 6 Publication 1762 UM 001A US P 4 Index real time clock battery operation 6 2 disabling 6 2 operation 6 1 removal installation under power 6 1 writing data 6 2 related documentation P 2 related publications P 2 relay G 6 relay contact rating table A 4 relay logic G 6 relays surge suppressors for 3 5 remote packet support E 15 replacement parts B 1 reserved bit G 7 restore G 6 retentive data G 7 Rockw ell Automation support P 3 local product support P 3 questions or comments on this manual P 3 technical product assistance P 3 RS 232 G 7 RS 232 communication interface E 1 run mode G 7 rung G 7 5 safety circuits 2 5 safety considerations 2 4 disconnecting main power 2 5 hazardous location 2 4 master control relay circuit periodic tests
35. 700 N24 Limit Switch EB e MCR Suppr MCR e M CR 115V ac or e 230V ac t 1 0 Circuits i dc Power Supply Use NEC Class 2 for UL Listing MCR f 2d 24 V dc d T 10 Line Terminals Circuits Connect to 1762 24AWA or 1762 24BWA terminals Publication 1762 UM 001A US P Line Terminals Connect to 24V dc terminals of Power Supply Installing Your Controller 2 13 Installing Memory 1 Removethe memory module port cover Module and or Real Time Clock 2 Align the connector on the memory module with the connector pins on the controller Publication 1762 UM 001A US P 2 14 Installing Your Controller Controller Mounting Dimensions C e e 22 22 CA EOS BABS ee ee Bl E 1762 L24AWA 1762 L24BWA 1762 LA0AWA 1762 L40BWA Table 2 1 Dimension 1762 L24AWA 1762 L40BWA A 90 mm 3 5 in 90 mm 3 5 in B 110 mm 4 33 in 160 mm 6 30 in 87 mm 3 43 in 87 mm 3 43 in Controller and The controller mounts horizontally with the expansion 1 0 extending to the right of the controller Allow 50 mm 2 in of space on all sides of the controller system for adequate ventilation M aintain spacing from enclosure walls wireways adjacent equipment etc as shown below Expansion 1 0 Spacing Top P Side MicroLogix Side 1200 1762 I O 1762 1762
36. 8 or WindowsNT based computer to run the download software TheControlFlash Upgrade Kit includes the operating system upgrade to be downloaded the ControlFlash programming tool along with its support drivers and on line help areadme first file explaining how to upgrade the operating system Before upgrading the controller s operating system you must e install ControlFlash software on your personal computer prepare the controller for updating IMPORTANT Installing a new operating system deletes the user program After the operating system upgrade is successful you must transfer your control program back to the controller The communication parameters are described on Page 4 1 Install ControlFlash Software D ouble click the 1762 LSC_FRN xx exe file to install the operating system upgrade where xx is the firmware revision number Publication 1762 IN 001A US P 0 2 Using Control Flash to Upgrade Your Operating System Sequence of Operation Missing Corrupt OS LED Pattern Publication 1762 IN 001A US P Prepare the Controller for Updating Controller Configuration The controller must be configured for default communications use communications toggle push button DCOM M LED on and bein the Program mode to allow the download of a new operating system T he following steps detail the key events in the upgrade process 1 Controller mode and communications parameters ate checked 2 Download
37. AC VDC 1 Group 2 VAC VDC 2 0 2 through 0 3 Group 3 VAC VDC 3 0 4 through 0 7 Group 4 VAC VDC 4 0 8 through 0 11 Group 5 VAC VDC 5 0 12 through 0 15 Publication 1762 UM 001A US P 3 10 Wiring Your Controller Sinking and Sourcing Wiring Diagrams Any of the icroLogix 1200 D C embedded input groups can be configured as sinking or sourcing depending on how theD C COM is wired on the group Refer to pages 3 11 through 3 13 for sinking and sourcing wiring diagrams Type Sinking Input Definition The input energizes when high level voltage is applied to the input terminal active high Connect the power supply VDC to the DC COM terminal Sourcing Input The input energizes when low level voltage is applied to the input terminal active low Connect the power supply VDC to the DC COM terminal ATTENTION The 24V dc user power source must not be used to power output circuits It should only be used to power input devices e g sensors switches Refer to M aster Control Relay on page 2 8 for information on M CR wiring in output circuits 1762 L24AWA and 1762 L24BWA Wiring Diagrams Figure 3 5 1762 L24AWA Input Wiring Diagram L2 TT ETT ees L1 1 NC terminals are not Publication 1762 UM 001A US P intended for use as connection points Wiring Your Controller 3 11 Figure 3 6 1762 L24BWA Sinking Input Wiring Diagram DC
38. AIC Any AIC not connected to a controller requires a 24V dc power supply The AIC requires 120 mA at 24V dc If both the controller and external power are connected to the AIC the power selection switch determines what device powers the AIC Publication 1762 UM 001A US P 4 16 Communication Connections ATTENTION If you use external power supply it must be 24V dc Permanent damage results if a higher voltage supply is used Set the DC Power Source selector switch to EXTERNAL before connecting the power supply to theAIC The following illustration shows where to connect external power for the AIC Bottom View ATTENTION Always connect the CH 5 GN D chassis ground terminal to thenearest earth ground T his connection must be made whether or not an external 24V dc supply is used Power Options Below are two options for powering the AIC Usethe 24V dc user power supply built into the M icroLogix 1200 controller T he AIC 15 powered through a hard wired connection using acommunication cable 1761 C BL H M 02 or equivalent connected to port 2 Usean external D C power supply with the following specifications operating voltage 24V dc 42096 or 15 output current 150 mA minimum rated N EC Class2 M ake a hard wired connection from the external supply to the screw terminals on the bottom of the AIC If you use external power supply it must be 24V dc ATTE
39. Allen Bradley MicroLogix 1200 Programmable Controllers Bulletin 1762 Controllers and Expansion 1 0 User Manual Automation Important User Information Because of the variety of uses for the products described 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 vatiables and requirements associated with any particular installation Rockwell Automation does not assume responsibility or lability 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 1n this publication Reproduction of the contents of this copyrighted publication whole or part without written permission of Rockwell Automation 1s pr
40. CBL ACOO NOTE T his 3 node network is not expandable Publication 1762 UM 001A US P Understanding the Communication Protocols 15 Networked Operator Interface Device and M icroLogix Controllers AICt PanelView 550 Personal um Computer zu TIT M icroLogix 1000 icroLogix 1200 M icroLogix 1500 DH485 Network M icroLogix Remote Packet Support M icroLogix 1200 controllers can respond and initiate with communications or commands that do not originate on the local D H 485 network T hisis useful in installations where communication is needed between the D H 485 and networks T he example below shows how to send messages from a PLC deviceor a PC on the DH network to a M icroLogix controller on the DH 485 network T his method uses an SLC 5 04 processor bridge connection W hen using this method as shown in the following illustration e PLC 5 devices can send read and write commands to M icroLogix 1200 controllers MicroLogix 1200 controllers can respond to M SG instructions received TheM icroLogix 1200 controllers can initiate M SG instructions to devices on th
41. L oading Example Calculations 24 Point Controller on page F 1 Current Loading Table F5 Calculating the Current for M icroLogix Accessories Catalog Number 1761 NET AICU when powered by the base unit communications port selector switch in the up position Device Current Requirements Calculated Current at5V dc mA 241 dc mA at5Vdc mA at24V dc mA 1 This is an optional accessory Current is consumed only if the accessory is installed Table F 6 Calculating the Current for Expansion 1 0 Catalog Number n A B nxA nxB Number of Device Current Requirements Calculated Current Modules at5V dc mA at24Vdc mA at5Vdc mA at 24V dc mA 1762 1A8 50 0 1762 OW 8 80 90 1762 1Q8 50 0 1762 IF20F2 40 105 Total Modules 4 maximum Subtotal 2 1 Refer to your expansion 1 0 Installation Instructions for Current Requirements not listed in this table Publication 1762 UM 001A US P F 4 System Loading and Heat Dissipation Table F 7 Validating Systems using 1762 24AW A Calculated Values Maximum Allow able Values Current Validating the System T he example systems shown in thetables below are verified to be acceptable configurations T he systems are valid because e Calculated Current Values lt Maximum Allowable Current Values e Calculated System Loading lt Maximum Allowable System Loading Current Subtotal 1 Subtotal 2 from page F 1
42. NEC A 24V dc IN4 oe T IN6 IN 7 DC COM Common connected DC sinking Y internally DC sourcing DC COM Figure 3 15 1762 0W 8 Wiring Diagram Lt VAC VDC2 OUT4 L2 rR OUT5 HER OUT 6 OUT7 eR Publication 1762 UM 001A US P 3 16 Wiring Your Controller Analog Wiring Diagrams 1762 IF20F2 W iring T he following illustrations show the analog expansion 1 0 wiring diagrams Figure 3 16 1762 IF20F2 Terminal Block Layout Common connected internally Figure 3 17 Differential Sensor Transmitter Types ff gt _ Yo y Tn y A Publication 1762 UM 001A US P Wiring Your Controller 3 17 Figure 3 18 Single ended Sensor Transmitter Types Transmitter Publication 1762 UM 001A US P 3 18 Wiring Your Controller Publication 1762 UM 001A US P Default Communication Configuration Chapter 4 Communication Connections This chapter describes how to communicate to your control system T he method you use and cabling required to connect your controller depends on what type of system you are employing T his chapter also describes how the controller establishes communication with the appropriate network Topics include e default communication configurations e using communications toggle push button e connecting to RS 232 port e connecting to DH
43. NT Permanent damage results if miswired with the wrong power source Publication 1762 UM 001A US P Communication Connections 4 17 DeviceNetCommunications You can connect a M icroLogix 1200 to a D eviceN et network using the D eviceN et Interface D catalog number 1761 N N I For additional information on using the DN I refer to the D eviceN e Interface U sr M anual publication 1761 6 5 T he following figure shows the external wiring connections of the DNI DeviceNet Node Port 1 Replacement connector part no 1761 RPL 0000 Use this write on area to mark the DeviceNet node address Cable Selection Guide BE 25 j i RS 232 Port 2 1761 CBL AM 00 Cable Length Connections from to DNI 1761 CBL AM 00 45 cm 17 7 in M icroLogix 1000 port 2 1761 CBL HM 02 2m 6 5 ft MicroLogix 1200 port 2 em is I 1761 CBL APOO 1761 CBL PM 02 Cable Length Connections from to DNI 1761 CBL APOO 45 cm 17 7 in SLC 5 03 or SLC 5 04 processors port 2 1761 CBL PM02 2m 6 5 ft channel 0 PC COM port port 2 1 Series C or higher cables are required Publication 1762 UM 00
44. TC during run mode is detected within one program scan Removal of the RTC whilein run mode causes the controller to write zeros to theRTC Function File T hefollowing table indicates the accuracy of the for various temperatures Publication 1762 UM 001A US P 6 2 Using Real Time Clock and emory odules Publication 1762 UM 001A US P Table 6 1 RTC Accuracy Ambient Temperature Accuracy 0 32 F 34 to 70 seconds month 425 C 7 F 36 to 68 seconds month 40 C 104 F 29 to 75 seconds month 455 C 131 F 133 to 237 seconds month These numbers are maximum worst case values over a 31 day month Writing Data to the Real Time Clock W hen valid data is sent to the real time clock from the programming device or another controller the new values take effect immediately T he real time clock does not recognize or accept invalid date or time data Use the Disable Clock button in your RSLogix programming software to disable the real time clock before storing a module T his decreases the drain on the RTC battery during storage RTC Battery Operation T he real time clock has an internal battery that is not replaceable The Function File features a battery low indicator bit RT C 0 BL which showsthe status of the RT C battery W hen the battery is low the indicator bit is set 1 T his means that the battery may fail within 14 days and the real time clock module needs to be
45. Table 1 1 Hardw are Features Feature 1 Description Terminal Blocks Removable Terminal Blocks 1762 40xWA only Feature 7 Description Terminal Doors and Labels 2 Bus Connector Interface to 8 Trim Pots Expansion 1 0 3 Input LEDs 9 Communications Toggle Push Button 4 Output LEDs 10 Memory Module Port Cover Memory Module and or Real Time Clock 5 Communication Port 11 DIN Rail Latches Channel 0 6 Status LEDs 1 Shipped with controller 2 Optional equipment Publication 1762 UM 001A US P 1 2 Hardware Overview Component Descriptions Publication 1762 UM 001A US P MicroLogix 1200 Memory Module and or Real Time Clock The controller is shipped with a memory module port cover in place You can order amemory module real time clock or memory module and real time clock as an accessory Table 1 2 Memory Module and or Real Time Clock Catalog Number Descriptions 1762 MM1 Memory Module only 1762 RTC Real Time Clock only 1762 MM1RTC Memory Module and Real Time Clock 1762 Expansion 1 0 1762 expansion 1 can be connected to the M icroLogix 1200 controller as shown below A maximum of 9 1 0 modules in certain combinations may be connected to a controller Refer to System Loading and H eat D issipation on page F 1 1762 Expansion 1 0 1762 Expansion Connected to M icroLogix 1200 Controller Communication Cables Pro
46. UT DC0 DC1 DC2 3 4 6 DC4 11 12 14 Publication 1762 UM 001A US P 3 14 Wiring Your Controller Controller 1 0 Wiring Expansion 1 0 Wiring Publication 1762 UM 001A US P Minimizing Electrical Noise Because of the variety of applications and environments where controllers are installed and operating it isimpossibleto ensure that all environmental noise will be removed by input filters To help reducethe effects of environmental noise install the M icroLogix 1200 system in a properly rated i e N EM A enclosure M ake sure that the M icroLogix 1200 system is properly grounded A system may malfunction dueto 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 M icrologix 1200 system Discrete Wiring Diagrams T he following illustrations show the discrete expansion 1 0 wiring diagrams Figure 3 13 1762 IA8 Wiring Diagram L1 IN 0 T IN 1 IN 2 HE o 100 120V ac IN 4 EE IN 6 gt 6 0 0 4 7 __ Common Y GOM connected L2 2 a internally Figure 3 14 1762 108 Wiring Diagram Wiring Your Controller 3 15 DC sinking DC sourcing IN 0 gt T RET IN 1 IN 2
47. W Group 0 Group 1 Group 2 Inputs Outputs vac vac vac our our our vac OUT pco pc1 Dc2 3 4 6 064 14 v o KA Terminal Groupings Table 3 3 Input Terminal Grouping Wiring Your Controller 3 9 Inputs Controller Input Group Common Input Terminal Terminal Group 0 DC COM 0 1 0 through 1 3 Group 1 DC 1 1 4 through 1713 Group 0 ACCOM 0 1 0 through 1 3 Group 1 1 1 4 through 1 13 Group 0 DC COM 0 1 0 through 1 3 1762 L40BWA Group 1 DC 1 1 4 through 1 7 Group 2 DC COM 2 1 8 through 1 23 Group 0 0 1 0 through 1 3 1762 L40AW A Group 1 ACCOM 1 1 4 through 1 7 Group 2 AC COM 2 1 8 through 1 23 Table 3 4 Output Terminal Grouping Outputs Controller Output Voltage Output Terminal Group Terminal Group 0 VAC VDC 0 0 0 Group 1 VAC VDC 1 1762 L24BWA Group 2 VAC VDC 2 0 2 through 0 3 Group 3 VAC VDC 3 0 4 through 0 5 Group 4 VAC VDC 4 0 6 through 0 9 Group 0 VAC VDC 0 0 0 Group 1 VAC VDC 1 1762 L24AW A Group 2 VAC VDC 2 0 2 through 0 3 Group 3 VAC VDC 3 04 through 0 5 Group 4 VAC VDC 4 0 6 through 0 9 Group 0 VAC VDC 0 0 0 Group 1 VAC VDC 1 O 1 Group 2 VAC VDC 2 0 2 through 0 3 Group 3 VAC VDC 3 0 4 through 0 7 Group 4 VAC VDC 4 0 8 through 0 11 Group 5 VAC VDC 5 0 12 through 0 15 Group 0 VAC VDC 0 0 0 Group 1 V
48. a connection from port 1 or port 2 to M icroLogix 1761 CBL AM 00 or 1761 CBL HM 02 AIC 3 5 1 Y 24V dc user supply needed if not connected to a controller 61 CBL AP00 or 1761 CBL PM 02 PC to port 1 or port 2 1761 CBL AP00 or 1761 CBL PM 02 2 1 DB 9 RS 232 port 2 mini DIN 8 RS 232 port 3 RS 485 port 1 Bs 1747 CP3 T or 1761 CBL AC00 24V dc user supplied NOTE Series C or higher cables are required Recommended Tools To connect a DH 485 network you need tools to strip the shielded cable and to attach the cable to the AIC Advanced Interface onverter W e recommend the following equipment or equivalent Table 4 3 Working with Cable for DH485 Netw ork Description Part Number Manufacturer Shielded Twisted Pair Cable 3106A or 9842 Belden Stripping Tool 45 164 Ideal Industries 1 8 Slotted Screw driver Not Applicable Not Applicable Publication 1762 UM 001A US P 4 8 Communication Connections Publication 1762 UM 001A US P DH485 Communication Cable T he suggested D H 485 communication cable is either Belden 3106A or 9842 T he cable is jacketed and shielded with one or two twisted wire pairs and a drain wire pair provides a balanced signal line and one additional wire is used for a common
49. abels each for all available controllers Controller Replacement DIN Latches Catalog Number 1762 RPLDIN 1 Thecontroller DIN latch kit consists of e Five DIN latches for controllers Controller 40 Point Replacement Terminal Blocks Catalog Number 1762 RPLRTB40 The 40 point controller removable terminal blocks kit consists of one25 point double row terminal block e one29 point double row terminal block Both terminal blocks for a 40 point controller Publication 1762 IN 001A US P B 2 Replacement Parts Publication 1762 IN 001A US P Controller 24 Point Terminal Doors Catalog Number 1762 RPLTDR24 T he 24 point controller terminal door kit consists of e Four terminal doors e Four sub terminal covers Enough doors for two 24 point controllers Controller 40 Point Terminal Doors Catalog Number 1762 RPLTDR40 The 40 point controller terminal door kit consists of e Four terminal doors e Four sub terminal covers Enough doors for two 40 point controllers 1762 Expansion 1 0 Replacement Parts 3 Expansion 1 0 Replacement Doors Catalog Number 1762 RPLDR2 expansion 1 0 door kit consists of e Two expansion 1 0 terminal doors e Two expansion 1 0 bus doors Expansion 1 0 Replacement DIN Latches Catalog Number 1762 RPLDIN2 The expansion 1 0 DIN latch kit consists of e Five DIN latches for expansion 1 0 Expansion 1 0 Replacement Door Labels Catalog Number 1762 RPLDTLBL2 The expansion 1 0 t
50. al external power source connected to item 5 5 Terminals for external 24V dc power supply and chassis ground For additional information on connecting the AIC refer to the Advanced Interface Converter AIC sr M anual publication 1761 6 4 Cable Selection Guide I i O SET ERE zs 1761 02 2 Cable Length Connections from to AIC External Power Power Supply Selection Setting 1761 CBL AP00 45 cm 17 7 in SLC 5 03 or SLC 5 04 processors ch 0 port 2 yes externa 2m 6 5 ft 1761 CBL PM 020 Te M icroLogix 1000 1200 or 1500 port 1 yes externa PanelView 550 through NULL modem port 2 yes externa adapter DTAM Plus DTAM Micro port 2 yes externa PC COM port port 2 yes externa 1 External power supply required unless the AIC is powered by the device connected to port 2 then the selection switch should be set to cable 2 Series C or higher cables are required Publication 1762 UM 001A US P 4 12 Communication Connections 1761 CBL HM 02 1761 CBL AM 000 Cable Length Connections from to AIC External Power Power Supply Selection Required Switch Setting 1761 CBL AM 002 45 cm 17 7 in M icroLogix 1000 1200 or 1500 port2 no cable 1761 CBL HM
51. alculated Current Values lt Maximum Allowable Current Values e Calculated System Loading lt Maximum Allowable System Loading Calculated Values Current Subtotal 1 Subtotal 2 from page 1 400 mA at 5V dc System Loading 350 mA at 24V dc 0 mA 260 mA 260 mA at 5V dc System Loading 120 mA 180 mA 300 mA at 24V dc 10 4 Watts Publication 1762 UM 001A US P 260 mA x 5V 300 mA x 24V 1300 mW 7200 mW 8500 mW 8 50 Watts System Loading and Heat Dissipation 3 Table F 4 Validating Systems using 1762 24BWA Maximum Allow able Values Current for Devices Connected to the 24 dc User Supply Calculated Values Sum of all sensor currents and or 1761 NET AIC connected to the 24 dc user supply AIC selector switch in the down position 350 mA at 24V dc Current for M icroLogix Accessories and Expansion 1 0 150 mA at 24V dc example sensor value Current Values Subtotal 1 Subtotal 2 from page F 1 400 mA at 5V dc System Loading 350 mA at 24V dc 0 mA 260 mA 260 mA at 5V dc System Loading 120 mA 180 mA 300 mA at 24V dc 12 Watts 150 mA x 24V 260 mA x 5V 300 mA x 24V 3600 mW 1800 mW 7200 mW 12 100 mW 12 10 Watts 1 No current is consumed from the controller when the 15 powered by an external source System Loading Worksheet Thetables below are provided for system loading validation See System
52. ation Output Group to Backplane Isolation Verified by one of the following dielectric tests 1836V ac for 1 second or 2596V dc for 1 second 265V ac Working Voltage IEC Class 2 reinforced insulation Output Group to Output Group Isolation Verified by one of the following dielectric tests 1836V ac for 1 second or 2596V dc for 1 second 265V ac Working Voltage basic insulation 150V Working Voltage IEC Class 2 reinforced insulation Table A 10 Expansion 1 0 Current Estimates Expansion 1 0 Catalog Number Estimated Current Requirement 1762 1A8 50 mA at 5V 1762 108 50 mA at 5V 1762 0W 8 80 mA at 5V 90 mA at 24V 1762 IF20F2 40 mA at 5V 105 mA at 24V Publication 1762 UM 001A US P A 6 Specifications Controller Dimensions Expansion 1 0 Dimensions Publication 1762 UM 001A US P See Controller M ounting Dimensions on page 2 14 Panel Mounting A Y Dimension Expansion 1 0 Module A 90 mm 3 5 in B 40 mm 1 57 in C 87 mm 3 43 in MicroLogix 1200 Replacement Kits Appendix B Replacement Parts Controllers Replacement Doors Catalog Number 1762 RPLDR1 T he controller door kit consists of e Two memory module doors e Two RS 232 communication port doors Two expansion bus doors Controller Replacement Door Labels Catalog Number 1762 RPLTLBL1 Thecontroller terminal door label kit consists of e Four l
53. ault Baud Rate 300 600 1200 2400 4800 9600 19 2K 38 4K 19 2K Parity none even none Source ID Node Address 0 to 254 decimal 1 Control Line no handshaking Full Duplex modem handshaking no handshaking Error Detection CRC BCC CRC Embedded Responses auto detect enabled auto detect Duplicate Packet M essage Detect enabled disabled enabled ACK Timeout 1 to 65535 counts 20 ms increments 50 counts NAK retries 0 to 255 3 retries ENQ retries 0 to 255 3 retries Stop Bits not a setting always 1 1 Publication 1762 UM 001A US P Example DF1 Full Duplex Connections For information about required network connecting equipment see chapter 3 Connecting the System Personal Computer Ir MicroLogix 1200 Optical Personal Computer 1111111 33 isolator iii cable Modem 1761 CBL PM 02 icroLogix 1200 Optical Isolator 1 zi PNE B 1761 CBL PM 0 1 Half Duplex Protocol Understanding the Communication Protocols 3 Werecommend using an AIC catalog number 1761 N ET AIC as your optical isolator DF1 Half D uplex protocol is a multi drop single master multiple slave network DF1H alf D uplex protocol supports data transparency American National Standards Institute AN SI X3 28 1976 specification subcategory D 1 In contrast to DF1 Full
54. begins 3 During thedownload the Force Battery and Comms LED s perform a walking bit pattern 4 When the download is complete the integrity of the new S is checked If the new OS 1 corrupt the controller sends an error message to the download tool and flashes the M issing or Corrupt OS LED pattern See M issing C orrupt OS LED Pattern below 5 Following a successful transfer the Power Force and Battery LED s flash on and remain on for five seconds T hen the controller resets W hen an operating system download is not successful or if the controller does not contain a valid operating system the controller flashes the Run Force and Fault LED S on and off RS 232 Communication Interface DF1 Full Duplex Protocol Appendix E Understanding the Communication Protocols Use the information in this appendix to understand the differences in communication protocols T he following protocols are supported from the RS 232 communication channel e DF1Full D uplex e DF1 Half D uplex Slave e DH 485 Modbus Refer to Communication Connections on page 4 1 for information about required network devices and accessories Thecommunications port on the M icroLogix 1200 utilizes RS 232 interface RS 232 isan Electronics Industries Association EIA standard that specifies the electrical and mechanical characteristics for serial binary communication It provides you with a variety of system configuration possib
55. ctly 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 Publication 1762 UM 001A US P 3 4 Wiring Your Controller The following diagram shows an output with a suppression device We recommend that you locate the suppression device as close as possible to the load device dc or L1 Suppression Device ac or dc Outputs dc COM or L2 If theoutputs are dc we recommend that you 1N 4004 diodefor surge suppression as shown below 424V dc VAC DC Out 0 Out 1 Out 2 Relay or Solid Out 3 State dc Outputs _Out 4 Out 5 IN4004 Diode Out 6 Out7 24V dc common COM Suitable surge suppression methods for inductive ac load devices include a varistor an RC network or an Allen Bradley surge suppressor all shown below T hese components must be appropriately rated to suppress the switching transient characteristic of the particular inductive device See thetable on page 3 5 for recommended suppressors Surge Suppression for Inductive ac Load Devices Output Device Output Device Output Device Surge Suppressor Varistor RC Network Publication 1762 UM 001A US P Wiring Your Controller 3 5 For inductive dc load devices a diode is suitable 1N 4004 diode is acceptable for most ap
56. cuits Refer to the figures on pages 2 11 and 2 12 ATTENTION N ever alter these circuits to defeat their function since serious injury and or machine damage could result Installing Your Controller 2 9 NOTE 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 Theac 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 f you mount a disconnect switch inside the controller enclosure place the switch operating handle the outside of the enclosure so that you can disconnect power without opening the enclosure W henever any of the emergency stop switches are opened power to input and output devices should be removed W hen you use the master control relay to remove power from the external 1 0 circuits power continuesto be provided to the controller s power supply so that diagnostic indicators on the processor can still be observed T he master control relay is not a substitutefor a disconnect to the controller It 15 intended for any situation where the operator must quickly de energizel O devices only W hen inspecting or installing terminal connections replacing output fuses or working o
57. d to 35 sealed VA Publication 1762 UM 001A US P 3 6 X Wiring Your Controller Grounding the Controller Publication 1762 UM 001A US P In solid state control systems grounding and wire routing helps limit the effects of noise dueto electromagnetic interference EM I Run the ground connection from the ground screw of the base unit to the electrical panel s ground bus prior to connecting any devices Use 14 wire T his connection must be made for safety purposes This product is intended to be mounted to a well grounded mounting surface such as a metal panel Refer to thelndusrial Automation Wiringand Grounding Guiddines publication 1770 4 1 for additional information Additional grounding connections from the mounting tab or DIN rail if used are not required unless the mounting surface cannot be grounded NOTE It is recommended to use all four mounting positions for panel mounting installation Grounding Stamping Remove the protective debris strip before applying power to ATTENTION the controller Failure to remove the strip may cause the controller to overheat Wiring Diagrams Wiring Your Controller 3 7 T he following illustrations show the wiring diagrams for the M icroLogix 1200 controllers Controllers with dc inputs can be wired as either sinking or sourcing inputs Sinking and sourcing does not apply to ac inputs Refer to Sinking and Sourcing W iring Diagrams on
58. e D network PC can send read and write commandsto M icroLogix 1200 controllers PC can do remote programming of M icroLogix 1200 controllers Publication 1762 UM 001A US P E 16 Understanding the Communication Protocols Publication 1762 UM 001A US P AIC AIC SLC 5 04 PanelView 550 DH485 Netw ork AIC AIC M icroLogix 1000 M icroLogix 1200 M icroLogix 1500 SLC 5 04 DH Network SLC 5 04 PLC 5 Understanding the Communication Protocols 17 Modbus Communication M odbusisaH alf D uplex master slave communications protocol T he Protocol M odbus network master reads and writes coils and registers M odbus protocol allows a single master to communicate with a maximum of 255 slave devices For more information on the M icroLogix 1200 configuration parameters for M odbus Slave RTU RemoteTerminal U nit transmission mode protocol refer to the MicroLogix 1200 and 1500 Programmable Controllers Instruction Set Reference Manual publication 1762 RMO001 A US P For information about the Modbus Slave protocol see the Modbus Protocol Specifications available from http www modicon com techpubs Table E 5 Modbus to MicroLogix Memory Modbus Addressing Description Valid MicroLogix Addressing File Type Data File Number Address 0001 to 4096 Read W rite M odbus Coil Data space Bit or Integer N
59. erious injury or machine damage could result Publication 1762 UM 001A US P 2 6 Installing Your Controller Power Considerations Publication 1762 UM 001A US P Power Distribution T here are some points about power distribution that you should know e The master control relay must be able to inhibit all machine motion by removing power to the machinel O devices when the relay is de energized It is recommended that the controller renain powered even when the master control relay is de energized e f you are using a dc power supply interrupt the load side rather than the ac line power T his avoids the additional delay of power supply turn off T he 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 T he failure of one of these switches would most likely cause an open circuit which would be a safe power off failure H owever if one of these switches shorts out it no longer provides any safety protection T hese switches should be tested periodically to assure they will stop machine motion when needed Thefollowing explains power considerations for the micro controllers Isolation Transformers You may want to use an isolation transformer in the ac lineto the co
60. erminal door label kit consists of e Four labels each for all available modules Publication 1762 IN 001A US P B 4 Replacement Parts Publication 1762 IN 001A US P Understanding the Controller LED Status Figure C 1 Controller LED Location Appendix C Troubleshooting Your System This chapter describes how to troubleshoot your controller Topics include e understanding the controller LED status controller error recovery model analog expansion 1 0 diagnostics and troubleshooting calling Rockwell Automation for assistance T he controller status LED s provide a mechanism to determine the current status of the controller if a programming device is not present or available Table C 1 Controller LED Indicators LED Color Indicates POW ER off No input power or power error condition green Power on RUN off Not executing the user program green Executing the user program in run mode green flashing M emory module transfer occurring FAULT off No fault detected red flashing Application fault detected red Controller hardware faulted FORCE off No forces installed amber Forces installed COMM 0 off Not transmitting via RS 232 port green Transmitting via RS 232 port DCOMM off Configured communications green Default communications INPUTS off Input is not energized amber Input is energized logic status OUTPUTS off Output is not energized amber Output is engerized log
61. ernal source Publication 1762 UM 001A US P Calculating Heat Dissipation Catalog Number System Loading and Heat Dissipation 9 Use the following table when you need to determine the heat dissipation for installation in an enclosure U se the following table For System Loading take the value from the table on page F 4 Heat Dissipation Equation or Constant Calculation Sub Total 1762 24AWA 14W 0 4 x System Loading 14W 04x W 1762 24BWA 16W 0 4 x System Loading 16W 004 W 1762 40AWA 17 5W 0 4 x System Loading 17 50 04 ______ W 1762 40BWA 20W 0 4 x System Loading 20W 0 4 x W Add Sub Totals to determine Heat Dissipation Publication 1762 UM 001A US P F 10 System Loading and Heat Dissipation Publication 1762 UM 001A US P Glossary T hefollowing terms are used throughout this manual Refer to the Allen Bradley Industrial Automation Glossary Publication Number AG 7 1 for a complete guide to Allen Bradley technical terms address A character string that uniquely identifies a memory location For example 1 0 isthe memory address for the data located in the Input file location word bit 0 AIC Advanced Interface Converter A device that provides a communication link between various networked devices Catalog umber 1761 N ET AIC application 1 A machine or process monitored and controlled by a controller 2 The use of computer or processor based routines f
62. evice watchdog timer A timer that monitors a cyclical process and is cleared at the conclusion of each cycle If the watchdog runs past its programmed time period it causes a fault workspace The main storage available for programs and data and allocated for working storage write To copy data to a storage device For example the processor W RIT Esthe information from the output data file to the output modules Numerics 1762 24AW A wiring diagram 3 10 1762 24BW A sinking wiring diagram 3 11 1762 24BW A sourcing wiring diagram 3 11 3 12 3 13 1762 1 8 wiring diagram 3 14 1762 IF20F2 terminal block layout 3 16 1762 IF20F2 wiring 3 16 1762 1908 wiring diagram 3 15 1762 0W 8 wiring diagram 3 15 A address G 1 agency certifications 2 1 AIC applying power to 4 15 attaching to the network 4 15 connecting 4 10 isolated modem 4 4 installing 4 15 recommended user supplied components 4 14 safety consideration 4 15 selecting cable 4 12 AlC Advanced Interface Converter G 1 analog expansion I O C 4 diagnostics C 4 module operation vs channel operation C 4 power up diagnostics C 4 troubleshooting C 4 application G 1 B battery 6 2 baud rate G 1 bit G 1 block diagrams G 1 Boolean operators G 1 branch G 1 C cables planning routes for DH485 connections E 11 selection guide for the AIC 4 12 selection guide for the DeviceNet network 4 17 calling for assistance C 7 CE mark 2 2 common techniques used in this manual P 3 co
63. f Power Source Thepower supply is designed to withstand brief power losses without affecting the operation of the system time the system is operational during power loss is called program scan hold up time after loss of power T he duration of the power supply hold up time depends on the type and state of thel O but is typically between 10 milliseconds and 3 seconds W hen the duration of power loss reaches this limit the power supply signals the processor that it can no longer provide adequate dc power to the system This is referred to as a power supply shutdown T he processor then performs an orderly shutdown of the controller Input States on Power Down The power supply hold up time as described above is generally longer than the turn on and turn off times of the inputs Because of this the input state change from O n to Off that occurs when power is removed may be recorded by the processor before the power supply shuts down the system Understanding this concept is important T he user program should be written to take this effect into account Other Types of Line Conditions O ccasionally 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 bealoss of power for the system Publication 1762 UM 001A US P 2 8 Installing Your Controller Preven
64. gramming Communication Options Hardware Overview 1 3 Use only the following communication cables with the M icroLogix 1200 controllers 1761 CBL PM 02 Series C or later e 1761 CBL H M 02 Series C or later 1761 CBL AM 00 Series or later e 1761 CBL AP00 Series C or later e 2707 N C8 Series B or later e 2702 N C9 Series B or later e 2707 N C 10 Series or later e 2707 N C 11 Series or later Programming the M icroLogix 1200 programmable controller is done using RSLogix 500 Revision 4 or later Communication cables for programming are not included with the software TheM icroLogix 1200 can be connected to a personal computer It can also be connected to the D H 485 network using an Advanced Interface Converter catalog number 1761 N ET AIC and to the D eviceN et network using a D eviceN Interface catalog number 1761 N ET D NI T he controller can also be connected to M odbus SCADA networks as an RTU slave Refer to Communication Connections on page 4 1 for more information on connecting to the available communication options Publication 1762 UM 001A US P 1 4 Hardware Overview Publication 1762 UM 001A US P Chapter 2 Installing Your Controller T his chapter shows you how to install your controller T he only tools you require are a flat or Phillips head screwdriver and drill Topics include agency certifications compliance to European U nion D irectives installation considerations safet
65. hased from your local electronics supplier Table 4 6 User Supplied Components Component Recommended Model external power supply and chassis ground power supply rated for 20 4 to 28 8V dc NULL modem adapter standard AT straight 9 25 pin RS 232 cable see table below for port information if making own cables 1761 0 or 1761 CBL PM 02 Port 1 Ge J UT DB 9 RS 232 Port 2 RS 485 connector EU cable straight D connector 6 2 6 78 5 per 4 Le sj 4 COM 9 5 3 adea 2 LA CHS GND 1 Table 4 7 Terminals Pin Port 1 DB 9 RS 232 Port 2 1761 CBL PM 02 Port 3 RS 485 cable Connector 1 line signal detector 24V dc chassis ground DCD 2 received data RxD ground GND cable shield 3 transmitted data TxD request to send RTS signal ground 4 DTE ready received data DH485 data B 5 signal common GND received line signal detector 0 485 data A DCD 6 DCE ready DSR 2 clear to send CTS termination 7 request to send RTS transmitted data TxD not applicable 8 send CTS ground GND not applicable 9 Inot applicable not applicable not applicable 1 On port 1 pin 4 is electronically jumpered to 6 Whenever the AlC is powered on pin 4 will match the state of pin 6 2 An 8 pin mini DIN connector is used for making connections t
66. he D F1 alf D uplex link TheM icroLogix 1200 can only act as a slave device A device that can act asa master is required to run the network Several Allen Bradley products support D F1 H alf D uplex master protocol T hey includetheSLC 5 03 and higher processors enhanced PL C 5 processors and Rockwell Software RSLinx version 2 x and higher DF1 Half D uplex supports up to 255 devices address 0 to 254 with address 255 reserved for master broadcasts T he icroLogix 1200 supports broadcast reception T he M icroLogix 1200 also supports H alf D uplex modems using RT S CT S hardware handshaking Publication 1762 UM 001A US P 4 Understanding the Communication Protocols W hen the system driver is D F1 alf D uplex Slave available parameters include Table E 2 DF1 Half Duplex Configuration Parameters Parameter Options Parity none even Source ID Node Address 0 to 254 decimal Control Line no handshaking handshaking Error Detection CRC BCC Suppression enabled disabled When EOT Suppression is enabled the slave does not respond when polled if no message is queued This Saves modem transmission power and time when there is no message to transmit Duplicate Packet M essage Detect enabled disabled Detects and eliminates duplicate responses to a message Duplicate packets may be sent under noisy communication conditions if the sender s M essage Retries are not set to 0
67. hould be set to the same maximum node address Example DH485 Connections T he following network diagrams provide examples of how to connect M icroLogix 1200 controllers to the D H 485 network using the Advanced Interface onverter AIC catalog number 1761 N ET AIC For more information on the AIC see the Advanced Interface Converter and D eviceN Interface Installation Instructions Publication 1761 5 11 Publication 1762 UM 001A US P 14 Understanding the Communication Protocols DH485 Network with a M icroLogix 1200 Controller M icroLogix 1200 connection from port 1 or port 2 to M icroLogix 1761 CBL AP00 or 1761 CBL PM 02 1761 CBL AM 00 or 1761 CBL HM 02 ES 24V dc user supply DH485 1 DB 9 RS 232 port 2 mini DIN 8 RS 232 port 3 RS 485 port d PE connection from port 1 or port 2 to PC EEEEEEEEEER 1761 CBL AP00 or 1761 CBL PM 02 AIC opaa i 1747 CP3 or 1761 CBL AC00 ag 24V dc user supply NOTE Series C or higher cables are required or 1761 CBL AS03 Typical 3 Node Network PanelView 550 PanelView M lcroLogh 1200 EB 1761 CBL AM 00 RJ 45 port or 1761 CBL HM 02 AIC saa 1761 CBL AS09 um 1747 CP3 or 1761
68. ic status Publication 1762 UM 001A US P C 2 Troubleshooting Your System Normal Operation ThePOWER and RUN LEDsareon If aforce condition is active the FORCE LED turnson and remains on until all forces are removed Error Conditions If an error exists within the controller the controller LED s operate as described in the following table If the The Follow ing Probable Cause Recommended Action LEDS Error Exists indicate AII LEDs Noinputpoweror line Power Verify proper line voltage and off power supply error connections to the controller Power Supply This problem can occur Overloaded intermittently if power supply is overloaded w hen output loading and temperature varies Powerand Hardware faulted Processor Hardware Cycle power Contact your FAULT Error local Allen Bradley LEDs on representative if the error solid persists Loose Wiring Verify connections to the controller PowerLED Application fault Hardware Software For error codes and Status File on and M ajor Fault information see M icroLogix FAULT LED Detected 1200 and 1500 Programmable flashing Controllers Instruction Set Reference M anual Publication 1762 RM 001A US P RUN Operating system Missing or Corrupt Referto Missing Corrupt OS FORCE fault Operating System LED Pattern on page D 2 FAULT LEDs all flashing Publication 1762 UM 001A US P Troubleshooting Your System 3 Controller Error Rec Overy U
69. ilities RS 232 is a definition of electrical characteristics it is not a protocol One of the biggest benefits of an RS 232 interface is that it lets you integrate telephone and radio modems into your control system using the appropriate D F1 protocol only not D H 485 protocol D F1 Full D uplex protocol provides a point to point connection between two devices DF1 Full D uplex protocol combines data transparency American N ational Standards Institute AN SI X3 28 1976 specification subcategory D 1 and 2 way simultaneous transmission with embedded responses subcategory F 1 TheM icroLogix 1200 controllers support theD F1 Full D uplex protocol via RS 232 connection to external devices such as computers or other controllers that support DF1 Full D uplex DF1 isan open protocol Refer to DF1 Protocol and Command Se Reference M anual publication 1770 6 5 16 for more information Publication 1762 UM 001A US P E 2 Understanding the Communication Protocols 1 Full Duplex Operation DF1 Full D uplex protocol also referred to as D F1 point to point protocol is useful where 5 232 point to point communication is required D F1 protocol controls message flow detects and signals errors and retries if errors are detected W hen the system driver is D F1 Full D uplex the following parameters can be changed Table E 1 DF1 Full Duplex Configuration Parameters Parameter Options Def
70. ion and communication with the controller Internal diagnostics are performed at both levels of operation Both module hardware and channel configuration error conditions are reported to the controller C hannel over range or under range conditions are reported in the modules input data table M odule hardware errors are reported in the controller s O status file Refer to the icroLogix 1200 and 1500 Programmable Controllers Instruction Set Reference M anual publication 1762 RM 001A U S P for more information W hen a fault condition is detected the analog outputs are reset to zero Power up Diagnostics At module power up a series of internal diagnostic tests are performed Table C 2 M odule Status LED State Table If module Indicated Corrective action status LED is condition On Proper Operation No action required Off M odule Fault Cycle power If condition persists replace the module Call your local distributor or Allen Bradley for assistance Critical and Non Critical Errors N on critical module errors are recoverable C hannel errors over range or under range errors are non critical N on critical error conditionsare indicated in the module input data table N on critical configuration errors are indicated by the extended error code See Table C 5 on page 7 Critical module errors are conditions that prevent normal or recoverable operation of the system W hen thesetypes of errors occur the s
71. k must have Terminals 1 and 2 jumpered together T his provides an earth ground connection for the shield of the communication cable Both ends of the network must have Terminals 5 and 6 jumpered together as shown below T his connects the termination impedance of 1200 that is built into each AIC as required by the D H 485 specification End of Line Termination J umper J umper Belden 3106 or 9842 Cable N 1219 m 4000ft M aximum TheAIC catalog number 1761 N ET AIC enables a M icroLogix 1200 to connect to a D H 485 network T he AIC has two R S 232 ports and one isolated RS 485 port Typically there is one AIC for each M icroLogix 1200 W hen two M icroLogix controllers are closely positioned you can connect a controller to each of the RS 232 ports on the AIC TheAIC can also be used as an RS 232 isolator providing an isolation barrier between the M icroLogix 1200 communications port and any equipment connected to it i e personal computer modem etc Communication Connections 4 11 T he following figure shows the external wiring connections and specifications of the AIC AIC Advanced Interface Converter 1761 NET AIC Item Description 1 Port 1 DB 9 RS 232 DTE 2 Port 2 mini DIN 8 RS 232 DTE 3 Port 3 RS 485 Phoenix plug 4 DC Power Source selector switch cable port 2 pow er source extern
72. ld holds no additional information Hardware 001 General and specific hardw are error codes are Errors specified in the extended error information field Configuration 010 M odule specific error codes are indicated in the Errors extended error field These error codes correspond to options that you can change directly For example the input range or input filter selection Extended Error Information Field Check the extended error information field when a non zero value is present in the module error field See Table C 5 7 If no errors are present in the module error field the NOTE extended error information field is set to zero Hardware Errors General or module specific hardware errors are indicated by module error code 2 See Table C 5 on page C 7 Configuration Errors If you set the fields in the configuration fileto invalid or unsupported values the module ignores invalid configuration generates a non critical error and keeps operating with the previous configuration Table C 5 on page C 7 lists the configuration error codes defined for the module Troubleshooting Your System 7 Error Codes Table C 5 Extended Error Codes Error Type Hex Module Extended Error Error Description Equivalent Error Code Information Code Binary Binary No Error X000 000 0 0000 0000 No error General Common X200 001 0 0000 0000 General hardware error
73. ller I O wiring expansion 1 0 wiring Wiring Recommendation ATTENTION ATTENTION Before you install and wire device disconnect power to the controller system Calculate the maximum possible current in each power and common wire O bserve 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 U nited States Only If the controller is installed within a potentially hazardous environment all wiring must comply with the requirements stated in the N ational Electrical Code 501 4 b e Allow for at least 50 mm 2 in between I O wiring ducts or terminal strips and the controller e Route incoming power to the controller by a path separate from the device wiring W here paths must cross their intersection should be perpendicular Publication 1762 UM 001A US P 3 2 Wiring Your Controller Publication 1762 UM 001A US P NOTE Do not run signal or communications wiring and power wiring in the same conduit W ires 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 devicesin the system Usetape shrink tubing or other dependable means for labeling purposes In addition to labeling use colored insulati
74. lready been factored into the calculations A system is valid if the current and power requirements are satisfied System Loading Example Calculations 24 Point Controller Current Loading Table F 1 Calculating the Current for M icroLogix Accessories Catalog Number Device Current Requirements Calculated Current at5V dc mA at24V dc mA at5V dc mA at24V dc mA 1761 NET AIC when powered by the base unit communications 0 120 0 120 port selector switch in the up position Subtotal 1 0 120 1 This is an optional accessory Current is consumed only if the accessory is installed Publication 1762 UM 001A US P F 2 System Loading and Heat Dissipation Table F 2 Calculating the Current for Expansion 1 0 Catalog Number n A B nxA nxB Number of Device Current Requirements max Calculated Current Modules at5V dc mA jat24Vdc mA 5 mA at24V dc mA 1762 1A8 2 50 0 100 0 1762 0W8 2 80 90 160 180 1762 1Q8 50 0 1762 IF20F2 40 105 Total Modules 4 maximum 4 Subtotal 2 260 180 1 Refer to your expansion 1 0 Installation Instructions for Current Requi Table F 3 Validating Systems Using 1762 24AWA Maximum Allow able Values Current rements not listed in this table Validating the System T he example systems shown in the tables below are verified to be acceptable configurations T he systems are valid because e C
75. mmunication Index DeviceNet 4 17 communication connections 4 1 communication options 1 3 communication protocols DF1 Full Duplex E 1 DF1 Half Duplex E 3 DH485 E 8 M odbus E 17 communication scan G 1 communications toggle push button using 4 2 component descriptions 1 2 1762 expansion 1 0 1 2 communication cables 1 3 memory module 1 2 real time clock 1 2 configuration errors C 6 connecting expansion 1 0 2 20 connecting the system 4 10 4 15 DeviceNet network 4 17 DF1 Full Duplex protocol 4 2 DF1 isolated point to point connection 4 3 DH485 network 4 7 connecting to DF1 Half Duplex netw ork 4 6 contacting Rockw ell Automation for assistance P 3 contactors bulletin 100 surge suppressors for 3 5 control profile G 2 ControlFlash missing corrupt OS LED pattern D 2 sequence of operation D 2 using D 1 controller G 1 grounding 3 6 I O wiring 3 14 installation 2 1 LED status C 1 LED status error conditions C 2 LED status normal operation C 2 minimizing electrical noise 3 14 mounting 2 15 mounting dimensions 2 14 mounting on DIN rail 2 16 mounting on panel 2 17 preventing excessive heat 2 8 controller overhead G 1 controller spacing 2 14 counter G 2 CPU Central Processing Unit G 2 Publication 1762 UM 001A US P 2 Index D data table G 2 default communication configuration 4 1 DeviceNet Communications 4 17 DeviceNet network connecting 4 17 selecting cable 4 17 DF1 Full Duplex protocol configuration paramete
76. n equipment within the enclosure use the disconnect to shut off power to the rest of the system NOTE 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 Publication 1762 UM 001A US P 2 10 Installing Your Controller Publication 1762 UM 001A US P Using Emergency Stop Switches W hen 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 e Observe all applicable local codes concerning the placement and labeling of emergency stop switches e Install emergency stop switches and the master control relay in your System M ake certain that relay contacts have a sufficient rating for your application Emergency stop switches must be easy to reach e the following illustration input and output circuits are shown with M CR protection H owever in most applications only output circuits require M CR protection T he following illustrations show the M aster Control Relay wired a grounded System In most applications input circuits do not requireM CR protection however if you need to remove power from all field devices you must include M CR contacts in series with input power wiring Installing Your Controller 2 11
77. nd DIN rail latch Unhook thetop of theDIN rail slot from the rail o FL Lm ih open closed Panel Mounting M ount to panel using 8 or M 4 screws To install your controller using mounting screws 1 Remove the mounting template from inside the back cover of the M icroLogix 1200 Programmable Controllers Ingallation Instructions publication 1762 IN 006A M L P Secure the template to the mounting surface M ake sure your controller is spaced properly See Controller and Expansion 1 0 Spacing on page 2 14 Drill holes through the template Remove the mounting template Publication 1762 UM 001A US P 2 18 Installing Your Controller Mounting 1762 Expansion 1 0 Publication 1762 UM 001A US P 5 Mount the controller 6 Leavethe protective debris shield in place until you arefinished wiring the controller and any other devices Debris Shield M ounting Template D uring panel or DIN rail mounting of all devices be sure ATTENTION that all debris metal chips wire stands etc is kept from falling into the module D ebris that falls into the module could cause damage when the module is under power DIN Rail Mounting The module can be mounted using the following DIN rails 35 x 7 5 mm EN 50 022 35 x 7 5 or 35 x15 mm EN 50 022 35x 15 Before mo
78. ndshaking For point to point Full D uplex modem connectionsthat require RTS CTS handshaking use D F1 Full D uplex protocol with handshaking For multi drop modem connections or for point to point modem connections that require RT S CT S handshaking use D alf D uplex slave protocol In this case one and only one of the other devices must be configured for D F1 alf D uplex master protocol IMPORTANT N ever attempt to use DH 485 protocol through modems under any circumstance NOTE All M icroLogix 1200 controllers support RT S CT S modem handshaking when configured for DF1 Full D uplex protocol with the control line parameter set to Full D uplex M odem H andshaking or D F1 H alf D uplex slave protocol with the control line parameter set to H alf D uplex No other modem handshaking lines i e D ata Se Ready Carrier D etect and D ata Terminal Ready are supported by any M icroLogix 1200 controllers Understanding the Communication Protocols 7 Dial Up Phone M odems Some dial up phone line modems support point to point Full D uplex communications A M icroLogix 1200 controller on the receiving end of the dial up connection can be configured for DF1 Full D uplex protocol with or without handshaking T he modem connected to the M icroLogix controller should support auto answer T he M icroLogix 1200 supports ASCII out communications T herefore it can cause a modem to initiate or disconnect a phone call
79. nly the following communication cables Class Division 2 hazardous locations Communication Cables Environment Classification 1761 CBL PM02 Series C or later Class Division 2 Hazardous Environment 1761 CBL HM 02 Series C or later 1761 CBL AMOO Series C or later 1761 CBL AP00 Series C or later 2707 NC8 Series B or later 2707 NC9 Series B or later 2707 NC10 Series B or later 2707 NC11 Series B or later Installing Your Controller 2 5 Disconnecting Main Power WARNING Explosion H azard Do not replace components or disconnect equipment unless power has been switched off Themain power disconnect switch should be located where operators and maintenance personnel have quick and easy access to it 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 H azard 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 T hese 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 N ever alter these circuits to defeat their function S
80. nment where normally only non conductive pollution occurs except that occasionally temporary conductivity caused by condensation shall be expected 2 Overvoltage Category II is the load level section of the electrical distribution system At this level transient voltages are controlled and do not exceed the impulse voltage capability of the products insulation Publication 1762 UM 001A US P 2 4 Installing Your Controller Safety Considerations Publication 1762 UM 001A US P Safety considerations are an important element of proper system installation Actively thinking about the safety of yourself and others as well asthe condition of your equipment is of primary importance We recommend reviewing the following safety considerations Hazardous Location Considerations T his equipment is suitable for use in Class Division 2 GroupsA B C D or non hazardous locations only T he following WARNING statement applies to use in hazardous locations EXPLOSION HAZARD e Substitution of components may impair suitability for Class Division 2 Do not replace components or disconnect equipment unless power has been switched off Do not connect or disconnect components unless power has been switched off e T his product must be installed in an enclosure All cables connected to the product must remain in the enclosure or be protected by conduit or other means e All wiring must comply with N E C article 501 4 b Use o
81. no additional information Hardware a 001 0 0000 0001 Pow er up reset state Hardware Specific X210 001 0 0001 0000 Reserved Error Configuration X400 010 0 0000 0000 General configuration error no additional information Emer X401 010 0 0000 0001 Invalid input data format selected channel 0 X402 010 0 0000 0010 Invalid input data format selected channel 1 X403 010 0 0000 0010 Invalid output data format selected channel 0 X404 010 0 0000 0100 Invalid output data format selected channel 1 1 X represents Don t Care Calling Rockw ell If you need to contact Rockwell Automation or local distributor for assistance Automation for Assistance it is helpful to obtain the following prior to calling e controller type series letter revision letter and firmware FRN number of the controller e controller LED status controller error codes Refer to M icroLogix 1200 and 1500 Programmable Controllers nsruction Set Reference M anual Publication 1762 RM 001 0 5 for error code information Publication 1762 UM 001A US P C 8 Troubleshooting Your System Publication 1762 UM 001A US P Preparing for Upgrade Appendix D Using Control Flash to Upgrade Your Operating System T he operating system S can be upgraded through the communication port on the controller order to download a new operating system you must have the following e ControlFlash Upgrade Kit containing the new OS aWindows 95 Windows 9
82. ntroller T histype of transformer provides isolation from your power distribution system to reducethe electrical noise that entersthe controller and is often used as a step down transformer to reduce line voltage Any transformer used with thecontroller must have a sufficient power rating for its load T he power rating is expressed in volt amperes VA Power Supply Inrush D uring power up the M icroLogix 1200 power supply allows a brief inrush current to charge internal capacitors M any 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 Installing Your Controller 2 7 Theonly effect of limited inrush current and voltage sag on the M icroLogix 1200 isthat the power supply capacitors charge more slowly H owever the effect of a voltage sag on other equipment should be considered For example a deep voltage sag may reset a computer connected to the same power source Thefollowing considerations determine whether the power source must be required to supply high inrush current e The power up sequence of devices in a system Theamount of the power source voltage sag if the inrush current cannot be supplied T he 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 o
83. o 1 ms increments Line is set to no handshaking this is the delay time before transmission Required for 1761 NET AIC physical Half Duplex networks The 1761 NET AIC needs delay time to change from tran e When the Contro smit to receive mode Line is set to DF1 Half Duplex M odem this is the minimum time delay between receiving the last character of a packet and the RTS assertion Publication 1762 UM 001A US P Rockw ell Software RSLinx 2 0 or higher SLC 5 03 SLC 5 04 and SLC 5 05 or PLC 5 processors configured for DF1 Half Duplex M aster Understanding the Communication Protocols 5 RS 232 uu DF1 Half Duplex Protocol II 4 E M icroLogix 1000 Slave M icroLogix 1500 Slave SLC 5 04 Slave SLC 5 03 with 1747 KE Interface M odule Slave NOTE It isrecommended that isolation 1761 N ET AIC be used between channel 0 of the M icroLogix controller and the modem Considerations When Communicating as a DF1Slave on a Multi drop Link W hen communication is between either your programming software and a M icroLogix Programmable Controller or between two icroLogix Programmable C ontrollers via a slave to slave connection on a larger multi drop link the devices depend on aDF1 alf D uplex M aster to give each of them permission to transmit in atimely manner Asthe number of Slave devices inc
84. o port 2 This connector is not commercially available If you are making a cable to connect to port 2 you must configure your cable to connect to the Allen Bradley cable shown above 3 In the 1761 CBL PM 02 cable pins 4 and 6 are jumpered together within the DB 9 connector Publication 1762 UM 001A US P Communication Connections 4 15 Safety Considerations T his equipment is suitable for use in Class Division 2 GroupsA B C D or non hazardous locations only WARNING EXPLOSION HAZARD AIC must be operated from an external power source This product must be installed in an enclosure All cables connected to the product must remain in the enclosure or be protected by conduit or other means Refer to Safety C onsiderations on page 2 4 for additional information Installing and Attaching the AIC 1 Take care when installing the AIC in an enclosure so that the cable connecting the icroLogix 1200 controller to the AIC does not interfere with the enclosure door 2 Carefully plug theterminal block into the RS 485 port on theAIC you are putting on the network Allow enough cable slack to prevent stress on the plug 3 Provide strain relief for the Belden cable after it is wired to the terminal block T his guards against breakage of the Belden cable wires Powering the AIC In normal operation with the M icroLogix 1200 programmable controller connected to port 2 of the AIC the controller powers the
85. of the following dielectric tests 1517V ac for 1 second or 2145V dc for 1 second 132V ac Working Voltage IEC Class 2 reinforced insulation Specifications 5 Table A 8 Working Voltage 1762 L24AW A 1762 LA0AW A Output Group to Backplane Isolation Verified by one of the following dielectric tests 1836V ac for 1 second or 2596V dc for 1second 265V ac Working Voltage IEC Class 2 reinforced insulation Output Group to Output Group Isolation Verified by one of the following dielectric tests 1836V ac for 1 second or 2596V dc for 1second 265V ac Working Voltage basic insulation 150V ac Working Voltage IEC Class 2 reinforced insulation Table A 9 Working Voltage 176 Specification Power Supply Input to Backplane Isolation 2 L24BWA 1762 L40BW 1762 L24BW A 1762 L40BWA Verified by one of the following dielectric tests 1836V ac for 1 second or 2596V dc for 1 second 265V ac Working Voltage IEC Class 2 reinforced insulation Power Supply User 24V Output to Backplane Isolation Verified by one of the following dielectric tests 600V ac for 1 second or 848V dc for 1 second 50V Working Voltage IEC Class 2 reinforced insulation Input Group to Backplane Isolation and Input Group to Input Verified by one of the following dielectric tests 1200V ac for 1 second or 1697V dc for 1 second Group Isolation 75V dc Working Voltage IEC Class 2 reinforced insul
86. ohibited Throughout this manual we use notes to make you aware of safety considerations Identifies information ATTENTION de tifies information about practices o1 circumstances that can lead to personal injury death property damage or economic loss Attention statements help you to identify a hazard avoid a hazard recognize the consequences IMPORTANT Identifies information that is critical for successful application and understanding of the product 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 W ho Should Use this Manual Purpose of this Manual Preface Read this preface to familiarize yourself with the rest of the manual It provides information concerning who should usethis manual e the purpose of this manual e related documentation e conventions used in this manual e Rockwell Automation support Use this manual if you are responsible for designing installing programming or troubleshooting control systems that use M icroLogix 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 This manual is a
87. omation including Allen Bradley controls Reliance Electric power transmission products Dodge mechanical power transmission components and Rockwell Software Rockwell Automation s unique flexible approach to helping customers achieve a competitive advantage is supported by thousands of authorized partners distributors and system integrators around the world Allen Bradley SENSE poor Americas Headquarters 1201 South Second Street Milwaukee WI 53204 USA Tel 1 414 382 2000 Fax 1 414 382 4444 ROCKWELL EY R kw i European Headquarters SA NV avenue Herrmann Debroux 46 1160 Brussels Belgium Tel 32 2 663 06 00 Fax 32 2 663 06 40 oc e Asia Pacific Headquarters 27 F Citicorp Centre 18 Whitfield Road Causeway Bay Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Automation Publication 1762 UM 001A US P J anuary 2000 PN 40072 078 01 A 2000 Rockwell International Corporation Printed in the U S A
88. on to identify wiring based on signal characteristics For example you may use blue for dc wiring and red for ac wiring Table 3 1 Wire Requirements screw Solid Cu 90 C 194 F 14 to 22 AWG Stranded Cu 90 C 194 F 16 to 22 AWG Wiring torque 0 791 Nm 7 in Ib rated Wiring without Spade Lugs W hen wiring without spade lugs it is recommended to keep the finger safe covers in place Loosen the terminal screw and route the wires through the opening in the finger safe cover Tighten the terminal screw making sure the pressure plate secures the wire Finger Safe Cover Using Surge Suppressors Wiring Your Controller 3 3 Wiring with Spade Lugs T he diameter of the terminal screw head is 5 5 mm 0 220 in Theinput and output terminals of the icroLogix 1200 controller are designed for a 6 35mm 0 25 in wide spade standard for 6 screw for up to 14 AWG or a4 mm metric 4 fork terminal W hen using spade lugs use a small flat blade screwdriver to pry the finger safe cover from the terminal blocks as shown below T hen loosen the terminal screw Inductive load devices such as motor starters and solenoids require the use of some type of surge suppression to protect and extend the operating life of the controllers output contacts Switching inductive loads without surge suppression can significantly reduce the life expectancy of relay contacts By adding a suppression device dire
89. or specific purposes baud rate T he speed of communication between devices All devices must communicate at the same baud rate on a network bit T he smallest storage location in memory that contains either a 1 ON or a0 OFF block diagrams A schematic drawing Boolean operators Logical operators such aSAN D OR NOR NOT and Exclusive O that can be used singularly or in combination to form logic statements or circuits Can have an output response of T or F branch A parallel logic path within a rung of ladder program communication scan part of the controller s operating cycle Communication with other devices such as software running on a personal computer takes place controller A device such as a programmable controller used to monitor input devices and control output devices controller overhead An internal portion of the operating cycle used for housekeeping and set up purposes Publication 1762 UM 001A US P 2 Glossary Publication 1762 UM 001A US P control profile The means by which a controller determines which outputs turn on under what conditions counter 1 An electro mechanical relay type devicethat counts the occurrence of some event M ay be pulses developed from operations such as switch closures or interruptions of light beams 2 In controllers a software counter eliminates the need for hardware counters T he software counter can be given a preset count value to co
90. page 3 10 he controller terminal block layouts are shown below T he shading on the labels indicates how the terminals are grouped A detail of the groupings is shown in thetable following the terminal block layouts D NOTE This lt symbol denotes a protective earth ground terminal which provides low impedance path between electrical circuits and earth for safety purposes and provides noise immunity improvement T his connection must be made for safety purposes Terminal Block Layouts Figure 3 1 1762 L24AW A Inputs Outputs Publication 1762 UM 001A US P 3 8 Wiring Your Controller Publication 1762 UM 001A US P ATTENTION The 24 dc user supply of the 1762 L24BWA should not be used to power output circuits It should only be used to power input devices e g sensors switches Refer to M aster Control Relay on page 2 8 for information on M CR wiring in output circuits Figure 3 2 1762 L24BWA Group 0 Group 1 24 COM al Inputs 24 COM VAC VAC VAC Outputs neur OUT o our 1 our 2 its OUT e our VAC VAC VAC VAC Figure 3 3 1762 140 A Group 0 Group 1 Group 2 did vac vac out our our vac our our our out vac our o NEUT 1 2 0 5 7 8 10 065 13 vac vac vac OUT our our vac OUT our our our Dc 1 062 3 4 6 ocaf 9 11 12 14 A Figure 3 4 1762 L40B
91. pe of communication medium A network may be made up of a single link or multiple links nominal input current T hecurrent at nominal input voltage normally closed Contacts on a relay or switch that are closed when the relay is de energized or the switch is deactivated they are open when the relay is energized or the switch is activated In ladder programming a symbol that allows logic continuity flow if the referenced input is logic 0 when evaluated normally open Contacts on a relay or switch that are open when the relay is de energized or the switch is deactivated T hey are closed when the relay is energized or the Switch is activated In ladder programming a symbol that allows logic continuity flow if the referenced input islogic 1 when evaluated off delay time TheOFF delay time is a measure of the time required for the controller logic to recognize that a signal has been removed from the input terminal of the controller The time is determined by circuit component delays and by any filter adjustment applied offline D escribes devices not under direct communication offset steady state deviation of a controlled variable from a fixed point off state leakage current W hen an ideal mechanical switch is opened off state no current flows through the switch Practical semiconductor switches and the transient suppression components which are sometimes used to protect switches allow a small current to flow
92. plications A surge suppressor can also be used See Table 3 2 for recommended suppressors As shown below these surge suppression circuits connect directly across the load device Surge Suppression for Inductive dc Load Devices Q Output Device Diode surge suppressor can also be used Recommended Surge Suppressors Use the Allen Bradley surge suppressors shown in the following table for use with relays contactors and starters Table 3 2 Recommended Surge Suppressors Device Coil Voltage Suppressor Catalog Number Bulletin 509 M otor Starter 120V ac 599 K04 Bulletin 509 M otor Starter 240V ac 599 KA04 Bulletin 100 Contactor 120V ac 199 FSMA1 Bulletin 100 Contactor 240V ac 199 FSM A2 Bulletin 709 M otor Starter 120V ac 1401 10 Bulletin 700 RM Relays ac coil None Required Bulletin 700 Type R Relay 12V dc 100 N22 Bulletin 700 Type RM Relay 12V dc 700 N28 Bulletin 700 Type R Relay 24V dc 700 N10 Bulletin 700 Type RM Relay 24V dc 700 N13 Bulletin 700 Type R Relay 48V dc 700 16 Bulletin 700 Type RM Relay 48V dc 700 N17 Bulletin 700 Type R Relay 115 125V dc 700 N11 Bulletin 700 Type RM Relay 115 125V dc 700 14 Bulletin 700 R Relay 230 250V dc 100 N 12 Bulletin 700 Type RM Relay 230 250V dc 700 N15 Bulletin 700 Type N P or PK Relay 150V max acorDC 700 N24 Miscellaneous electromagnetic 150V max acorDC 700 N24 devices limite
93. pressed and held for one second to activate T here are two ways to connect the M icroLogix 1200 programmable controller to your personal computer using the D F1 protocol using a point to point connection or using a modem D escriptions of these methods follow ATTENTION Chassis ground internal 24V dc ground user 24V dc ground and RS 232 ground are internally connected You must connect the chassis ground terminal screw to chassis ground prior to connecting any devices It isimportant that you understand your personal computer s grounding system before connecting to the controller An optical isolator is recommended between the controller and your personal computer Table 42 Available Communication Cables Communication Connections 4 3 Communication Cables Length 1761 CBL PM 02 Series C or later 2m 6 5 ft 1761 CBL HM 02 Series C or later 2m 6 5 ft 1761 CBL AM 00 Series C or later 45 cm 17 7 in 1761 CBL AP00 Series C or later 45 cm 17 7 in 2107 NC8 Series or later 2m 6 5 ft 2107 NC9 Series or later 15m 49 2 ft 2707 NC10 Series B or later 2m 6 5 ft 2707 NC11 Series B or later 2m 6 5 ft Making a DF1 Point to Point Connection You can connect the M icroLogix 1200 programmable controller to your personal computer using a serial cable 1762 C BL PM 02 from your personal computer s serial port to the controller as shown below T he recommended protocol for this configura
94. protection 2 8 high byte G 3 1 0 Inputs and Outputs G 3 input device G 3 input states on power down 2 7 inrush current G 3 installing ControlFlash software D 1 memory module 2 13 your controller 2 1 installing real time clock 2 13 instruction G 3 instruction set G 3 isolated link coupler installing 4 8 isolation transformers power considerations 2 6 J jump G 4 L ladder logic G 4 least significant bit LSB G 4 LED Light Emitting Diode G 4 LIFO Last In First Out G 4 logic G 4 low byte G 4 M manuals related P 2 master control relay 2 8 emergency stop switches 2 10 using ANSI CSA symbols schematic 2 12 using IEC symbols schematic 2 11 M aster Control Relay MCR G 4 master control relay circuit periodic tests 2 6 memory module data file protection 6 4 operation 6 3 program compare 6 3 program data backup 6 3 removal installation under power 6 4 write protection 6 4 minimizing electrical noise 3 14 mnemonic G 4 M odbus communication protocol E 17 modem G 4 modem cable constructing your own 4 5 modems dial up phone E 7 leased line E 7 line drivers E 7 radio E 7 using with M icroLogix controllers E 6 modes G 4 module error field C 5 motor starters bulletin 509 surge suppressors 3 5 motor starters bulletin 709 surge suppressors 3 5 Index 3 N negative logic G 4 network G 5 nominal input current G 5 normally closed G 5 normally open G 5 null modem cable 4 5 0 offline G 5 offset G
95. r 1 0 module by means of a flat ribbon cable after mounting as shown below Pull Loop Use the pull loop on the connector to disconnect modules NOTE D o not pull on the ribbon cable ATTENTION Remove power before removing or inserting an 1 0 module When you remove or insert a module with power applied an electrical arc may occur An electrical arc can cause personal injury or property damage by e sending an erroneous signal to your system s field devices causing the controller to fault e causing an explosion in a hazardous environment Electrical arcing causes excessive wear to contacts on both the module and its mating connector Worn contacts may create electrical resistance reducing product reliability EXPLOSION HAZARD In Class Division 2 applications the bus connector must be fully seated and the bus connector cover must be snapped in place In Class Division 2 applications all modules must be mounted in direct contact with each other as shown on page 2 20 If DIN rail mounting is used an end stop must beinstalled ahead of the controller and after the last 1762 1 0 module Publication 1762 UM 001A US P Wiring Requirements Chapter j Wiring Your Controller T his chapter describes how to wire your controller and expansion 1 0 Topics include e wire requirements using surge suppressors grounding the controller wiring diagrams e sinking and sourcing wiring diagrams e contro
96. r s RUN LED flashes Program Compare Thememory module can also provide application security allowing you to specify that if the program stored in the memory module does not match the program in the controller the controller will not enter an executing run or test mode To enablethis feature set the 5 2 9 bit in the system status file See Status System File in theM icroLogix 1200 and 1500 Programmable Controllers nstruction 56 Reference M anual Publication 1762 RM 001 0 S P for more information Publication 1762 UM 001A US P 6 4 Using Real Time Clock and M emory odules Publication 1762 UM 001A US P Data File Download Protection The memory module allows the user to specify individual data files in the controller that are protected from the download procedure T his allows user data to be saved not overwritten during a download NOTE D ata file download protection is only functional if the processor does not have a fault and if the size of the protected data file structures of the memory module exactly matches the size of the protected data file structure within the controller See Protecting D ata Files D uring D ownload in the M icroLogix 1200 and 1500 Programmable Controllers nsruction Se Reference M anual Publication 1762 RM 001 0 5 Memory Module Write Protection The memory module supports write once read many behavior Write protection is enabled using your programming software IM PORTANT O
97. r to Calculating Heat Dissipation on page F 9 Dissipation Power Supply 400mAat5V 400 mA at 5V 600mAat5V 600 mA at SV Output 350 mA at 24V 350 mA at 24 0 500 mA at 24V 500 mA at 24v User Power none 24V dc at 250 none 24V dc at 400 400 max 400 uF max Input Circuit 120V ac 24V dc 120V ac 24V dc Type sink source sink source Output Circuit Relay Relay Relay Relay Type Operating 0 C to 55 432 F to 4131 ambient Temperature Storage 40 C to 85 C 40 F to 4185 ambient Temperature Operating 5 to 95 relative humidity non condensing Humidity Vibration Operating 10 to 500 Hz 5G 0 030 in max peak to peak Relay Operation 1 5G Publication 1762 UM 001A US P A 2 Specifications Publication 1762 UM 001A US P Table A 1 General Specifications Description 1762 L24AWA 1762 L24BWA 1762 L40AWA 1762 L40BWA Shock Operating 30G Relay Operation 7G Non Operating 50G panel mounted 40G DIN Rail mounted Agency e UL 508 Certification 213 e C UL under CSA C222 142 e Class Div 2 Groups A B C D UL 1604 C UL under CSA C22 2 no e CE C Tick compliant for all applicable directives acts Electrical EMC The controller has passed testing at the following levels IEC1000 4 2 4 kV contact 8 kV air 4 kV indirect IEC1000 4 3 10V m IEC1000 4 4 2 kV 5 kHz communications cable 1 kV 5 kHz IEC1000 4 5 communications cable 1 kV
98. rease on the link up to 254 the time between when your programming software or the M icroLogix Controller is polled also increases T his increase in time may also be large if you are using low baud rates Asthese time periods grow thefollowing values may need to be changed to avoid loss of communication e programming software increase poll timeout and reply timeout values e MicroLogix Programmable Controllers increase poll timeout and reply timeout values Publication 1762 UM 001A US P E 6 Understanding the Communication Protocols Publication 1762 UM 001A US P If a program download is started when using DF 1 H alf IMPORTANT Eon IMPORTANT D uplex but then is interrupted due to electromagnetic interference or other events discontinue communications to the controller for the ownership timeout period and then restart the program download T he ownership timeout period 1560 seconds After the timeout you can reestablish communications with the processor and try the program download again T he only other way to remove program ownership isto cycle power on the processor Using Modems with MicroLogix 1200 Programmable Controllers The types of modems you can use with M icroLogix 1200 controllers include dial up phone modems leased line modems radio modems and line drivers For point to point Full D uplex modem connections that do not require any modem handshaking signals to operate useD F1 Full D uplex protocol with no ha
99. reference guide for M icroLogix 1200 controllers and expansion 1 0 It describes the procedures you use to install wire and troubleshoot your controller T his manual explains how to install and wire your controllers gives you an overview of the M icroLogix 1200 controller system Refer to Publication 1762 RM 001A U S P M icroLogix 1200 and 1500 Programmable Controllers Instruction Set Reference M anual for the M icroL ogix 1200 and 1500 instruction set and for application examplesto show the instruction set in use Refer to your programming software user documentation for more information on programming your M icroLogix 1200 controller Publication 1762 UM 001A US P 2 Preface Related Documentation The following documents contain additional information concerning Rockwell Automation products To obtain a copy contact your local Rockwell Automation office or distributor For Information on understanding and applying micro controllers Read this Document M icroM entor Document Number 1761 MM B Information on the M icroLogix 1200 Controllers instruction set M icroLogix 1200 and 1500 Programmable Controllers Instruction Set Reference M anual 1762 RM 001A US P Reference M anual Information on mounting and wiring the M icroLogix 1200 M icroLogix 1200 Programmable 1762 5 1 Controllers including a mounting template for easy installation Controllers Installation Instructions A description on how
100. reference line between all nodes on the network T he shield reduces the effect of electrostatic noise from the industrial environment on network communication The communication cable consists of a number of cable segments daisy chained together T he total length of the cable segments cannot exceed 1219 m 4000 ft H owever two segments can be used to extend the D H 485 network to 2438 m 8000 ft For additional information on connectionsusing the AIC refer to the Advanced Interface Converter AIC U ser M anual publication 1761 6 4 W hen cutting cable segments make them long enough to route them from one AIC to the next with sufficient slack to prevent strain on the connector Allow enough extra cable to prevent chafing and kinking in the cable U se these instructions for wiring the Belden 3106 or 9842 cable Refer to Cable Selection Guide on page 4 11 if you are using standard Allen Bradley cables Connecting the Communication Cable to the DH485 Connector NOTE A daisy chained network is recommended D o not make the incorrect connection shown below Belden 43106A Belden 3106 or Belden 3106A or or 9842 9842 9842 Connector Connector Connector Incorrect Communication Connections 4 9 Single Cable Connection W hen connecting a single cableto the D H 485 connector usethe following diagram Orange with W hite Stripes W hite with Orange Stripes iio
101. replaced W hen the battery low indicator bit is clear 0 the battery level is acceptable or a real time clock is not attached If the RTC battery is low and the controller is powered the RT C operates normally If the controller power is removed and the RTC battery islow RTC data is lost Table 6 2 RTC Battery Life Span Life Span Operati ng Temperature Storage Temperature 5 years 0 C to 40 C 432 F to 104 F 40 C to 60 C 40 F to 140 F Stored for six months ATTENTION O perating with a low battery indication for more than 14 days may result in invalid RTC data unless power is on continuously Using Real Time Clock and Memory Modules 6 3 M emory Module Operation Thememory module supports program back up as well asthefollowing features User Program and D ata Back up User Program Compare Data File Download Protection e Memory M odule Write Protection Removal Insertion Under Power Electrostatic discharge can damage the M emory M odule ATTENTION 2 Do not touch the connector pins or other sensitive areas User Program and Data Back up module provides a simple and flexible program data transport mechanism allowing the user to transfer the program and data to the controller without the use of a personal computer and programming software Thememory module can store one user program at a time D uring program transfers to or from the memory module the controlle
102. rs E 2 connecting 4 2 4 3 description E 1 example system configuration E 2 using a modem 4 4 E 6 DF1 Half Duplex protocol description E 3 DH485 communication protocol configuration parameters E 9 DH485 network configuration parameters E 12 connecting 4 7 description E 8 devices that use the network E 9 example system configuration E 13 installation 4 7 planning considerations E 10 protocol E 8 token rotation E 8 DIN rail G 2 disconnecting main power 2 5 dow nload G 2 DTE Data Terminal Equipment G 2 E Electronics Industries Association EIA E 1 Directive 2 2 EMI G 2 encoder G 2 error recovery model C 3 errors configuration C 6 critical C 4 extended error information field C 6 hardware C 6 module error field C 5 non critical C 4 European Union Directive compliance 2 2 EMC Directive 2 2 low voltage directive 2 2 executing mode G 2 Publication 1762 UM 001A US P expansion 1 0 mounting 2 18 2 19 mounting on DIN rail 2 18 expansion 1 0 wiring 3 14 1762 1 8 wiring diagram 3 14 1762 IF20F2 terminal block layout 3 16 1762 IF20F2 wiring 3 16 1762 108 wiring diagram 3 15 1762 0W 8 wiring diagram 3 15 extended error information field C 6 F false G 2 FIFO First In First Out G 3 file G 3 Full Duplex 4 3 full duplex G 3 G general considerations 2 3 grounding the controller 3 6 H Half Duplex 4 6 G 3 hard disk G 3 hardware errors C 6 hardware features 1 1 heat dissipation calculating F 9 heat
103. s Delay ms 50 Duty Cycle 1 0 kHz 0 500 0 090 0 500 0 020 0 500 0 5 kHz 1 000 0 500 1 000 0 400 1 000 200 Hz 2 000 1 100 2 000 1 300 2 000 125 Hz 4 000 2 800 4 000 2 100 4 000 63 Hz 8 0000 5 800 8 000 5 300 8 000 31Hz 16 000 11 000 16 000 10 000 16 000 1 This is the default setti g Publication 1762 UM 001A US P Table A 7 Relay Contact Rating Table 1762 24AW A 24BWA 40AWA 40BWA Maximum Amperes Amperes Voltamperes vr Make Break Make Break 240V ac 7 5 0 75 2540 1800VA 1g0vA0 120V ac 15A 1 5A 125V dc 0 2240 1 0A 28VA 24V dc 1 248 2 0A 28VA 1 1 5A above 40 C 2 The total load controlled by the 1762 24AWA 24BWA 40AWA and 40BWA is limited to 1440 VA break 3 For dc voltage applications the make break ampere rating for relay contacts can be determined by dividing 28 VA by the applied dc voltage For example 28 VA 48V dc 0 58A For dc voltage applications less than 14V the make break ratings for relay contacts cannot exceed 2A Table A 8 Working Voltage 1762 L24AW A 1762 L40AWA Specification Power Supply Input to Backplane Isolation 1762 L24AW A 1762 L40AWA Verified by one of the following dielectric tests 1836V ac for 1 second or 2596V dc for 1 second 265V ac Working Voltage IEC Class 2 reinforced insulation Input Group to Backplane Isolation and Input Group to Input Group Isolation Verified by one
104. s electronic operator interface for SLC 500 processors 2711 802 B5A2 K5A5 PanelView 900 2711 816 B5A5 K5A1 Operator Terminals B5A1 K9A2 T9A2 K9A5 T9A5 K9A1 and T9A1 Publication 1762 UM 001A US P NA Not Applicable Important DH485 Netw ork Planning Considerations Carefully plan your network configuration before installing any hardware Listed below aresome of the factors that can affect system performance amount of electrical noise temperature and humidity in the network environment number of devices on the network connection and grounding quality in installation amount of communication traffic on the network type of process being controlled network configuration The major hardware and software issues you need to resolve before installing a network are discussed in the following sections Hardware Considerations You need to decide the length of the communication cable where you route it and how to protect it from the environment where it will be installed W hen the communication cable is installed you need to know how many devices are to be connected during installation and how many devices will be added in the future T he following sections help you understand and plan the network Understanding the Communication Protocols 11 Number of Devices and Length of Communication Cable The maximum length of the communication cable is 1219m 4000 ft T hisis the total
105. s operating cycle D uring the scan the ladder program is executed and the output data file is updated based on the program and the input data file programming device Executable programming package used to develop ladder diagrams protocol T he packaging of information that is transmitted across a network read To acquire data from a storage place For example the processor READ s information from the input data file to solve the ladder program relay An electrically operated device that mechanically switches electrical circuits relay logic representation of the program or other logic in a form normally used for relays restore To download transfer a program from a personal computer to a controller Glossary 7 reserved bit A status file location that the user should not read or write to retentive data Information associated with data files timers counters inputs and outputs in a program that is preserved through power cycles RS 232 An EIA standard that specifies electrical mechanical and functional characteristics for serial binary communication circuits A single ended serial communication interface run mode Thisisan executing mode during which the controller scans or executes the ladder program monitors input devices energizes output devices and acts on enabled 1 0 forces rung Ladder logic is comprised of set of rungs A rung contains input and output instructions D uring Run mode the inpu
106. sethefollowing error recovery model to help you diagnose software and Model hardware problems in the micro controller The model provides common questions you might ask to help troubleshoot your system Refer to the recommended pages within the mode for further help Identify the error code and description Is the error hardware related Refer to page C 2 for probable cause and Are the wire No Tighten wire connections recommended action connections tight Yes Is the Power No Does the No controller have power supplied Clear Fault LED on Check power Yes Refer to page C 2 for No probable cause and recommended action Correct the condition causing the fault Is the RUN LED on Yes Is the Fault Is an input LED No Return controller to RUN or LED on any of the REM test modes EO Yes Refer to page C 2 for Refer to page C 2 for probable cause and probably cause and recommended action recommended action Test and verify system operation Publication 1762 UM 001A US P C 4 Troubleshooting Your System Analog Expansion 1 0 Diagnostics and Troubleshooting Publication 1762 UM 001A US P Module Operation and Channel Operation T he module performs operations at two levels e module level e channel level M odule level operations include functions such as power up configurat
107. stalling Your Controller Wiring Your Controller Communication Connections Table of Contents Chapter 1 ardware Features 1 1 Component D lt lt 1 2 Communication 1 3 Programming baie aah Me ad 1 3 Communication 5 1 3 Chapter 2 Agency Certifications 2 1 Compliance to European Union 2 2 Ingallation 5 5 2 3 Safety amp 5 2 4 Power t onsderadolts Cie RETI RE RC RS 2 6 Preventing Excessive H 2 8 M aster Control 2 8 Installing a emory odule and or Real Time Clock 2 13 Controller 2 14 Controller and Expansion I O 5 2 14 M ounting the Controller rore irpoc erts rp 2 15 M ounting 1762 EXDabisolt p 2 18 Connecting Expansion 1 2 20 Chapter 3 W iring lt 3 1 U sing Surge 5 5 3 3 Grounding the
108. the PLC 59 1785 6 5 5 Gateway Chassis and SLC 500 DH485 networks Enables communication and data 1 85 1 21 transfer from PLC to SLC 500 on DH485 network Also enables programming software programming or data acquisition across DH to DH485 2760 RB Flexible Interface 1771 Provides an interface for SLC 500 using protocol cartridge 1747 KE M odule Chassis 2760 SFC3 to other PLCs and devices Three configurable 2160 ND001 channels are available to interface with Bar Code Vision RF Dataliner and PLC systems 1784 KTXD PC DH485 IM IBM XT AT Provides DH485 using RSLinx 1784 6 5 22 Computer Bus 1784 PCM K PCM CIA IM PCM CIA slot Provides DH485 using RSLinx 1784 6 5 19 in computer and Interchange Publication 1762 UM 001A US P E 10 Understanding the Communication Protocols Table E 4 Allen Bradley Devices that Support DH485 Communication Catalog Number Description Installation Function Publication 1747 PT1 Hand Held Provides hand held programming monitoring configuring and 1747 NP002 Terminal troubleshooting capabilities for SLC 500 processors 1747 DTAM DTAM Plus Panel M ount Provides electronic operator interface for SLC 500 processors 1747 ND013 2707 L8P1 L8P2 Jand Micro 2707 800 L40P1 L40P2 Operator 2707 803 V40P1 V40P2 Interfaces V40P2N M 232P3 and M 485P3 2711 K5A2 PanelView 550 and Panel M ount Provide
109. ting Excessive Heat Master Control Relay Publication 1762 UM 001A US P 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 fansinside 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 NOTE Do not bring in unfiltered outside air Place the controller in an enclosure to protect it from a corrosive atmosphere H armful 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 A hard wired master control relay M CR 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 isimportant from a safety standpoint O vertravel 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 T his removes power to input and output device cir
110. tion is DF1 Full D uplex W e recommend using an Advanced Interface C onverter AIC catalog number 1761 N ET AIC as your optical isolator as shown below See page 4 11 for specific AIC cabling information M icroLogix 1200 1761 CBL AM 00 or 1761 CBL HM 02 Personal Computer P E 1747 CP3 or 1761 CBL AC00 24V dc icroLogix 1200 provides power to the AlC or an external power supply may be used NOTE Series C or higher cables are required Publication 1762 UM 001A US P 4 4 Communication Connections Publication 1762 UM 001A US P EN eres n Protocol Options e DF1 Full Duplex protocol to 1 controller Optical Isolator is e DF1 Half Duplex protocol to multiple controllers recommended Modbus Slave protocol c E Modem 3 Using a Modem You can use modems to connect a personal computer to one M icroLogix 1200 controller using DF1 Full D uplex protocol to multiple controllers using DF1 Half D uplex protocol or Modbus Slave protocol as shown in the following illustration D o not attempt to use D H 485 protocol through modems under any circumstance Refer to Understanding the Communication Protocols on page E 1 for information on types of modems you can use with the micro controllers Personal Computer Modem Cable M icroLogix 1200
111. ts on a rung are evaluated to be true or false If a path of true logic exists the outputs are made true If all paths are false the outputs are made false save To upload transfer a program stored in memory from a controller to personal computer OR to save a program to a computer hard disk scan time Thetimerequired for the controller to execute the instructions in the program time may vary depending on the instructions and each instruction s status during the scan sinking A term used to describe current flow between an 1 0 device and controller 1 0 circuit typically a sinking device or circuit provides a path to ground low or negative side of power supply sourcing A term used to describe current flow between an 1 0 device and controller 1 0 circuit typically a sourcing device or circuit provides a path to the source high or positive side of power supply status T hecondition of a circuit or system represented as logic 0 OFF or 1 ON terminal A point on an 1 0 module that external 1 0 devices such as a push button or pilot light are wired to Publication 1762 UM 001A US P 8 Glossary Publication 1762 UM 001A US P throughput T he time between when an input turns on and the corresponding output turns on true The status of an instruction that provides a continuous logical path on a ladder rung upload D ata istransferred to a programming or storage device from another d
112. tware s user manual for more information Number of Nodes The number of nodes on the network directly affects the data transfer time between nodes Unnecessary nodes such as a second programming terminal that is not being used slow the data transfer rate The maximum number of nodes on the network is 32 Understanding the Communication Protocols E 13 Setting Node Addresses T he best network performance occurs when node addresses are assigned in sequential order Initiators such as personal computers should be assigned the lowest numbered addresses to minimize the time required to initialize the network T he valid range for the icroLogix 1200 controllers is 1 31 controllers cannot be node 0 T he default setting is 1 T he node address is stored in the controller Communications Status file 50 5 0 to C 50 5 7 Setting Controller Baud Rate T hebest network performance occurs at the highest baud rate which is 19200 Thisisthe default baud rate for a M icroLogix 1200 device on the DH 485 network devices must beat the same baud rate T his rate is stored in the controller Communications Status file CS0 5 8 to CS0 5 15 Setting M aximum Node Address O nce you havean established network set up and are confident that you will not be adding more devices you may enhance performance by adjusting the maximum node address of your controllers It should be set to the highest node address being used IMPORTANT All devices s
113. uipment Requirements and Tests For specific information required by EN 61131 2 seethe appropriate sections in this publication as well as the following Allen Bradley publications e Industrial Automation Wiring and Grounding Guidelines for oise Immunity publication 1770 4 1 e Guidelines for andling Lithium Batteries publication AG 5 4 e Automation Systems Catalog publication B111 Installing Your Controller 2 3 Installation Considerations M ost applications require installation in an industrial enclosure Pollution D egree 2 to reduce the effects of electrical interference ver Voltage Category 112 and environmental exposure Locate your controller as far as possible from power lines load lines and other sources of electrical noise such as hard contact switches relays and AC motor drives For moreinformation on proper grounding guidelines see the Industrial Automation W iring and Grounding G uiddines publication 1770 4 1 ATTENTION Vertical mounting of the controller is not recommended dueto heat build up considerations Be careful of metal chips when drilling mounting holes for ATTENTION Zia your controller or other equipment within the enclosure or panel D rilled fragments that fall into the controller or 1 0 modules could cause damage D o not drill holes above a mounted controller if the protective debris shields are removed or the processor is installed 1 Pollution Degree 2 is an enviro
114. unt up or down whenever the counted event occurs CPU Central Processing Unit T he decision making and data storage section of a programmable controller data table T he part of processor memory that contains 1 0 values and files where data is monitored manipulated and changed for control purposes DIN rail M anufactured according to D eutsche Industrie N ormenausshus D IN standards a metal railing designed to ease installation and mounting of your controller dow nload D ata is transferred from a programming or storage device to another device DTE Data Terminal Equipment Equipment that is attached to a network to send or receive data or both embedded 1 0 Embedded 1 0 isthe controller s on board 1 0 EMI Electromagnetic interference encode 1 A rotary device that transmits position information 2 A device that transmits a fixed number of pulses for each revolution executing mode Any run or test mode expansion 1 0 Expansion 1 0 151 0 that is connected to the controller via a bus or cable M icroLogix 1200 controllers use Bulletin 1762 expansion 1 0 false T he status of an instruction that does not provide a continuous logical path on a ladder rung Glossary 3 FIFO First In First Out The order that data is entered into and retrieved from a file file A collection of information organized into one group full duplex A bidirectional mode of communication where data may be transmitted and recei
115. unting the module on aDIN rail closethe DIN rail latch Press the DIN rail mounting area of the module against the IN rail T he latch momentarily opens and locks into place UseDIN rail end anchors Allen Bradley part number 1492 EA35 or 1492 EAH 35 for vibration or shock environments T hefollowing illustration shows the location of the end anchors Installing Your Controller 2 19 End Anchor NOTE 1762 expansion 1 0 must be mounted horizontally as illustrated NOTE For environments with greater vibration and shock concerns use the panel mounting method described below instead of DIN rail mounting Panel Mounting Use the dimensional template shown below to mount the module T he preferred mounting method is to use two M 4 or 8 panhead screws per module M 3 5 or 6 panhead screws may also be used but a washer is needed to ensure a good ground current M ounting screws are required on every module For more than 2 modules number of modules 1 x 40 mm 1 58 in NOTE All m dimensions are in gum LT 5 mm inches Hole 63 9i Spacing tolerance 0 4 mm 0 016 in 100 9 3 94 3 54 LH re NM 59 MicroLogix 1200 Cortroller MicroLogix 1200 Exparsionl O Publication 1762 UM 001A US P 2 20 Installing Your Controller Connecting Expansion 1 0 Theexpansion 1 0 moduleisattached to the controller or anothe
116. ved simultaneously contrast with half duplex half duplex A communication link in which data transmission is limited to one direction at atime hard disk A storage area in a personal computer that may be used to save processor files and reports for future use high byte Bits 8 15 of a word input device A device such asa push button or a switch that supplies signals through input circuits to the controller inrush current Thetemporary surge current produced when a device or circuit is initially energized instruction A mnemonic and data address defining an operation to be performed by the processor A rung in a program consists of a set of input and output instructions T heinput instructions are evaluated by the controller as being true or false In turn the controller sets the output instructions to true or false instruction set The set of general purpose instructions available with a given controller 1 0 Inputs and Outputs Consists of input and output devices that provide and or receive data from the controller Publication 1762 UM 001A US P 4 Glossary Publication 1762 UM 001A US P jump Changein normal sequence of program execution by executing an instruction that alters the program counter sometimes called a branch In ladder programs a JU M P JM P instruction causes execution to jump to a labeled rung ladder logic A program written in a format resembling a ladder like diagram T he program is
117. work DH485 Network Description The DH 485 protocol defines the communication between multiple devices that coexist on a single pair of wires D H 485 protocol uses RS 485 H alf D uplex as its physical interface RS 485 is a definition of electrical characteristics it is not a protocol RS 485 uses devices that are capable of co existing on a common data circuit thus allowing data to be easily shared between devices TheDH 485 network offers e interconnection of 32 devices e multi master capability e token passing access control e the ability to add or remove nodes without disrupting the network maximum network segment of 1219 m 4000 ft The DH 485 protocol supports two classes of devices initiators and responders All initiators on the network get a chance to initiate message transfers To determine which initiator has the right to transmit a token passing algorithm is used The following section describes the protocol used to control message transfers on the D H 485 network DH485 Token Rotation A node holding the token can send a message onto the network Each nodeis allowed a fixed number of transmissions based on the Token H old Factor each time it receives the token After a node sends a message it passes the token to the next device T he allowable range of node addresses is 0 to 31 T here must be at least one initiator on the network such asa icroLogix controller or an SLC 5 02 higher processor
118. y considerations power considerations preventing excessive heat master control relay installing the memory module and or real time clock controller mounting dimensions controller and expansion 1 0 spacing mounting the controller mounting 1762 expansion 1 0 connecting expansion 1 0 Agency Certifications e UL 508 e C UL under CSA 22 2 142 e Classl Division 2 GroupsA B C D UL 1604 C UL under CSA C22 2 no 213 CE compliant for all applicable directives C Tick compliant for all applicable acts Publication 1762 UM 001A US P 2 2 Installing Your Controller Compliance to European Union Directives Publication 1762 UM 001A US P This product has the C E mark and is approved for installation within the European Union and EEA regions It has been designed and tested to meet the following directives EMC Directive This product is tested to meet ouncil D irective 89 336 EEC Electromagnetic Compatibility EM C and the following standards in whole or in part documented in a technical construction file e EN 50081 2 EM C Generic Emission Standard Part 2 Industrial Environment e EN 50082 2 EM C Generic Immunity Standard Part 2 Industrial Environment This product is intended for use an industrial environment Low Voltage Directive This product istested to meet Council Directive 73 23 EEC Low Voltage by applying the safety requirements of EN 61131 2 Programmable Controllers Part 2 Eq
119. ystem leavesthe run mode of operation Critical module errors are indicated in Table C 5 on page C 7 Table C 3 Module Error Table Troubleshooting Your System 5 Module Error Definition Table Analog module errors are expressed in two fields as four digit H ex format with the most significant digit as dont care and irrelevant T he two fields are M odule Error and Extended Error Information T he structure of the module error data is shown below Don t Care Bits Module Error Extended Error Information 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Hex Digit 4 Hex Digit 3 Hex Digit 2 Hex Digit 1 M odule Error Field The purpose of the module error field is to classify module errors into three distinct groups as described in the table below T hetype of error determines what kind of information exists in the extended error information field T hese types of module errors are typically reported in the controller s 1 0 status file Refer to the M icroLogix 1200 and 1500 Programmable Controllers nstructi on Set Reference M anual publication 1762 RM 001A U S P for more information Publication 1762 UM 001A US P C 6 Troubleshooting Your System Publication 1762 UM 001A US P Table C 4 Module Error Types Error Type Module Error Description Field Value Bits 11 through 09 Binary No Errors 000 No error is present The extended error fie

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