Allen-Bradley MicroLogix 1200 1762 Programmable Controller User Manual

MicroLogix™ 1200
Programmable
Controllers
Bulletin 1762 Controllers and
Expansion I/O
User Manual
Important User Information
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Preface
Read this preface to familiarize yourself with the rest of the manual. It provides
information concerning:
•
•
•
•
•
Who Should Use this
Manual
who should use this manual
the purpose of this manual
related documentation
conventions used in this manual
Rockwell Automation support
Use this manual if you are responsible for designing, installing, programming,
or troubleshooting control systems that use MicroLogix 1200 controllers.
You should have a basic understanding of electrical circuitry and familiarity
with relay logic. If you do not, obtain the proper training before using this
product.
Purpose of this Manual
This manual is a reference guide for MicroLogix 1200 controllers and
expansion I/O. It describes the procedures you use to install, wire, and
troubleshoot your controller. This manual:
• explains how to install and wire your controllers
• gives you an overview of the MicroLogix 1200 controller system
Refer to Publication 1762-RM001A-US-P, MicroLogix 1200 and 1500
Programmable Controllers Instruction Set Reference Manual for the MicroLogix
1200 and 1500 instruction set and for application examples to show the
instruction set in use. Refer to your programming software user
documentation for more information on programming your MicroLogix 1200
controller.
1
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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
Read this Document
Document Number
Information on understanding and applying micro controllers.
MicroMentor
1761-MMB
Information on the MicroLogix 1200 Controllers instruction set.
MicroLogix 1200 and 1500
Programmable Controllers Instruction
Set Reference Manual
1762-RM001A-US-P
Information on mounting and wiring the MicroLogix 1200
Controllers, including a mounting template for easy installation.
MicroLogix 1200 Programmable
Controllers Installation Instructions
1762-5.1
A description on how to install and connect an AIC+. This manual
also contains information on network wiring.
Advanced Interface Converter (AIC+)
User Manual
1761-6.4
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
Reference Manual
1770-6.5.16
Information about the Modbus Slave protocol.
Modbus Protocol Specifications
Available from Schneider
Automation, Inc.
In-depth information on grounding and wiring Allen-Bradley
programmable controllers.
Allen-Bradley Programmable
Controller Grounding and Wiring
Guidelines
1770-4.1
A description of important differences between solid-state
programmable controller products and hard-wired
electromechanical devices.
Application Considerations for
Solid-State Controls
SGI-1.1
An article on wire sizes and types for grounding electrical
equipment.
National Electrical Code - Published by the National Fire
Protection Association of Boston, MA.
A complete listing of current documentation, including ordering
instructions. Also indicates whether the documents are available on
CD-ROM or in multi-languages.
Allen-Bradley Publication Index
SD499
A glossary of industrial automation terms and abbreviations.
Allen-Bradley Industrial Automation
Glossary
AG-7.1
Publication 1762-UM001A-US-P
Preface
Common Techniques Used
in this Manual
The following conventions are used throughout this manual:
Rockwell Automation
Support
Rockwell Automation offers support services worldwide, with over 75 Sales/
Support Offices, 512 authorized Distributors and 260 authorized Systems
Integrators located throughout the United States alone, plus Rockwell
Automation representatives in every major country in the world.
3
• Bulleted lists such as this one provide information, not procedural steps.
• Numbered lists provide sequential steps or hierarchical information.
• Italic type is used for emphasis.
Local Product Support
Contact your local Rockwell Automation representative for:
•
•
•
•
sales and order support
product technical training
warranty support
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, Dept. A602V
P.O. Box 2086
Milwaukee, WI 53201-2086
or visit our internet page at: h ttp://www.ab.com/micrologix
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Preface
Publication 1762-UM001A-US-P
Table of Contents
Hardware Overview
Chapter 1
Hardware Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Communication Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Communication Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Your Controller
1-1
1-2
1-3
1-3
1-3
Chapter 2
Agency Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Compliance to European Union Directives . . . . . . . . . . . . . . . . . . . 2-2
Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Power Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Preventing Excessive Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Master Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Installing a Memory Module and/or Real-Time Clock . . . . . . . . . 2-13
Controller Mounting Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Controller and
Expansion I/O Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Mounting the Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Mounting 1762
Expansion I/O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Connecting Expansion I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Wiring Your Controller
Chapter 3
Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Using Surge Suppressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Grounding the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Sinking and Sourcing Wiring Diagrams . . . . . . . . . . . . . . . . . . . . 3-10
Controller I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Expansion I/O Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Communication Connections
Chapter 4
Default Communication Configuration . . . . . . . . . . . . . . . . . . . . . 4-1
Using the Communications Toggle Push Button . . . . . . . . . . . . . . 4-2
Connecting to the RS-232 Port. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Connecting to a DH485 Network . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Connecting the AIC+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
DeviceNet Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
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Table of Contents
Using Trim Pots
Chapter 5
Trim Pot Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Using Real-Time Clock and
Memory Modules
Specifications
Chapter 6
Real-Time Clock Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Memory Module Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Appendix A
Controller Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Expansion I/O Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Replacement Parts
Appendix B
MicroLogix 1200 Replacement Kits . . . . . . . . . . . . . . . . . . . . . . . . B-1
1762 Expansion I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Troubleshooting Your System
Appendix C
Understanding the Controller LED Status . . . . . . . . . . . . . . . . . .
Controller Error Recovery Model . . . . . . . . . . . . . . . . . . . . . . . . .
Analog Expansion I/O Diagnostics and Troubleshooting . . . . . . .
Calling Rockwell Automation for Assistance . . . . . . . . . . . . . . . . .
Using Control Flash to Upgrade
Your Operating System
Understanding the
Communication Protocols
System Loading and Heat
Dissipation
Appendix D
Preparing for Upgrade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Missing/Corrupt OS LED Pattern . . . . . . . . . . . . . . . . . . . . . . . . D-2
Appendix E
RS-232 Communication Interface. . . . . . . . . . . . . . . . . . . . . . . . . . E-1
DF1 Full-Duplex Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
DF1 Half-Duplex Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3
DH485 Communication Protocol . . . . . . . . . . . . . . . . . . . . . . . . . E-8
Modbus Communication Protocol . . . . . . . . . . . . . . . . . . . . . . . . E-17
Appendix F
System Loading Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Loading Worksheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Loading Worksheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Calculating Heat Dissipation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Glossary
Index
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C-1
C-3
C-4
C-7
F-1
F-3
F-7
F-9
1
Chapter
Hardware Overview
Hardware Features
The Bulletin 1762, MicroLogix 1200 programmable controller contains a
power supply, input and output circuits, and a processor. The controller is
available in 24 I/O and 40 I/O configurations.
The hardware features of the controller are:
7
6
10
8
2
0
1
5
COM
3
9
4
7
11
1
Table 1.1 Hardware Features
Feature Description
Feature Description
1
Terminal Blocks
(Removable Terminal Blocks
1762-40xWA only)
7
Terminal Doors and Labels
2
Bus Connector Interface to
Expansion I/O
8
Trim Pots
3
Input LEDs
9
Communications Toggle Push Button
4
Output LEDs
10
Memory Module Port Cover(1) -orMemory Module and/or Real-Time Clock(2)
5
Communication Port/
Channel 0
11
DIN Rail Latches
6
Status LEDs
(1) Shipped with controller.
(2) Optional equipment.
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Hardware Overview
Component Descriptions
MicroLogix 1200 Memory Module and/or Real-Time Clock
The controller is shipped with a memory module port cover in place. You can
order a memory 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 I/O
1762 expansion I/O can be connected to the MicroLogix 1200 controller, as
shown below. A maximum of six I/O modules, in certain combinations, may
be connected to a controller. Refer to System Loading and Heat Dissipation on
page F-1..
1762 Expansion I/O
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1762 Expansion I/O Connected to MicroLogix 1200 Controller
Hardware Overview
Communication Cables
1-3
Use only the following communication cables with the MicroLogix 1200
controllers.
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1761-CBL-PM02 Series C or later
1761-CBL-HM02 Series C or later
1761-CBL-AM00 Series C or later
1761-CBL-AP00 Series C or later
2707-NC8 Series B or later
2702-NC9 Series B or later
2707-NC10 Series B or later
2707-NC11 Series B or later
Programming
Programming the MicroLogix 1200 programmable controller is done using
RSLogix™ 500, Revision 4 or later. Communication cables for programming
are not included with the software.
Communication Options
The MicroLogix 1200 can be connected to a personal computer. It can also be
connected to the DH485 network using an Advanced Interface Converter
(catalog number 1761-NET-AIC) and to the DeviceNet™ network using a
DeviceNet Interface (catalog number 1761-NET-DNI). The controller can
also be connected to Modbus™ SCADA networks as an RTU slave. Refer
to Communication Connections on page 4-1 for more information on
connecting to the available communication options.
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Hardware Overview
Publication 1762-UM001A-US-P
Chapter
2
Installing Your Controller
This chapter shows you how to install your controller. The only tools you
require are a flat or Phillips head screwdriver and drill. Topics include:
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Agency Certifications
1
agency certifications
compliance to European Union Directives
installation considerations
safety considerations
power considerations
preventing excessive heat
master control relay
installing the memory module and/or real-time clock
controller mounting dimensions
controller and expansion I/O spacing
mounting the controller
mounting 1762 expansion I/O
connecting expansion I/O
• UL 508
• C-UL under CSA C22.2 no. 142
• Class I, Division 2, Groups A, 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.
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Installing Your Controller
Compliance to European
Union Directives
This product has the CE 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 Council Directive 89/336/EEC Electromagnetic
Compatibility (EMC) and the following standards, in whole or in part,
documented in a technical construction file:
• EN 50081-2
EMC - Generic Emission Standard, Part 2 - Industrial Environment
• EN 50082-2
EMC - Generic Immunity Standard, Part 2 - Industrial Environment
This product is intended for use in an industrial environment.
Low Voltage Directive
This product is tested to meet Council Directive 73/23/EEC Low Voltage, by
applying the safety requirements of EN 61131-2 Programmable Controllers,
Part 2 - Equipment Requirements and Tests.
For specific information required by EN 61131-2, see the appropriate sections
in this publication, as well as the following Allen-Bradley publications:
• Industrial Automation Wiring and Grounding Guidelines for Noise
Immunity, publication 1770-4.1
• Guidelines for Handling Lithium Batteries, publication AG-5.4
• Automation Systems Catalog, publication B111
Publication 1762-UM001A-US-P
Installing Your Controller
Installation Considerations
2-3
Most applications require installation in an industrial enclosure (Pollution
Degree 2(1)) to reduce the effects of electrical interference (Over Voltage
Category II(2)) 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 more information
on proper grounding guidelines, see the Industrial Automation Wiring and
Grounding Guidelines publication 1770-4.1.
ATTENTION
Vertical mounting of the controller is not recommended
due to heat build-up considerations.
!
ATTENTION
!
Be careful of metal chips when drilling mounting holes for
your controller or other equipment within the enclosure or
panel. Drilled fragments that fall into the controller or I/O
modules could cause damage. Do 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 environment 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.
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Installing Your Controller
Safety Considerations
Safety considerations are an important element of proper system installation.
Actively thinking about the safety of yourself and others, as well as the
condition of your equipment, is of primary importance. We recommend
reviewing the following safety considerations.
Hazardous Location Considerations
This equipment is suitable for use in Class I, Division 2, Groups A, B, C, D or
non-hazardous locations only. The following WARNING statement applies to
use in hazardous locations.
WARNING
!
EXPLOSION HAZARD
• Substitution of components may impair suitability for
Class I, 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.
• 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.
• All wiring must comply with N.E.C. article 501-4(b).
Use only the following communication cables in Class I, Division 2 hazardous
locations.
Environment Classification
Communication Cables
Class I, Division 2 Hazardous
Environment
1761-CBL-PM02 Series C or later
1761-CBL-HM02 Series C or later
1761-CBL-AM00 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
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Installing Your Controller
2-5
Disconnecting Main Power
WARNING
Explosion Hazard - Do not replace components or
disconnect equipment unless power has been switched off.
!
The main power disconnect switch should be located where operators and
maintenance personnel have quick and easy access to it. In addition to
disconnecting electrical power, all other sources of power (pneumatic and
hydraulic) should be de-energized before working on a machine or process
controlled by a controller.
Safety Circuits
WARNING
Explosion Hazard - Do not connect or disconnect
connectors while circuit is live.
!
Circuits installed on the machine for safety reasons, like overtravel limit
switches, stop push buttons, and interlocks, should always be hard-wired
directly to the master control relay. These devices must be wired in series so
that when any one device opens, the master control relay is de-energized,
thereby removing power to the machine. Never alter these circuits to defeat
their function. Serious injury or machine damage could result.
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Installing Your Controller
Power Distribution
There are some points about power distribution that you should know:
• The master control relay must be able to inhibit all machine motion by
removing power to the machine I/O devices when the relay is
de-energized. It is recommended that the controller remain powered
even when the master control relay is de-energized.
• If you are using a dc power supply, interrupt the load side rather than the
ac line power. This avoids the additional delay of power supply turn-off.
The dc power supply should be powered directly from the fused
secondary of the transformer. Power to the dc input and output circuits
should be connected through a set of master control relay contacts.
Periodic Tests of Master Control Relay Circuit
Any part can fail, including the switches in a master control relay circuit. The
failure of one of these switches would most likely cause an open circuit, which
would be a safe power-off failure. However, if one of these switches shorts out,
it no longer provides any safety protection. These switches should be tested
periodically to assure they will stop machine motion when needed.
Power Considerations
The following explains power considerations for the micro controllers.
Isolation Transformers
You may want to use an isolation transformer in the ac line to the controller.
This type of transformer provides isolation from your power distribution
system to reduce the electrical noise that enters the controller and is often used
as a step-down transformer to reduce line voltage. Any transformer used with
the controller must have a sufficient power rating for its load. The power rating
is expressed in volt-amperes (VA).
Power Supply Inrush
During power-up, the MicroLogix 1200 power supply allows a brief inrush
current to charge internal capacitors. Many power lines and control
transformers can supply inrush current for a brief time. If the power source
cannot supply this inrush current, the source voltage may sag momentarily.
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Installing Your Controller
2-7
The only effect of limited inrush current and voltage sag on the MicroLogix
1200 is that the power supply capacitors charge more slowly. However, 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.
The following considerations determine whether the power source must be
required to supply high inrush current:
• The power-up sequence of devices in a system.
• The amount of the power source voltage sag if the inrush current cannot
be supplied.
• The effect of voltage sag on other equipment in the system.
If the entire system is powered-up at the same time, a brief sag in the power
source voltage typically will not affect any equipment.
Loss of Power Source
The power supply is designed to withstand brief power losses without affecting
the operation of the system. The time the system is operational during power
loss is called “program scan hold-up time after loss of power.” The duration of
the power supply hold-up time depends on the type and state of the I/O, but is
typically between 10 milliseconds and 3 seconds. When 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. The 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 “On” 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. The user program should be written
to take this effect into account.
Other Types of Line Conditions
Occasionally the power source to the system can be temporarily interrupted. It
is also possible that the voltage level may drop substantially below the normal
line voltage range for a period of time. Both of these conditions are considered
to be a loss of power for the system.
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2-8
Installing Your Controller
Preventing Excessive Heat
For most applications, normal convective cooling keeps the controller within
the specified operating range. Ensure that the specified temperature range is
maintained. Proper spacing of components within an enclosure is usually
sufficient for heat dissipation.
In some applications, a substantial amount of heat is produced by other
equipment inside or outside the enclosure. In this case, place blower fans inside
the enclosure to assist in air circulation and to reduce “hot spots” near the
controller.
Additional cooling provisions might be necessary when high ambient
temperatures are encountered.
NOTE
Master Control Relay
A hard-wired master control relay (MCR) provides a reliable means for
emergency machine shutdown. Since the master control relay allows the
placement of several emergency-stop switches in different locations, its
installation is important from a safety standpoint. Overtravel limit switches or
mushroom-head push buttons are wired in series so that when any of them
opens, the master control relay is de-energized. This removes power to input
and output device circuits. Refer to the figures on pages 2-11 and 2-12.
ATTENTION
!
Publication 1762-UM001A-US-P
Do not bring in unfiltered outside air. Place the controller
in an enclosure to protect it from a corrosive atmosphere.
Harmful contaminants or dirt could cause improper
operation or damage to components. In extreme cases, you
may need to use air conditioning to protect against heat
build-up within the enclosure.
Never alter these circuits to defeat their function since
serious injury and/or machine damage could result.
Installing Your Controller
NOTE
2-9
If you are using an external dc power supply, interrupt the
dc output side rather than the ac line side of the supply to
avoid the additional delay of power supply turn-off.
The ac line of the dc output power supply should be fused.
Connect a set of master control relays in series with the dc
power supplying the input and output circuits.
Place the main power disconnect switch where operators and maintenance
personnel have quick and easy access to it. If you mount a disconnect switch
inside the controller enclosure, place the switch operating handle on the
outside of the enclosure, so that you can disconnect power without opening
the enclosure.
Whenever any of the emergency-stop switches are opened, power to input and
output devices should be removed.
When you use the master control relay to remove power from the external I/O
circuits, power continues to be provided to the controller’s power supply so
that diagnostic indicators on the processor can still be observed.
The master control relay is not a substitute for a disconnect to the controller. It
is intended for any situation where the operator must quickly de-energize I/O
devices only. When inspecting or installing terminal connections, replacing
output fuses, or working on equipment within the enclosure, use the
disconnect to shut off power to the rest of the system.
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-UM001A-US-P
2-10
Installing Your Controller
Using Emergency-Stop Switches
When using emergency-stop switches, adhere to the following points:
• Do not program emergency-stop switches in the controller program.
Any emergency-stop switch should turn off all machine power by
turning off the master control relay.
• Observe all applicable local codes concerning the placement and labeling
of emergency-stop switches.
• Install emergency-stop switches and the master control relay in your
system. Make certain that relay contacts have a sufficient rating for your
application. Emergency-stop switches must be easy to reach.
• In the following illustration, input and output circuits are shown with
MCR protection. However, in most applications, only output circuits
require MCR protection.
The following illustrations show the Master Control Relay wired in a grounded
system.
NOTE
Publication 1762-UM001A-US-P
In most applications input circuits do not require MCR
protection; however, if you need to remove power from all
field devices, you must include MCR contacts in series with
input power wiring.
Installing Your Controller
2-11
Schematic (Using IEC Symbols)
L1
L2
230V ac
Disconnect
MCR
Fuse
230V ac
I/O
Circuits
Isolation
Transformer
X1 115V ac
or 230V ac
Fuse
X2
Operation of either ofthese contacts will
remove power from the external I/O
circuits, stopping machine motion.
Emergency-Stop
Push Button
Overtravel
Limit Switch
Stop
Start
Master Control Relay (MCR)
Cat. No. 700-PK400A1
Suppressor
Cat. No. 700-N24
MCR
Suppr.
MCR
MCR
115V ac or
230V ac
I/O Circuits
dc Power Supply.
Use IEC 950/EN 60950
_
+
(Hi)
(Lo)
Line Terminals: Connect to terminals of
Power Supply (1762-24AWA and
1762-24BWA).
MCR
24V dc
I/O
Circuits
Line Terminals: Connect to 24V dc
terminals of Power Supply.
Publication 1762-UM001A-US-P
2-12
Installing Your Controller
Schematic (Using ANSI/CSA Symbols)
L1
230V ac
L2
Disconnect
MCR
Fuse
Isolation
Transformer
X1
115V ac or
X2
230V ac
Fuse
Operation of either of these contacts will
remove power from the external I/O
circuits, stopping machine motion.
Emergency-Stop
Push Button
Overtravel
Limit Switch
230V ac
Output
Circuits
Master Control Relay (MCR)
Cat. No. 700-PK400A1
Suppressor
Cat. No. 700-N24
Start
Stop
MCR
Suppr.
MCR
MCR
dc Power Supply. Use
NEC Class 2 for UL
Listing.
_
(Lo)
(Hi)
Line Terminals:
Connect to 1762-24AWA
or 1762-24BWA terminals.
Publication 1762-UM001A-US-P
+
115V ac or
230V ac
I/O Circuits
MCR
Line Terminals: Connect to 24V
dc terminals of Power Supply.
24 V dc
I/O
Circuits
Installing Your Controller
Installing a Memory
Module and/or Real-Time
Clock
2-13
1. Remove the memory module port cover.
2. Align the connector on the memory module with the connector pins on
the controller.
3. Firmly seat the memory module into the controller.
Publication 1762-UM001A-US-P
2-14
Installing Your Controller
Controller Mounting
Dimensions
C
C
A
A
B
B
1762-L24AWA, 1762-L24BWA
1762-L40AWA, 1762-L40BWA
Table 2.1
Dimension
Controller and
Expansion I/O Spacing
1762-L24AWA
1762-L24BWA
1762-L40AWA
A
90 mm (3.5 in.)
90 mm (3.5 in.)
B
110 mm (4.33 in.)
160 mm (6.30 in.)
C
87 mm (3.43 in.)
87 mm (3.43 in.)
The controller mounts horizontally, with the expansion I/O extending to the
right of the controller. Allow 50 mm (2 in.) of space on all sides of the
controller system for adequate ventilation. Maintain spacing from enclosure
walls, wireways, adjacent equipment, etc., as shown below.
Bottom
1762 I/O
MicroLogix
1200
1762 I/O
Side
1762 I/O
Top
Publication 1762-UM001A-US-P
1762-L40BWA
Side
Installing Your Controller
Mounting the 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 Over Voltage Category II(2) (IEC
60664-1).(3)
ATTENTION
!
Do not remove the protective debris shield until after the
controller and all other equipment in the panel near the
controller are mounted and wiring is complete. Once
wiring is complete, remove protective debris shield. Failure
to remove shield before operating can cause overheating.
debris shield
ATTENTION
!
Electrostatic discharge can damage semiconductor device
inside the controller. Do 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 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 product’s insulation.
(3) Pollution Degree 2 and Over Voltage Category II are International Electrotechnical Commission (IEC)
designations.
Publication 1762-UM001A-US-P
2-16
Installing Your Controller
DIN Rail Mounting
The maximum extension of the latch is 14 mm (0.55 in.) in the open position.
A flat-blade screwdriver is required for removal of the controller. The controller
can be mounted to EN50022-35x7.5 or EN50022-35x15 DIN rails. DIN rail
mounting dimensions are shown below.
B
A
C
Table 2.2 Controller Dimensions
Dimension
Height
A
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. (Make sure that the placement of the controller
on the DIN rail meets the recommended spacing requirements,
see Controller and Expansion I/O Spacing on page 2-14. Refer to the
mounting template inside the back cover of this document.)
2. Close the DIN latch, if it is open.
3. Hook the top slot over the DIN rail.
4. While pressing the controller down against the top of the rail, snap the
bottom of the controller into position.
5. Leave the protective debris shield attached until you are finished wiring
the controller and any other devices.
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Installing Your Controller
2-17
To remove your controller from the DIN rail:
1. Place a flat-blade screwdriver in the DIN rail latch at the bottom of the
controller.
2. Holding the controller, pry downward on the latch until the latch locks
in the open position.
3. Repeat steps 1 and 2 for the second DIN rail latch.
4. Unhook the top of the DIN rail slot from the rail.
open
closed
Panel Mounting
Mount to panel using #8 or M4 screws. To install your controller using
mounting screws:
1. Remove the mounting template from inside the back cover of the
MicroLogix 1200 Programmable Controllers Installation Instructions,
publication 1762-IN006A-ML-P.
2. Secure the template to the mounting surface. (Make sure your controller
is spaced properly. See Controller and Expansion I/O Spacing on page
2-14.)
3. Drill holes through the template.
4. Remove the mounting template.
Publication 1762-UM001A-US-P
2-18
Installing Your Controller
5. Mount the controller.
6. Leave the protective debris shield in place until you are finished wiring
the controller and any other devices.
Debris Shield
Mounting Template
Mounting 1762
Expansion I/O
ATTENTION
!
During panel or DIN rail mounting of all devices, be sure
that all debris (metal chips, wire stands, etc.) is kept from
falling into the module. Debris 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 x 15 mm (EN 50 022 - 35 x 15).
Before mounting the module on a DIN rail, close the DIN rail latch. Press the
DIN rail mounting area of the module against the DIN rail. The latch
momentarily opens and locks into place.
Use DIN rail end anchors (Allen-Bradley part number 1492-EA35 or
1492-EAH35) for vibration or shock environments. The following illustration
shows the location of the end anchors.
Publication 1762-UM001A-US-P
Installing Your Controller
2-19
End Anchor
End Anchor
NOTE
1762 expansion I/O 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. The
preferred mounting method is to use two M4 or #8 panhead screws per
module. M3.5 or #6 panhead screws may also be used, but a washer is needed
to ensure a good ground current. Mounting screws are required on every
module.
For more than 2 modules: (number of modules - 1) x 40 mm (1.58 in.)
MicroLogix 1200
Expansion I/O
MicroLogix 1200
Expansion I/O
100 90
(3.94) (3.54)
40.4
(1.59)
MicroLogix 1200
Expansion I/O
14.5
(0.57)
MicroLogix 1200
Controller
NOTE: All
dimensions are in
mm (inches). Hole
spacing tolerance:
±0.4 mm
(0.016 in.).
40.4
(1.59)
Publication 1762-UM001A-US-P
2-20
Installing Your Controller
Connecting Expansion I/O
The expansion I/O module is attached to the controller or another I/O module
by means of a flat ribbon cable after mounting, as shown below.
Pull Loop
NOTE
ATTENTION
!
WARNING
!
Publication 1762-UM001A-US-P
Use the pull loop on the connector to disconnect modules.
Do not pull on the ribbon cable.
Remove power before removing or inserting an I/O
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:
• sending an erroneous signal to your system’s field
devices, causing the controller to fault
• 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 I, Division 2 applications, the bus connector must
be fully seated and the bus connector cover must be
snapped in place.
In Class I, 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
be installed ahead of the controller and after the last
1762 I/O module.
Chapter
3
Wiring Your Controller
This chapter describes how to wire your controller and expansion I/O. Topics
include:
•
•
•
•
•
•
•
Wiring Requirements
wire requirements
using surge suppressors
grounding the controller
wiring diagrams
sinking and sourcing wiring diagrams
controller I/O wiring
expansion I/O wiring
Wiring Recommendation
ATTENTION
Before you install and wire any device, disconnect power to
the controller system.
!
ATTENTION
!
Calculate the maximum possible current in each power and
common wire. Observe all electrical codes dictating the
maximum current allowable for each wire size. Current
above the maximum ratings may cause wiring to overheat,
which can cause damage.
United States Only: If the controller is installed within a
potentially hazardous environment, all wiring must comply
with the requirements stated in the National Electrical
Code 501-4 (b).
• Allow for at least 50 mm. (2 in.) between I/O wiring ducts or terminal
strips and the controller.
• Route incoming power to the controller by a path separate from the
device wiring. Where paths must cross, their intersection should be
perpendicular.
1
Publication 1762-UM001A-US-P
3-2
Wiring Your Controller
NOTE
Do not run signal or communications wiring and power
wiring in the same conduit. Wires with different signal
characteristics should be routed by separate paths.
• Separate wiring by signal type. Bundle wiring with similar electrical
characteristics together.
• Separate input wiring from output wiring.
• Label wiring to all devices in the system. Use tape, shrink-tubing, or
other dependable means for labeling purposes. In addition to labeling,
use colored insulation to identify wiring based on signal characteristics.
For example, you may use blue for dc wiring and red for ac wiring.
Table 3.1 Wire Requirements
Wire Type
Wire Size (2 wire maximum per terminal
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-lb) rated
Wiring without Spade Lugs
When 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
Publication 1762-UM001A-US-P
Wiring Your Controller
3-3
Wiring with Spade Lugs
The diameter of the terminal screw head is 5.5 mm (0.220 in.). The input and
output terminals of the MicroLogix 1200 controller are designed for a 6.35mm
(0.25 in.) wide spade (standard for #6 screw for up to 14 AWG) or a 4 mm
(metric #4) fork terminal.
When using spade lugs, use a small, flat-blade screwdriver to pry the finger-safe
cover from the terminal blocks as shown below. Then loosen the terminal
screw.
Using Surge Suppressors
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 directly across the coil of an inductive device, you
prolong the life of the output or relay contacts. You also reduce the effects of
voltage transients and electrical noise from radiating into adjacent systems.
Publication 1762-UM001A-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
ac or dc
Outputs
Suppression
Device
VAC/DC
Out 0
Out 1
Out 2
Out 3
Out 4
Out 5
Out 6
Out 7
COM
Load
dc COM or L2
If the outputs are dc, we recommend that you use an 1N4004 diode for surge
suppression, as shown below.
+24V dc
VAC/DC
Out 0
Out 1
Out 2
Relay or Solid
Out 3
State dc Outputs Out 4
Out 5
Out 6
Out 7 24V dc common
COM
IN4004 Diode
Suitable surge suppression methods for inductive ac load devices include a
varistor, an RC network, or an Allen-Bradley surge suppressor, all shown below.
These components must be appropriately rated to suppress the switching
transient characteristic of the particular inductive device. See the table on
page 3-5 for recommended suppressors.
Surge Suppression for Inductive ac Load Devices
Output Device
Output Device
Output Device
Surge
Suppressor
Varistor
Publication 1762-UM001A-US-P
RC Network
Wiring Your Controller
3-5
For inductive dc load devices, a diode is suitable. A 1N4004 diode is acceptable
for most applications. A surge suppressor can also be used. See 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
_
+
Output Device
Diode
(A 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 Motor Starter
Bulletin 509 Motor Starter
120V ac
240V ac
599-K04
599-KA04
Bulletin 100 Contactor
Bulletin 100 Contactor
120V ac
240V ac
199-FSMA1
199-FSMA2
Bulletin 709 Motor Starter
120V ac
1401-N10
Bulletin 700 Type R, RM Relays
ac coil
None Required
Bulletin 700 Type R Relay
Bulletin 700 Type RM Relay
12V dc
12V dc
700-N22
700-N28
Bulletin 700 Type R Relay
Bulletin 700 Type RM Relay
24V dc
24V dc
700-N10
700-N13
Bulletin 700 Type R Relay
Bulletin 700 Type RM Relay
48V dc
48V dc
700-N16
700-N17
Bulletin 700 Type R Relay
Bulletin 700 Type RM Relay
115-125V dc
115-125V dc
700-N11
700-N14
Bulletin 700 Type R Relay
Bulletin 700 Type RM Relay
230-250V dc
230-250V dc
700-N12
700-N15
Bulletin 700 Type N, P, or PK Relay
150V max, ac or DC
700-N24
Miscellaneous electromagnetic
devices limited to 35 sealed VA
150V max, ac or DC
700-N24
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3-6
Wiring Your Controller
Grounding the Controller
In solid-state control systems, grounding and wire routing helps limit the
effects of noise due to electromagnetic interference (EMI). 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 AWG #14 wire. This
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 the Industrial Automation Wiring and Grounding
Guidelines, 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
ATTENTION
!
Publication 1762-UM001A-US-P
Remove the protective debris strip before applying power to
the controller. Failure to remove the strip may cause the
controller to overheat.
Wiring Your Controller
Wiring Diagrams
3-7
The following illustrations show the wiring diagrams for the MicroLogix 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 Wiring Diagrams on page 3-10
The controller terminal block layouts are shown below. The shading on the
labels indicates how the terminals are grouped. A detail of the groupings is
shown in the table following the terminal block layouts.
NOTE
This
symbol denotes a protective earth ground terminal
which provides a low impedance path between electrical
circuits and earth for safety purposes and provides noise
immunity improvement. This connection must be made
for safety purposes.
Terminal Block Layouts
Figure 3.1 1762-L24AWA
Group 0
NC
Inputs
Outputs
IN 0
Group 1
COM
1
IN 2
IN 5
NC
COM
0
VAC
L1
VAC OUT 0 OUT 1 OUT 2
NEUT
IN 1
VAC
DC 0
IN 3
VAC
DC 1
IN 4
IN 7
IN 6
IN 9
IN 11
IN 8 IN 10
IN 13
IN 12
VAC OUT 5 OUT 6 OUT 8
DC3
VAC OUT 3 OUT 4 VAC OUT 7 OUT 9
DC 2
DC 4
G ro
G ro
G ro
G ro
G ro
4
up
3
up
2
up
1
up
0
up
Publication 1762-UM001A-US-P
3-8
Wiring Your Controller
The 24V 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 Master
Control Relay on page 2-8 for information on MCR wiring
in output circuits.
ATTENTION
!
Figure 3.2 1762-L24BWA
Group 0
+24
VDC
Inputs
IN 0
24 COM
COM
0
Group 1
COM
1
IN 2
IN 1
IN 3
IN 5
IN 4
IN 6
VAC VAC
L1 NEUT OUT 0 OUT 1 OUT 2
Outputs
VAC VAC
DC 0 DC 1
IN 7
IN 9 IN 11
IN 8
IN 10
IN 13
IN 12
VAC
DC 3 OUT 5 OUT 6 OUT 8
VAC
VAC
OUT 7 OUT 9
OUT 3 OUT 4
DC 2
DC 4
up
G ro
up
G ro
up
G ro
up
G ro
up
G ro
4
3
2
1
0
Figure 3.3 1762-L40AWA
Group 0
NC
Inputs
NC
IN 0
Group 1
COM
1
IN 2
COM
0
IN 1
IN 3
VAC
L1
VAC
NEUT
OUT
0
Outputs
VAC
DC 0
Group 2
IN 5
IN 7
IN 8
IN 10
IN 12
IN 14
IN 16
IN 18
IN 20
IN 22
IN 4
COM
IN 6
2
IN 9 IN 11
IN 13
IN 15
IN 17
IN 19
IN 21
OUT
1
OUT
2
OUT
5
OUT
8
OUT
10
VAC
DC 5
OUT
13
OUT
15
VAC
DC 1
VAC
DC 2
VAC
DC 3
OUT
3
OUT
4
OUT
7
OUT
6
VAC
DC 4
OUT
9
OUT
12
IN 16
IN 18
OUT
14
5
up
G ro
4
up
G ro
3
up
G ro
2
up
G ro
1
up
G ro
0
up
G ro
OUT
11
IN 23
Figure 3.4 1762-L40BWA
Group 0
Inputs
+24
VDC
24
COM
COM
0
Outputs
IN 0
IN 2
IN 1
VAC VAC
L1 NEUT
COM
1
IN 5
IN 3
OUT
0
VAC
DC 0
IN 4
OUT
1
VAC
DC 1
IN 7
IN 6
OUT
2
VAC
DC 2
OUT
3
IN 8 IN 10
COM
2
VAC
DC 3
IN 9
OUT
5
OUT
4
IN 12
IN 11
OUT
7
OUT
6
IN 13
OUT
8
VAC
DC 4
IN 14
IN 15
OUT
10
OUT
9
IN 17
VAC
DC 5
OUT
11
IN 20 IN 22
IN 19
IN 21 IN 23
OUT
15
OUT
13
OUT OUT
12
14
G ro
G ro
G ro
G ro
G ro
G ro
5
up
4
up
3
up
2
up
1
up
0
up
Publication 1762-UM001A-US-P
Group 2
Group 1
Wiring Your Controller
3-9
Terminal Groupings
Table 3.3 Input Terminal Grouping
Controller
1762-L24BWA
1762-L24AWA
1762-L40BWA
1762-L40AWA
Inputs
Input Group Common
Terminal
Group 0
DC COM 0
Group 1
DC COM 1
Group 0
AC COM 0
Group 1
AC COM 1
Group 0
DC COM 0
Group 1
DC COM 1
Group 2
DC COM 2
Group 0
AC COM 0
Group 1
AC COM 1
Group 2
AC COM 2
Input Terminal
I/0 through I/3
I/4 through I/13
I/0 through I/3
I/4 through I/13
I/0 through I/3
I/4 through I/7
I/8 through I/23
I/0 through I/3
I/4 through I/7
I/8 through I/23
Table 3.4 Output Terminal Grouping
Controller
1762-L24BWA
1762-L24AWA
1762-L40BWA
1762-L40AWA
Output
Group
Group 0
Group 1
Group 2
Group 3
Group 4
Group 0
Group 1
Group 2
Group 3
Group 4
Group 0
Group 1
Group 2
Group 3
Group 4
Group 5
Group 0
Group 1
Group 2
Group 3
Group 4
Group 5
Outputs
Voltage
Terminal
VAC/VDC 0
VAC/VDC 1
VAC/VDC 2
VAC/VDC 3
VAC/VDC 4
VAC/VDC 0
VAC/VDC 1
VAC/VDC 2
VAC/VDC 3
VAC/VDC 4
VAC/VDC 0
VAC/VDC 1
VAC/VDC 2
VAC/VDC 3
VAC/VDC 4
VAC/VDC 5
VAC/VDC 0
VAC/VDC 1
VAC/VDC 2
VAC/VDC 3
VAC/VDC 4
VAC/VDC 5
Output Terminal
O/0
O/1
O/2 through O/3
O/4 through O/5
O/6 through O/9
O/0
O/1
O/2 through O/3
O4 through O/5
O/6 through O/9
O/0
O/1
O/2 through O/3
O/4 through O/7
O/8 through O/11
O/12 through O/15
O/0
O/1
O/2 through O/3
O/4 through O/7
O/8 through O/11
O/12 through O/15
Publication 1762-UM001A-US-P
3-10
Wiring Your Controller
Sinking and Sourcing
Wiring Diagrams
Any of the MicroLogix 1200 DC embedded input groups can be configured as
sinking or sourcing depending on how the DC COM is wired on the group.
Refer to pages 3-11 through 3-13 for sinking and sourcing wiring diagrams.
Type
Definition
Sinking Input
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 Master Control
Relay on page 2-8 for information on MCR wiring in
output circuits.
1762-L24AWA and 1762-L24BWA Wiring Diagrams
Figure 3.5 1762-L24AWA Input Wiring Diagram(1)
NC
NC
COM
0
IN 0
IN 2
IN 1
COM
1
IN 3
IN 5
IN 4
L2
L1
(1)
Publication 1762-UM001A-US-P
“NC” terminals are not intended for use as connection points.
IN 7
IN 6
IN 9
IN 11
IN 8 IN 10
IN 13
IN 12
Wiring Your Controller
3-11
Figure 3.6 1762-L24BWA Sinking Input Wiring Diagram
-DC +DC Second Power Source
24V User Power
+24
VDC
IN 0
24
COM COM 0
IN 2 COM 1
IN 1
IN 3
IN 5
IN 4
IN 7
IN 6
IN 9 IN 11
IN 8
IN 10
IN 13
IN 12
Figure 3.7 1762-L24BWA Sourcing Input Wiring Diagram
+DC
+24
VDC
IN 0
24
COM COM 0
IN 1
-DC
IN 2 COM 1
IN 3
IN 4
IN 5
IN 6
IN 7
IN 8
IN 9 IN 11
IN 10
IN 13
IN 12
Publication 1762-UM001A-US-P
3-12
Wiring Your Controller
Figure 3.8 1762-L24AWA and 1762-L24BWA Output Wiring Diagram
L2
CR
L1
VAC
L1
CR
VAC OUT 0 OUT 1 OUT 2 VAC OUT 5 OUT 6 OUT 8
DC 3
NEUT
VAC
DC 0
VAC
DC 1
VAC OUT 3 OUT 4 VAC OUT 7 OUT 9
DC 2
DC 4
CR
CR
1762-L40AWA and 1762-L40BWA Wiring Diagrams
Figure 3.9 1762-40AWA Input Wiring Diagram
NC
NC
L2
L1
Publication 1762-UM001A-US-P
IN 0
COM
0
IN 2
IN 1
COM
1
IN 3
IN 5
IN 4
IN 7
IN 6
IN 8
COM
2
IN 10
IN 12
IN 9 IN 11
IN 14
IN 13
IN 16
IN 15
IN 18
IN 17
IN 20
IN 19
IN 22
IN 21
IN 23
Wiring Your Controller
3-13
Figure 3.10 1762-L40BWA Sinking Input Wiring Diagram
-DC +DC
+24
VDC
IN 0
COM
24
0
COM
COM
1
IN 2
IN 1
IN 3
IN 5
IN 4
IN 7
IN 8
COM
2
IN 6
IN 10
IN 12
IN 9 IN 11
IN 14
IN 13
IN 16
IN 15
IN 18
IN 17
IN 20
IN 19
IN 22
IN 21
IN 23
Figure 3.11 1762-L40BWA Sourcing Input Wiring Diagram
+24
VDC
IN 0
COM
24
0
COM
IN 2
IN 1
+DC
-DC
COM
1
IN 5
IN 3
IN 4
IN 7
IN 8
COM
2
IN 6
IN 10
IN 12
IN 9 IN 11
IN 14
IN 13
IN 16
IN 15
IN 18
IN 17
IN 20
IN 19
IN 22
IN 21
IN 23
Figure 3.12 1762-L40AWA and 1762-L40BWA Output Wiring Diagram
L2
CR
L1
VAC VAC
L1 NEUT
OUT
0
VAC
DC 0
OUT
1
VAC
DC 1
OUT
2
VAC
DC 2
CR
CR
VAC
DC 3
OUT
3
CR
OUT
5
OUT
4
OUT
7
OUT
6
CR
OUT
8
VAC
DC 4
OUT
10
OUT
9
CR
VAC
DC 5
OUT
13
OUT
15
OUT
11
OUT OUT
12
14
CR
CR
Publication 1762-UM001A-US-P
3-14
Wiring Your Controller
Controller I/O Wiring
Minimizing Electrical Noise
Because of the variety of applications and environments where controllers are
installed and operating, it is impossible to ensure that all environmental noise
will be removed by input filters. To help reduce the effects of environmental
noise, install the MicroLogix 1200 system in a properly rated (i.e. NEMA)
enclosure. Make sure that the MicroLogix 1200 system is properly grounded.
A system may malfunction due to a change in the operating environment after
a period of time. We recommend periodically checking system operation,
particularly when new machinery or other noise sources are installed near the
Micrologix 1200 system.
Expansion I/O Wiring
Discrete Wiring Diagrams
The following illustrations show the discrete expansion I/O wiring diagrams.
Figure 3.13 1762-IA8 Wiring Diagram
L1
IN 0
IN 1
IN 2
IN 3
100/120V ac
IN 4
IN 5
IN 6
IN 7
L2
Publication 1762-UM001A-US-P
AC
COM
AC
COM
Common
connected
internally.
Wiring Your Controller
3-15
Figure 3.14 1762-IQ8 Wiring Diagram
+DC (sinking)
-DC (sourcing)
IN 0
IN 1
IN 2
IN 3
24V dc
IN 4
IN 5
IN 6
IN 7
DC
COM
DC
COM
-DC (sinking)
+DC (sourcing)
Common connected
internally.
Figure 3.15 1762-OW8 Wiring Diagram
L1
VAC-VDC 1
OUT 0
CR
L1
L2
OUT 1
CR
OUT3
CR
OUT 4
CR
L2
OUT 2
VAC-VDC2
CR
OUT 5
CR
OUT 6
OUT 7
Publication 1762-UM001A-US-P
3-16
Wiring Your Controller
Analog Wiring Diagrams
1762-IF2OF2 Wiring
The following illustrations show the analog expansion I/O wiring diagrams.
Figure 3.16 1762-IF2OF2 Terminal Block Layout
IN 0 (+)
IN 0 (-)
IN 1 (+)
IN 1 (-)
V Out 0
I Out 0
V Out 1
I Out 1
COM
Common connected
internally.
COM
Figure 3.17 Differential Sensor Transmitter Types
IN 0 (+)
Analog Sensor
IN 0 (-)
IN 1 (+)
IN 1 (-)
Load
I out 0
I out 1
V out 0
V out 1
COM
COM
Publication 1762-UM001A-US-P
Wiring Your Controller
3-17
Figure 3.18 Single-ended Sensor/Transmitter Types
Transmitter
Power
Supply
+
-
+
-
Module
IN +
IN COM
Transmitter
Supply
Power
Supply
Signal
+
-
Module
IN +
IN COM
Transmitter
Supply
Signal
Power
Supply
+
-
+
-
+
-
Module
IN +
IN COM
Publication 1762-UM001A-US-P
3-18
Wiring Your Controller
Publication 1762-UM001A-US-P
Chapter
4
Communication Connections
This chapter describes how to communicate to your control system. The
method you use and cabling required to connect your controller depends on
what type of system you are employing. This chapter also describes how the
controller establishes communication with the appropriate network. Topics
include:
•
•
•
•
•
•
Default Communication
Configuration
default communication configurations
using communications toggle push button
connecting to RS-232 port
connecting to DH485 network
connecting to AIC+
DeviceNet communications
The MicroLogix 1200 has the following default communication configuration.
NOTE
The default configuration is present when:
• The controller is powered-up for the first time.
• The communications toggle push button specifies
default communications (the DCOMM LED is on).
• An OS upgrade is completed.
Refer to Understanding 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
1
Publication 1762-UM001A-US-P
4-2
Communication Connections
Using the Communications
Toggle Push Button
The Communications Toggle Push Button is located on the processor under
the processor door (if installed), as shown below.
Use the Communications Toggle Push Button to change from the user-defined
communication configuration to the default communications mode and back.
The Default Communications (DCOMM) LED operates to show when the
controller is in the default communications mode (settings shown on
page 4-1).
0
1
0
1
COM
COM
Communications Toggle
Push Button
NOTE
Connecting to the RS-232
Port
There are two ways to connect the MicroLogix 1200 programmable controller
to your personal computer using the DF1 protocol: using a point-to-point
connection, or using a modem. Descriptions of these methods follow.
ATTENTION
!
Publication 1762-UM001A-US-P
The Communication Toggle Push Button must be pressed
and held for one second to activate.
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 is important 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.
Communication Connections
4-3
Table 4.2 Available Communication Cables
Communication Cables
Length
1761-CBL-PM02 Series C or later
2m (6.5 ft)
1761-CBL-HM02 Series C or later
2m (6.5 ft)
1761-CBL-AM00 Series C or later
45 cm (17.7 in)
1761-CBL-AP00 Series C or later
45 cm (17.7 in)
2707-NC8 Series B or later
2m (6.5 ft)
2707-NC9 Series B 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 MicroLogix 1200 programmable controller to your
personal computer using a serial cable (1762-CBL-PM02) from your personal
computer’s serial port to the controller, as shown below. The recommended
protocol for this configuration is DF1 Full-Duplex.
We recommend using an Advanced Interface Converter (AIC+), catalog
number 1761-NET-AIC, as your optical isolator, as shown below.
See page 4-11 for specific AIC+ cabling information.
Personal Computer
MicroLogix 1200
1761-CBL-AM00 or 1761-CBL-HM02
TERM
A
B
COM
SHLD
CHS GND
TX
TX
TX
PWR
DC SOURCE
CABLE
1747-CP3 or 1761-CBL-AC00
24V dc
MicroLogix 1200 provides power
to the AIC+ or an external power
supply may be used.
EXTERNAL
NOTE
Series C or higher cables are required.
Publication 1762-UM001A-US-P
4-4
Communication Connections
Using a Modem
You can use modems to connect a personal computer to one MicroLogix 1200
controller (using DF1 Full-Duplex protocol), to multiple controllers (using
DF1 Half-Duplex protocol), or Modbus RTU Slave protocol, as shown in the
following illustration. Do not attempt to use DH485 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
(straight-through)
Modem
MicroLogix 1200
Protocol Options
• DF1 Full-Duplex protocol (to 1 controller)
• DF1 Half-Duplex protocol (to multiple controllers)
• Modbus RTU Slave protocol
Optical Isolator
(recommended)
TERM
A
B
COM
SHLD
CHS GND
TX
TX
TX
PWR
DC SOURCE
CABLE
Modem
EXTERNAL
We recommend using an AIC+, catalog number 1761-NET-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.
24V dc
MicroLogix 1200 provides power to the AIC+ or
an external power supply may be used.
MicroLogix 1200
TERM
A
B
COM
SHLD
CHS GND
TX
TX
TX
1761-CBL-AM00 or 1761-CBL-HM02
Modem
PWR
DC SOURCE
CABLE
EXTERNAL
User-supplied modem cable
For additional information on connections using the AIC+, refer to the
Advanced Interface Converter (AIC+) User Manual, publication 1761-6.4.
NOTE
Publication 1762-UM001A-US-P
Series C or higher cables are required.
Communication Connections
4-5
Constructing Your Own Modem Cable
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 straight-through cable:
AIC+
Optical Isolator
Modem
9-Pin
25-Pin
9-Pin
3
TXD
TXD
2
3
2
RXD
RXD
3
2
5
GND
GND
7
5
1
CD
CD
8
1
4
DTR
DTR
20
4
6
DSR
DSR
6
6
8
CTS
CTS
5
8
7
RTS
RTS
4
7
Constructing Your Own Null Modem Cable
If you construct your own null 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:
Optical
Isolator
Modem
9-Pin
25-Pin
9-Pin
3
TXD
TXD
2
3
2
RXD
RXD
3
2
5
GND
GND
7
5
1
CD
CD
8
1
4
DTR
DTR
20
4
6
DSR
DSR
6
6
8
CTS
CTS
5
8
7
RTS
RTS
4
7
Publication 1762-UM001A-US-P
4-6
Communication Connections
Connecting to a DF1 Half-Duplex Network
Use this diagram for DF1 Half-Duplex Master-Slave protocol without
hardware handshaking.
SLC 5/03 processor
MicroLogix 1200
DF1
Master
CH0
(3)
(1)
(2)
(3)
radio modem
or lease line
CH0 to port 1
or port 2
0
1
straight 9-25
pin cable
MicroLogix 1200
CH0 to port 1
or port 2
1761-CBL-AP00 or
1761-CBL-PM02 to controller
DF1 Slave
(1)
(1)
radio
modem or
lease line
COM
(2)
(2)
AIC+
straight 9-25 pin cable
(3)
0
1
COM
1761-CBL-AM00 or 1761-CBL-HM02
1761-CBL-AP00 or 1761-CBL-PM02
DF1 Slave
MicroLogix 1200
0
1
COM
1761-CBL-AM00 or
1761-CBL-HM02 to
controller
DF1
Slave
(3)
1761-CBL-AM00 or
1761-CBL-HM02 to controller
AIC+
(1)
(2)
AIC+
DH485
DH485
NOTE
(1) DB-9 RS-232 port
(2) mini-DIN 8 RS-232 port
(3) RS-485 port
Publication 1762-UM001A-US-P
CH0
Series C or higher cables are required.
1761-CBL-AP00 or
1761-CBL-PM02 to
controller
Communication Connections
Connecting to a DH485
Network
4-7
The following illustration shows how to connect to a DH485 network.
MicroLogix DH485 Network
MicroLogix 1200
PC
connection from port 1 or
port 2 to MicroLogix
1761-CBL-AM00
or 1761-CBL-HM02
PC to port 1
or port 2
AIC+
(3)
(2)
TERM
A
1761-CBL-AP00
or 1761-CBL-PM02
B
COM
SHLD
CHS GND
TX
TX
(1)
TX
PWR
1761-CBL-AP00
or 1761-CBL-PM02
DC SOURCE
CABLE
EXTERNAL
AIC+
(3)
(2)
TERM
A
B
COM
SHLD
CHS GND
24V dc
(user supply needed if not
connected to a controller)
TX
TX
(1)
TX
PWR
DC SOURCE
CABLE
EXTERNAL
1747-CP3
or 1761-CBL-AC00
24V dc
(user supplied)
(1) DB-9 RS-232 port
(2) mini-DIN 8 RS-232 port
(3) RS-485 port
NOTE
Series C or higher cables are required.
Recommended Tools
To connect a DH485 network, you need tools to strip the shielded cable and to
attach the cable to the AIC+ Advanced Interface Converter. We recommend
the following equipment (or equivalent):
Table 4.3 Working with Cable for DH485 Network
Description
Part Number
Manufacturer
Shielded Twisted Pair Cable
#3106A or #9842
Belden
Stripping Tool
45-164
Ideal Industries
1/8” Slotted Screwdriver
Not Applicable
Not Applicable
Publication 1762-UM001A-US-P
4-8
Communication Connections
DH485 Communication Cable
The suggested DH485 communication cable is either Belden #3106A or
#9842. The cable is jacketed and shielded with one or two twisted-wire pairs
and a drain wire.
One pair provides a balanced signal line and one additional wire is used for a
common reference line between all nodes on the network. The 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. The total length of the cable segments cannot exceed
1219 m (4000 ft). However, two segments can be used to extend the DH485
network to 2438 m (8000 ft). For additional information on connections using
the AIC+, refer to the Advanced Interface Converter (AIC+) User Manual,
publication 1761-6.4.
When 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.
Use these instructions for wiring the Belden #3106A 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. Do not make
the incorrect connection shown below:
Belden #3106A
or #9842
Connector
Belden #3106A or Belden #3106A or
#9842
#9842
Connector
Connector
Incorrect
Publication 1762-UM001A-US-P
Communication Connections
4-9
Single Cable Connection
When connecting a single cable to the DH485 connector, use the following
diagram.
6 Termination
5A
4B
3 Common
2 Shield
1 Chassis Ground
Orange with White Stripes
White with Orange Stripes
Shrink Tubing Recommended
Blue (#3106A) or
Blue with White Drain Wire
Stripes (#9842)
Multiple Cable Connection
When connecting multiple cables to the DH485 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
White with Orange Stripe
Terminal 4 - (Data B)
Orange with White Stripe
Terminal 5 - (Data A)
Table 4.5 Connections using Belden #9842 Cable
For this Wire/Pair
Connect this Wire
To this Terminal
Shield/Drain
Non-jacketed
Terminal 2 - Shield
Blue/White
White with Blue Stripe
Cut back - no connection(1)
Blue with White Stripe
Terminal 3 - (Common)
White with Orange Stripe
Terminal 4 - (Data B)
Orange with White Stripe
Terminal 5 - (Data A)
White/Orange
(1) To prevent confusion when installing the communication 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-UM001A-US-P
4-10
Communication Connections
Grounding and Terminating the DH485 Network
Only one connector at the end of the link must have Terminals 1 and 2
jumpered together. This 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. This connects the termination impedance (of 120Ω) that is built
into each AIC+ as required by the DH485 specification.
End-of-Line Termination
Jumper
Jumper
Belden #3106A or #9842 Cable
1219 m (4000ft) Maximum
Jumper
Connecting the AIC+
The AIC+, catalog number 1761-NET-AIC, enables a MicroLogix 1200 to
connect to a DH485 network. The AIC+ has two RS-232 ports and one
isolated RS-485 port. Typically, there is one AIC+ for each MicroLogix 1200.
When two MicroLogix controllers are closely positioned, you can connect a
controller to each of the RS-232 ports on the AIC+.
The AIC+ can also be used as an RS-232 isolator, providing an isolation barrier
between the MicroLogix 1200 communications port and any equipment
connected to it (i.e. personal computer, modem, etc.).
Publication 1762-UM001A-US-P
Communication Connections
4-11
The following figure shows the external wiring connections and specifications
of the AIC+.
3
2
AIC+ Advanced Interface Converter
(1761-NET-AIC)
4
1
5
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 power source,
external = 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+) User Manual, publication 1761-6.4.
Cable Selection Guide
1761-CBL-PM02 (2)
1761-CBL-AP00(2)
Cable
Length
Connections from
to AIC+
External
Power Supply
Required(1)
Power
Selection
Switch
Setting(1)
1761-CBL-AP00(2)
1761-CBL-PM02(2)
45 cm (17.7 in)
2m (6.5 ft)
SLC 5/03 or SLC 5/04 processors, ch 0
port 2
yes
external
MicroLogix 1000, 1200, or 1500
port 1
yes
external
PanelView 550 through NULL modem
adapter
port 2
yes
external
DTAM Plus / DTAM Micro
port 2
yes
external
PC COM port
port 2
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.
Publication 1762-UM001A-US-P
4-12
Communication Connections
1761-CBL-HM02(2)
1761-CBL-AM00
(2)
Cable
Length
Connections from
to AIC+ External
Power Supply
Required(1)
Power
Selection
Switch Setting
1761-CBL-AM00(2)
1761-CBL-HM02(2)
45 cm (17.7 in)
2m (6.5 ft)
MicroLogix 1000, 1200, or 1500
port 2
no
cable
to port 2 on another AIC+
port 2
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.
1747-CP3
1761-CBL-AC00
Cable
Length
Connections from
to AIC+ External
Power Supply
Required(1)
Power
Selection
Switch
Setting(1)
1747-CP3
1761-CBL-AC00(1)
3m (9.8 ft)
45 cm (17.7 in)
SLC 5/03 or SLC 5/04 processor, channel 0 port 1
yes
external
PC COM port
port 1
yes
external
PanelView 550 through NULL modem
adapter
port 1
yes
external
DTAM Plus / DTAM Micro™
port 1
yes
external
Port 1 on another AIC+
port 1
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.
user-supplied cable
Cable
Length
Connections from
to AIC+ External
Power Supply
Required(1)
Power
Selection
Switch
Setting(1)
straight 9-25 pin
—
modem or other communication device
port 1
external
yes
(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 1762-UM001A-US-P
Communication Connections
4-13
1761-CBL-AS09
1761-CBL-AS03
Cable
Length
Connections from
to AIC+ External
Power Supply
Required(1)
Power
Selection
Switch
Setting(1)
1761-CBL-AS03
1761-CBL-AS09
3m (9.8 ft)
9.5m (31.17 ft)
SLC 500 Fixed,
SLC 5/01, SLC 5/02, and SLC 5/03
processors
port 3
yes
external
PanelView 550 RJ45 port
port 3
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.
1761-CBL-PM02 Series C (or equivalent) Cable Wiring Diagram
Programming
Device
Controller
9-Pin D-Shell
8-Pin Mini Din
9
RI
24V
1
8
CTS
GND
2
7
RTS
RTS
3
6
DSR
RXD
4
5
GND
DCD
5
4
DTR
CTS
6
3
TXD
TXD
7
2
RXD
GND
8
1
DCD
1761-CBL-PM02 Series C or later Cable
9
8
7
6
5
4
3
2
1
8-pin Mini Din
6 78
9-pin D-shell
3
4
5
12
Publication 1762-UM001A-US-P
4-14
Communication Connections
Recommended User-Supplied Components
These components can be purchased 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-CBL-AP00 or 1761-CBL-PM02
Port 1
DB-9 RS-232
7
1
2
8
3
4
9
5
6
Port 2
cable straight D connector
6 7 8
6
Port 3
RS-485 connector
5
4
3
5
3
4
1 2
2
1
Table 4.7 AIC+ Terminals
Pin Port 1: DB-9 RS-232
Port 3: RS-485
Connector
1
chassis ground
2
3
4
5
6
7
8
9
Port 2(2): (1761-CBL-PM02
cable)
received line signal detector 24V dc
(DCD)
received data (RxD)
ground (GND)
transmitted data (TxD)
request to send (RTS)
DTE ready (DTR)(1)
signal common (GND)
received data (RxD)(3)
received line signal detector
(DCD)
DCE ready (DSR)(2)
request to send (RTS)
clear to send (CTS)
not applicable
clear to send (CTS)(3)
transmitted data (TxD)
ground (GND)
not applicable
cable shield
signal ground
DH485 data B
DH485 data A
termination
not applicable
not applicable
not applicable
(1) On port 1, pin 4 is electronically jumpered to pin 6. Whenever the AIC+ is powered on, pin 4 will match the
state of pin 6.
(2) An 8-pin mini DIN connector is used for making connections to 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-PM02 cable, pins 4 and 6 are jumpered together within the DB-9 connector.
Publication 1762-UM001A-US-P
Communication Connections
4-15
Safety Considerations
This equipment is suitable for use in Class I, Division 2, Groups A, 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 Considerations 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 MicroLogix 1200 controller to the AIC+ does not
interfere with the enclosure door.
2. Carefully plug the terminal block into the RS-485 port on the AIC+ 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. This guards against breakage of the Belden cable wires.
Powering the AIC+
In normal operation with the MicroLogix 1200 programmable controller
connected to port 2 of the AIC+, the controller powers the 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-UM001A-US-P
4-16
Communication Connections
ATTENTION
If you use an 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 the AIC+. The following illustration shows where to
connect external power for the AIC+.
Bottom View
24VDC
DC
NEUT
CHS
GND
ATTENTION
!
Always connect the CHS GND (chassis ground) terminal
to the nearest earth ground. This connection must be made
whether or not an external 24V dc supply is used.
Power Options
Below are two options for powering the AIC+:
• Use the 24V dc user power supply built into the MicroLogix 1200
controller. The AIC+ is powered through a hard-wired connection using
a communication cable (1761-CBL-HM02, or equivalent) connected to
port 2.
• Use an external DC power supply with the following specifications:
– operating voltage: 24V dc +20% or -15%
– output current: 150 mA minimum
– rated NEC Class 2
Make a hard-wired connection from the external supply to the screw
terminals on the bottom of the AIC+.
ATTENTION
!
Publication 1762-UM001A-US-P
If you use an external power supply, it must be 24V dc.
Permanent damage results if miswired with the wrong
power source.
Communication Connections
DeviceNet Communications
4-17
You can connect a MicroLogix 1200 to a DeviceNet network using the
DeviceNet Interface (DNI), catalog number 1761-NET-DNI. For additional
information on using the DNI, refer to the DeviceNet Interface User Manual,
publication 1761-6.5. The following figure shows the external wiring
connections of the DNI.
V–
CAN_L
NET
SHIELD
CAN_H
V+
DeviceNet Node (Port 1)
(Replacement connector
part no. 1761-RPL-0000)
Use this write-on
area to mark the
DeviceNet node
address.
MOD
NODE
DANGER
TX/RX
GND
RS-232 (Port 2)
Cable Selection Guide(1)
1761-CBL-HM02
1761-CBL-AM00
Cable
Length
Connections from
to DNI
1761-CBL-AM00
1761-CBL-HM02
45 cm (17.7 in)
2m (6.5 ft)
MicroLogix 1000
port 2
MicroLogix 1200
port 2
1761-CBL-PM02 (2)
1761-CBL-AP00
Cable
Length
Connections from
to DNI
1761-CBL-AP00
1761-CBL-PM02
45 cm (17.7 in)
2m (6.5 ft)
SLC 5/03 or SLC 5/04 processors,
channel 0
port 2
PC COM port
port 2
(1) Series C (or higher) cables are required.
Publication 1762-UM001A-US-P
4-18
Communication Connections
Publication 1762-UM001A-US-P
Chapter
5
Using Trim Pots
Trim Pot Operation
The 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 (TPI) register.
The data 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.
The trim pots are located below the memory module port cover and to the
right of the communications port, as shown below.
Trim Pot 0
Trim Pot 1
0
1
COM
Use a small flathead screwdriver to turn the trim pots. Adjusting their value
causes data to change within a range of 0 to 250 (fully clockwise). The
maximum rotation of each trim pot is three-quarters, as shown below. Trim
pot stability over time and temperature is typically ±2 counts.
Maximum
(fully clockwise)
Minimum
(fully counterclockwise)
Trim pot file data is updated continuously whenever the controller is
powered-up.
1
Publication 1762-UM001A-US-P
5-2
Using Trim Pots
Trim Pot Information Function File
The composition of the Trim Pot Information (TPI) Function File is described
in the MicroLogix 1200 and 1500 Programmable Controllers Instruction Set
Reference Manual, publication 1762-RM001A-US-P.
Error Conditions
Error conditions of the TPI Function File are described in the MicroLogix 1200
and 1500 Programmable Controllers Instruction Set Reference Manual,
publication 1762-RM001A-US-P.
Publication 1762-UM001A-US-P
Chapter
6
Using Real-Time Clock and Memory Modules
NOTE
For more information on “Real-Time Clock Function File”
and “Memory Module Information File” please refer to the
MicroLogix 1200 and 1500 Programmable Controllers
Instruction Set Reference Manual, publication
1762-RM001A-US-P.
Three modules with different levels of functionality are available for use with
the MicroLogix 1200 controller.
Catalog Number
Function
1762-RTC
Real-Time Clock
1762-MM1
Memory Module
1762-MM1RTC
Memory Module and Real-Time Clock
Real-Time Clock Operation 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 (RTC) is present. If an RTC is present,
its values (date, time and status) are written to the RTC Function File in the
controller.
The RTC module can be installed or removed at any time without risk of
damage to either the module or the controller. If an RTC is installed while the
MicroLogix 1200 is in 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 the RTC during run mode is detected within one program scan.
Removal of the RTC while in run mode causes the controller to write zeros to
the RTC Function File.
The following table indicates the accuracy of the RTC for various
temperatures.
1
Publication 1762-UM001A-US-P
6-2
Using Real-Time Clock and Memory Modules
Table 6.1 RTC Accuracy
Ambient Temperature
Accuracy(1)
0°C (+32°F)
+34 to -70 seconds/month
+25°C (+77°F)
+36 to -68 seconds/month
+40°C (+104°F)
+29 to -75 seconds/month
+55°C (+131°F)
-133 to -237 seconds/month
(1)
These numbers are maximum worst case values over a 31-day month.
Writing Data to the Real-Time Clock
When valid data is sent to the real-time clock from the programming device or
another controller, the new values take effect immediately.
The 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. This decreases the drain on
the RTC battery during storage.
RTC Battery Operation
The real-time clock has an internal battery that is not replaceable. The RTC
Function File features a battery low indicator bit (RTC:0/BL), which shows the
status of the RTC battery. When the battery is low, the indicator bit is set (1).
This means that the battery may fail within 14 days and the real-time clock
module needs to be replaced. When 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 RTC operates
normally. If the controller power is removed and the RTC battery is low, RTC
data is lost.
Table 6.2 RTC Battery Life Span
Life Span
Operating Temperature
Storage Temperature(1)
5 years
+0°C to +40°C (+32°F to +104°F)
-40°C to +60°C (-40°F to +140°F)
(1)
Stored for six months.
ATTENTION
!
Publication 1762-UM001A-US-P
Operating 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
Memory Module Operation
6-3
The memory module supports program back-up as well as the following
features:
• User Program and Data Back-up
• User Program Compare
• Data File Download Protection
• Memory Module Write Protection
• Removal/Insertion Under Power
ATTENTION
Electrostatic discharge can damage the Memory Module.
Do not touch the connector pins or other sensitive areas.
!
User Program and Data Back-up
The memory 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.
The memory module can store one user program at a time.
During program transfers to or from the memory module, the controller’s
RUN LED flashes.
Program Compare
The memory 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 enable this feature, set the S:2/9 bit in the system status file. See
“Status System File” in the MicroLogix 1200 and 1500 Programmable
Controllers Instruction Set Reference Manual, Publication 1762-RM001A-US-P
for more information.
Publication 1762-UM001A-US-P
6-4
Using Real-Time Clock and Memory Modules
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. This allows user
data to be saved (not overwritten) during a download.
NOTE
Data 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 Data Files During
Download” in the MicroLogix 1200 and 1500
Programmable Controllers Instruction Set Reference Manual,
Publication 1762-RM001A-US-P.
Memory Module Write Protection
The memory module supports write-once, read-many behavior. Write
protection is enabled using your programming software.
IMPORTANT
Once set, write protection cannot be removed. A change
cannot be made to the control program stored in a write
protected memory module. If a change is required, use a
different memory module.
Removal/Insertion Under Power
The memory module can be installed or removed at any time without risk of
damage to either the memory module or the controller. If a memory module is
installed while the MicroLogix 1200 is executing, the memory 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).
Publication 1762-UM001A-US-P
Appendix
A
Specifications
Table A.1 General Specifications
1
Description
1762-L24AWA 1762-L24BWA
1762-L40AWA 1762-L40BWA
Dimensions
Height: 90 mm (3.55 in)
104 mm (4.10 in)
(with DIN latch open)
Width: 110 mm (4.33 in)
Depth: 87 mm (3.43 in)
Height: 90 mm (3.55 in)
104 mm (4.10 in)
(with DIN latch open)
Width: 160 mm (6.30 in)
Depth: 87 mm (3.43 in)
Shipping
Weight
0.9 kg (2.0 lb)
1.1 kg (2.4 lb)
Number of I/O
14 inputs
10 outputs
14 inputs
10 outputs
24 inputs
16 outputs
24 inputs
16 outputs
Line Power
85 to 265V ac
at 47 to 63 Hz
85 to 265V ac at
47 to 63 Hz
85 to 265V ac
at 47 to 63 Hz
85 to 265V ac at
47 to 63 Hz
Power Supply
Nominal
100/120V ac
200/240 V ac
Power Supply
Usage
68 VA
70 VA
80 VA
82 VA
Power Supply
Inrush
120V ac = 25A for 8 ms
240V ac = 40A for 4 ms
Heat
Dissipation
Refer to Calculating Heat Dissipation on page F-9
Power Supply
Output
400 mA at 5V
350 mA at 24V
400 mA at 5V(1) 600 mA at 5V
500 mA at 24V
350 mA at 24V(1)
User Power
Output
none
24V dc at 250
mA(1)
400 µF max.
none
24V dc at 400
mA(2)
400 µF max.
Input Circuit
Type
120V ac
24V dc
sink/source
120V ac
24V dc
sink/source
Output Circuit
Type
Relay
Relay
Relay
Relay
Operating
Temperature
+0°C to +55°C (+32°F to +131°F) ambient
Storage
Temperature
-40°C to +85°C (-40°F to +185°F) ambient
Operating
Humidity
5% to 95% relative humidity (non-condensing)
Vibration
Operating: 10 to 500 Hz, 5G, 0.030 in. max. peak-to-peak,
Relay Operation: 1.5G
600 mA at 5V(2)
500 mA at 24V(2)
Publication 1762-UM001A-US-P
A-2
Specifications
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
Certification
• UL 508
• C-UL under CSA C22.2 no. 142
• Class I, Div. 2, Groups A, B, C, D (UL 1604, C-UL under CSA C22.2 no.
213)
• 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 galvanic gun
I/O: 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(3)
Terminal Screw 0.791 Nm (7 in-lb) 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 MHz if the Radiated Immunity frequency range is
30 MHz to 1000 MHz.
Table A.2 Input Specifications
Description
Publication 1762-UM001A-US-P
1762-L24AWA
1762-L40AWA
1762-L24BWA and 1762-L40BWA
Inputs 0 through 3
Inputs 4 and higher
On-State Voltage
Range
79 to 132V ac
14 to 26.4V dc at
55°C (131°F)
14 to 30.0V dc at
30°C (86°F)
10 to 26.4V dc at
55°C (131°F)
10 to 30.0V dc at
30°C (86°F)
Off-State Voltage
Range
0 to 20V ac
0 to 5V dc
Operating
Frequency
47 Hz to 63 Hz
0 Hz to 20 kHz
0 Hz to 1 kHz (scan
time dependent)
On-State Current:
• 50 mA at
79V dc (min.)
• 12 mA at 120V dc
(nom.)
• 6.0 mA at
132V dc (max.)
• 2.5 mA at 14V dc
(min.)
• 8.8 mA at 24V dc
(nom.)
• 12.0 mA at 30V dc
(max.)
• 2.0 mA at 10V dc
(min.)
• 8.5 mA at 24V dc
(nom.)
• 12.0 mA at 30V dc
(max.)
Off-State Leakage
Current
2.5 mA max.
1.5 mA min.
Nominal
Impedance
12K ohms at 50 Hz
10K ohms at 60 Hz
2.5K ohms
Inrush Current
(max.) at 120V ac
250 mA
Not Applicable
2.6K ohms
Specifications
A-3
Table A.3 Output Specifications - Maximum Continuous Current
Specification
1762-L24AWA, 1762-L24BWA 1762-L40AWA,
1762-L40BWA
Current per Common
8A
8A
23A(1)
20A(1)
30A(2)
20A
Current per Controller:
at 150V max
at 240V max
(1) 15A above 40°C
(2) 24A above 40°C
Table A.4 AC Input Filter Requirements
Nominal Filter Minimum ON
Setting (ms)
Delay (ms)
Maximum ON
Delay (ms)
Minimum OFF
Delay (ms)
Maximum OFF
Delay (ms)
8
20
10
20
2
Table A.5 Fast DC Input Filter Requirements (Settings 0 to 3)
Maximum Counter Nominal Filter
Setting (ms)
Frequency (Hz)
50% Duty Cycle
Minimum ON
Delay (ms)
Maximum ON
Delay (ms)
Minimum OFF
Delay (ms)
Maximum OFF
Delay (ms)
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
8.000(1)
6.700
8.000
7.300
8.000
31 Hz
16.000
14.000
16.000
14.000
16.000
(1) This is the default setting.
Publication 1762-UM001A-US-P
A-4
Specifications
Table A.6 Normal DC Input Filter Requirements (Settings 4 and higher)
Maximum Counter Nominal Filter
Setting (ms)
Frequency (Hz)
50% Duty Cycle
Minimum ON
Delay (ms)
Maximum ON
Delay (ms)
Minimum OFF
Delay (ms)
Maximum OFF
Delay (ms)
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
2.700
4.000
63 Hz
8.000(1)
5.800
8.000
5.300
8.000
31 Hz
16.000
11.000
16.000
10.000
16.000
(1) This is the default setting.
Table A.7 Relay Contact Rating Table 1762-24AWA, -24BWA, -40AWA, -40BWA
Maximum
Volts
Amperes
Amperes
Continuous
Voltamperes
Make
Break
Make
Break
240V ac
7.5A
0.75A
2.5A(1)
1800VA
180VA(2)
120V ac
15A
1.5A
125V dc
0.22A(3)
1.0A
28VA
24V dc
1.2A(3)
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-L24AWA, 1762-L40AWA)
Specification
1762-L24AWA, 1762-L40AWA
Power Supply Input to Backplane Verified by one of the following dielectric tests:
Isolation
1836V ac for 1 second or 2596V dc for 1 second
265V ac Working Voltage (IEC Class 2 reinforced
insulation)
Input Group to Backplane
Verified by one of the following dielectric tests:
Isolation and Input Group to Input 1517V ac for 1 second or 2145V dc for 1 second
Group Isolation
132V ac Working Voltage (IEC Class 2 reinforced
insulation)
Publication 1762-UM001A-US-P
Specifications
A-5
Table A.8 Working Voltage (1762-L24AWA, 1762-L40AWA)
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 (1762-L24BWA, 1762-L40BWA)
Specification
1762-L24BWA, 1762-L40BWA
Power Supply Input to Backplane Verified by one of the following dielectric tests:
Isolation
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 Verified by one of the following dielectric tests:
Backplane Isolation
600V ac for 1 second or 848V dc for 1 second
50V Working Voltage (IEC Class 2 reinforced
insulation)
Input Group to Backplane
Verified by one of the following dielectric tests:
Isolation and Input Group to Input 1200V ac for 1 second or 1697V dc for 1 second
Group Isolation
75V dc Working Voltage (IEC Class 2 reinforced
insulation)
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 I/O Current Estimates
Expansion I/O Catalog Number
Estimated Current Requirement
1762-IA8
50 mA at 5V
1762-IQ8
50 mA at 5V
1762-OW8
80 mA at 5V, 90 mA at 24V
1762-IF2OF2
40 mA at 5V, 105 mA at 24V
Publication 1762-UM001A-US-P
A-6
Specifications
Controller Dimensions
See Controller Mounting Dimensions on page 2-14.
Expansion I/O Dimensions
Panel Mounting
A
C
B
Dimension
Publication 1762-UM001A-US-P
Expansion I/O Module
A
90 mm (3.5 in.)
B
40 mm (1.57 in.)
C
87 mm (3.43 in.)
Appendix
B
Replacement Parts
MicroLogix 1200
Replacement Kits
Controllers Replacement Doors
Catalog Number 1762-RPLDR1
The controller door kit consists of:
• Two memory module doors
• Two RS-232 communication port doors
• Two expansion bus doors
Controller Replacement Door Labels
Catalog Number 1762-RPLTLBL1
The controller terminal door label kit consists of:
• Four labels each for all available controllers
Controller Replacement DIN Latches
Catalog Number 1762-RPLDIN1
The controller DIN latch kit consists of:
• 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:
• one 25-point double row terminal block
• one 29-point double row terminal block
(Both terminal blocks for a 40-point controller.)
1
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B-2
Replacement Parts
Controller 24-Point Terminal Doors
Catalog Number 1762-RPLTDR24
The 24-point controller terminal door kit consists of:
• Four terminal doors
• 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:
• Four terminal doors
• Four sub-terminal covers
(Enough doors for two 40-point controllers.)
Publication 1762-IN001A-US-P
Replacement Parts
1762 Expansion I/O
B-3
Expansion I/O Replacement Doors
Catalog Number 1762-RPLDR2
The expansion I/O door kit consists of:
• Two expansion I/O terminal doors
• Two expansion I/O (bus doors)
Expansion I/O Replacement DIN Latches
Catalog Number 1762-RPLDIN2
The expansion I/O DIN latch kit consists of:
• Five DIN latches for expansion I/O
Expansion I/O Replacement Door Labels
Catalog Number 1762-RPLDTLBL2
The expansion I/O terminal door label kit consists of:
• Four labels each for all available modules
Publication 1762-IN001A-US-P
B-4
Replacement Parts
Publication 1762-IN001A-US-P
Appendix
C
Troubleshooting Your System
This chapter describes how to troubleshoot your controller. Topics include:
•
•
•
•
Understanding the
Controller LED Status
understanding the controller LED status
controller error recovery model
analog expansion I/O diagnostics and troubleshooting
calling Rockwell Automation for assistance
The controller status LEDs provide a mechanism to determine the current
status of the controller if a programming device is not present or available.
Figure C.1 Controller LED Location
POWER
RUN
FAULT
FORCE
COMM 0
DCOMM
IN
0
1
2
3
0
1
2
3
4
5
6
7
8
9 10 11 12 13
4
5
6
7
8
9
Table C.1 Controller LED Indicators
LED
Color
Indicates
POWER
off
No input power, or power error condition
green
Power on
off
Not executing the user program
green
Executing the user program in run mode
green flashing
Memory module transfer occurring
off
No fault detected
red flashing
Application fault detected
red
Controller hardware faulted
off
No forces installed
amber
Forces installed
off
Not transmitting via RS-232 port
green
Transmitting via RS-232 port
off
Configured communications
green
Default communications
off
Input is not energized
amber
Input is energized (logic status)
off
Output is not energized
amber
Output is engerized (logic status)
RUN
OUT
FAULT
FORCE
COMM 0
DCOMM
INPUTS
OUTPUTS
1
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Troubleshooting Your System
Normal Operation
The POWER and RUN LEDs are on. If a force condition is active, the
FORCE LED turns on and remains on until all forces are removed.
Error Conditions
If an error exists within the controller, the controller LEDs operate as described
in the following table.
If the
LEDS
indicate:
The Following
Error Exists
Probable Cause
Recommended Action
All LEDs
off
No input power or
power supply error
No line Power
Verify proper line voltage and
connections to the controller.
Power Supply
Overloaded
This problem can occur
intermittently if power supply
is overloaded when output
loading and temperature
varies.
Processor Hardware
Error
Cycle power. Contact your
local Allen-Bradley
representative if the error
persists.
Loose Wiring
Verify connections to the
controller.
Power LED Application fault
on and
FAULT LED
flashing
Hardware/Software
Major Fault
Detected
For error codes and Status File
information, see MicroLogix
1200 and 1500 Programmable
Controllers Instruction Set
Reference Manual, Publication
1762-RM001A-US-P.
RUN
FORCE
FAULT
LEDs all
flashing
Missing or Corrupt
Operating System
Refer to Missing/Corrupt OS
LED Pattern on page D-2.
Power and Hardware faulted
FAULT
LEDs on
solid
Publication 1762-UM001A-US-P
Operating system
fault
Troubleshooting Your System
Controller Error Recovery
Model
Identify the error code and
description.
No
C-3
Use the following error recovery model to help you diagnose software and
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 model for further help.
Is the error
hardware related?
Start
Yes
Refer to page C-2 for
probable cause and
recommended action.
No
Are the wire
connections tight?
Tighten wire connections.
Yes
Clear Fault.
Is the Power
LED on?
No
Does the
controller have
power supplied?
No
Check power.
Yes
Correct the condition
causing the fault.
Is the RUN
LED on?
Refer to page C-2 for
probable cause and
recommended action.
No
Yes
Return controller to RUN or
any of the REM test modes.
Is the Fault
LED on?
Yes
Test and verify system
operation.
Refer to page C-2 for
probable cause and
recommended action.
No
Is an input LED
accurately showing
status?
No
Yes
Refer to page C-2 for
probably cause and
recommended action.
End
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C-4
Troubleshooting Your System
Analog Expansion I/O
Diagnostics and
Troubleshooting
Module Operation and Channel Operation
The module performs operations at two levels:
• module level
• channel level
Module-level operations include functions such as power-up, configuration,
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. Channel over-range or under-range conditions are reported in the
module’s input data table. Module hardware errors are reported in the
controller’s I/O status file. Refer to the MicroLogix 1200 and 1500
Programmable Controllers Instruction Set Reference Manual, publication
1762-RM001A-US-P for more information.
When 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 Module Status LED State Table
If module
status LED is:
Indicated
condition:
Corrective action:
On
Proper Operation
No action required.
Off
Module Fault
Cycle power. If condition persists, replace the
module. Call your local distributor or
Allen-Bradley for assistance.
Critical and Non-Critical Errors
Non-critical module errors are recoverable. Channel errors (over-range or
under-range errors) are non-critical. Non-critical error conditions are indicated
in the module input data table. Non-critical configuration errors are indicated
by the extended error code. See Table C.5 on page C-7.
Critical module errors are conditions that prevent normal or recoverable
operation of the system. When these types of errors occur, the system leaves the
run mode of operation. Critical module errors are indicated in Table C.5 on
page C-7.
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Troubleshooting Your System
C-5
Module Error Definition Table
Analog module errors are expressed in two fields as four-digit Hex format with
the most significant digit as “don’t care” and irrelevant. The two fields are
“Module Error” and “Extended Error Information”. The structure of the
module error data is shown below.
Table C.3 Module Error Table
“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
Module Error Field
The purpose of the module error field is to classify module errors into three
distinct groups, as described in the table below. The type of error determines
what kind of information exists in the extended error information field. These
types of module errors are typically reported in the controller’s I/O status file.
Refer to the MicroLogix 1200 and 1500 Programmable Controllers Instruction
Set Reference Manual, publication 1762-RM001A-US-P for more information
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C-6
Troubleshooting Your System
Table C.4 Module Error Types
Error Type
Module Error
Field Value
Description
Bits 11 through 09
(Binary)
No Errors
000
No error is present. The extended error field holds
no additional information.
Hardware
Errors
001
General and specific hardware error codes are
specified in the extended error information field.
Configuration
Errors
010
Module-specific error codes are indicated in the
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 on page C-7.
NOTE
If no errors are present in the module error field, the
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 file to invalid or unsupported values,
the module ignores the 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.
Publication 1762-UM001A-US-P
Troubleshooting Your System
C-7
Error Codes
Table C.5 Extended Error Codes
Error Type
Hex
Equivalent(1)
Module
Extended Error
Error Code Information
Code
Binary
Binary
Error Description
No Error
X000
000
0 0000 0000
No error
General Common
Hardware Error
X200
001
0 0000 0000
General hardware error; no additional information
X201
001
0 0000 0001
Power-up reset state
Hardware-Specific X210
Error
001
0 0001 0000
Reserved
Configuration
Error
X400
010
0 0000 0000
General configuration error; no additional information
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 Rockwell
Automation for Assistance
If you need to contact Rockwell Automation or local distributor for assistance,
it is helpful to obtain the following (prior to calling):
• controller type, series letter, revision letter, and firmware (FRN) number
of the controller
• controller LED status
• controller error codes (Refer to MicroLogix 1200 and 1500
Programmable Controllers Instruction Set Reference Manual, Publication
1762-RM001A-US-P for error code information.)
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Troubleshooting Your System
Publication 1762-UM001A-US-P
Appendix
D
Using Control Flash to Upgrade Your
Operating System
The operating system (OS) can be upgraded through the communication port
on the controller. In order to download a new operating system, you must have
the following:
• ControlFlash™ Upgrade Kit containing the new OS
• a Windows 95®, Windows 98® or Windows NT™ based computer to
run the download software.
The ControlFlash™ Upgrade Kit includes:
• the operating system upgrade to be downloaded
• the ControlFlash programming tool, along with its support drivers and
on-line help
• a readme first file explaining how to upgrade the operating system
Preparing for Upgrade
Before upgrading the controller’s operating system, you must:
• 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
Double click the 1762-LSC_FRNxx.exe file to install the operating system
upgrade (where xx is the firmware revision number).
1
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D-2
Using Control Flash to Upgrade Your Operating System
Prepare the Controller for Updating
Controller Configuration
The controller must be configured for default communications (use
communications toggle push button; DCOMM LED on) and be in the
Program mode to allow the download of a new operating system.
Sequence of Operation
The following steps detail the key events in the upgrade process.
&RQWUROOHU PRGH DQG FRPPXQLFDWLRQV SDUDPHWHUV DUH FKHFNHG
2. Download begins.
3. During the download, the Force, Battery, and Comms LEDs perform a
walking bit pattern.
4. When the download is complete, the integrity of the new OS is checked.
If the new OS is corrupt, the controller sends an error message to the
download tool and flashes the Missing or Corrupt OS LED pattern.
See“Missing/Corrupt OS LED Pattern” below.
5. Following a successful transfer, the Power, Force, and Battery LEDs flash
on and remain on for five seconds. Then the controller resets.
Missing/Corrupt OS LED
Pattern
Publication 1762-IN001A-US-P
When 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 LEDS on and off.
Appendix
E
Understanding the Communication Protocols
Use the information in this appendix to understand the differences in
communication protocols. The following protocols are supported from the
RS-232 communication channel:
•
•
•
•
DF1 Full-Duplex
DF1 Half-Duplex Slave
DH485
Modbus
Refer to Communication Connections on page 4-1 for information about
required network devices and accessories.
RS-232 Communication
Interface
The communications port on the MicroLogix 1200 utilizes an RS-232
interface. RS-232 is an 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
possibilities. (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
DF1 protocol only, not DH485 protocol).
DF1 Full-Duplex Protocol
DF1 Full-Duplex protocol provides a point-to-point connection between two
devices. DF1 Full-Duplex protocol combines data transparency (American
National Standards Institute ANSI - X3.28-1976 specification subcategory
D1) and 2-way simultaneous transmission with embedded responses
(subcategory F1).
The MicroLogix 1200 controllers support the DF1 Full-Duplex protocol via
RS-232 connection to external devices, such as computers, or other controllers
that support DF1 Full-Duplex.
DF1 is an open protocol. Refer to DF1 Protocol and Command Set Reference
Manual, publication 1770-6.5.16, for more information.
1
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Understanding the Communication Protocols
DF1 Full-Duplex Operation
DF1 Full-Duplex protocol (also referred to as DF1 point-to-point protocol) is
useful where RS-232 point-to-point communication is required. DF1 protocol
controls message flow, detects and signals errors, and retries if errors are
detected.
When the system driver is DF1 Full-Duplex, the following parameters can be
changed:
Table E.1 DF1 Full-Duplex Configuration Parameters
Parameter
Options
Baud Rate
300, 600, 1200, 2400, 4800, 9600, 19.2K, 38.4K
Parity
none, even
Source ID (Node Address)
0 to 254 decimal
Control Line
no handshaking, Full-Duplex modem handshaking
Error Detection
CRC, BCC
Embedded Responses
auto-detect, enabled
Duplicate Packet (Message) Detect
enabled, disabled
ACK Timeout
1 to 65535 counts (20 ms increments)
NAK retries
0 to 255
ENQ retries
0 to 255
Stop Bits
not a setting, always 1
Default
19.2K
none
1
no handshaking
CRC
auto detect
enabled
50 counts
3 retries
3 retries
1
Example DF1 Full-Duplex Connections
For information about required network connecting equipment, see chapter 3,
Connecting the System.
Personal Computer
MicroLogix 1200
TERM
A
B
COM
SHLD
CHS GND
TX
TX
Personal Computer
TX
PWR
DC SOURCE
CABLE
EXTERNAL
Optical
Isolator
Modem cable
1761-CBL-PM02
Modem
MicroLogix 1200
Optical Isolator
TERM
A
B
COM
SHLD
CHS GND
TX
Modem
TX
TX
PWR
DC SOURCE
CABLE
EXTERNAL
1761-CBL-PM02
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Understanding the Communication Protocols
E-3
We recommend using an AIC+, catalog number 1761-NET-AIC, as your
optical isolator.
DF1 Half-Duplex Protocol
DF1 Half-Duplex protocol is a multi-drop single master/multiple slave
network. DF1 Half-Duplex protocol supports data transparency (American
National Standards Institute ANSI - X3.28-1976 specification subcategory
D1). In contrast to DF1 Full-Duplex, communication takes place in one
direction at a time. You can use the RS-232 port on the MicroLogix 1200 as
both a Half-Duplex programming port and a Half-Duplex peer-to-peer
messaging port.
DF1 Half-Duplex Operation
The master device initiates all communication by “polling” each slave device.
The slave device may only transmit message packets when it is polled by the
master. It is the master’s responsibility to poll each slave on a regular and
sequential basis to allow slave devices an opportunity to communicate. During
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 one time per
polling sequence, depending on how the master is configured.
An additional feature of the DF1 Half-Duplex protocol is that it is possible for
a slave device to enable a MSG instruction in its ladder program to send or
request data to/from another slave. When the initiating slave is polled, the
MSG instruction is sent to the master. The master recognizes that the message
is not intended for it, but for another slave, so the master immediately forwards
the message to the intended slave. The master does this automatically, you do
not need to program the master to move data between slave nodes. This
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 the DF1 Half-Duplex link.
The MicroLogix 1200 can only act as a slave device. A device that can act as a
master is required to “run” the network. Several Allen-Bradley products
support DF1 Half-Duplex master protocol. They include the SLC 5/03™ and
higher processors, enhanced PLC-5® processors and Rockwell Software RSLinx
(version 2.x and higher).
DF1 Half-Duplex supports up to 255 devices (address 0 to 254) with address
255 reserved for master broadcasts. The MicroLogix 1200 supports broadcast
reception. The MicroLogix 1200 also supports Half-Duplex modems using
RTS/CTS hardware handshaking.
Publication 1762-UM001A-US-P
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Understanding the Communication Protocols
When the system driver is DF1 Half-Duplex Slave, available parameters
include:
Table E.2 DF1 Half-Duplex Configuration Parameters
Parameter
Options
Baud Rate
300, 600, 1200, 2400, 4800, 9600, 19.2K, 38.4K
Parity
none, even
Source ID (Node Address)
0 to 254 decimal
Control Line
no handshaking, handshaking
Error Detection
CRC, BCC
EOT 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 (Message)
enabled, disabled
Detect
Detects and eliminates duplicate responses to a message. Duplicate packets may be sent under noisy
communication conditions if the sender’s Message Retries are not set to 0.
Poll Timeout (x20 ms)
0 to 65535 (can be set in 20 ms increments)
Poll Timeout only applies when a slave device initiates a MSG 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 MSG instruction error is generated, and the ladder program needs to requeue the MSG
instruction. If you are using a MSG instruction, it is recommended that a Poll Timeout value of zero not be
used. Poll Timeout is disabled when set to zero.
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 20 ms increments)
Specifies the time delay 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.
Message Retries
0 to 255
Specifies the number of times a slave device attempts to resend a message packet when it does not
receive an ACK from the master device. For use in noisy environments where message packets may
become corrupted in transmission.
Pre Transmit Delay
0 to 65535 (can be set in 1 ms increments)
(x1 ms)
• When the Control 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 transmit to receive mode.
• When the Control Line is set to DF1 Half-Duplex Modem, this is the minimum time delay between
receiving the last character of a packet and the RTS assertion.
Publication 1762-UM001A-US-P
Understanding the Communication Protocols
Rockwell 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
Master.
TERM
RS-232
(DF1 Half-Duplex Protocol)
Modem
TERM
A
TERM
A
B
A
B
COM
B
COM
SHLD
COM
SHLD
CHS GND
TX
TX
SHLD
CHS GND
TX
TX
PWR
TX
DC SOURCE
CHS GND
TX
TX
PWR
TX
DC SOURCE
CABLE
PWR
CABLE
EXTERNAL
MicroLogix
1000 (Slave)
TX
DC SOURCE
CABLE
EXTERNAL
E-5
EXTERNAL
MicroLogix
1200 (Slave)
MicroLogix
1500 (Slave)
NOTE
SLC 5/04 (Slave)
SLC 5/03 with 1747-KE
Interface Module (Slave)
It is recommended that isolation (1761-NET-AIC) be used
between channel 0 of the MicroLogix controller and the
modem.
Considerations When Communicating as a DF1 Slave on a
Multi-drop Link
When communication is between either your programming software and a
MicroLogix Programmable Controller or between two MicroLogix
Programmable Controllers via a slave-to-slave connection on a larger
multi-drop link, the devices depend on a DF1 Half-Duplex Master to give
each of them permission to transmit in a timely manner. As the number of
slave devices increase on the link (up to 254), the time between when your
programming software or the MicroLogix Controller is polled also increases.
This increase in time may also be large if you are using low baud rates.
As these time periods grow, the following values may need to be changed to
avoid loss of communication:
• programming software: increase poll timeout and reply timeout values
• MicroLogix Programmable Controllers: increase poll timeout and reply
timeout values
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Understanding the Communication Protocols
IMPORTANT
If a program download is started when using DF1 Half
Duplex 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. The ownership timeout
period is 60 seconds. After the timeout, you can re-establish
communications with the processor and try the program
download again. The only other way to remove program
ownership is to cycle power on the processor.
Using Modems with MicroLogix 1200 Programmable Controllers
The types of modems you can use with MicroLogix 1200 controllers include
dial-up phone modems, leased-line modems, radio modems and line drivers.
For point-to-point Full-Duplex modem connections that do not require any
modem handshaking signals to operate, use DF1 Full-Duplex protocol with no
handshaking. For point-to-point Full-Duplex modem connections that require
RTS/CTS handshaking, use DF1 Full-Duplex protocol with handshaking.
For multi-drop modem connections, or for point-to-point modem
connections that require RTS/CTS handshaking, use DF1 Half-Duplex slave
protocol. In this case, one (and only one) of the other devices must be
configured for DF1 Half-Duplex master protocol.
IMPORTANT
NOTE
Publication 1762-UM001A-US-P
Never attempt to use DH485 protocol through modems
under any circumstance.
All MicroLogix 1200 controllers support RTS/CTS
modem handshaking when configured for DF1
Full-Duplex protocol with the control line parameter set to
Full-Duplex Modem Handshaking or DF1 Half-Duplex
slave protocol with the control line parameter set to
“Half-Duplex Modem”. No other modem handshaking
lines (i.e. Data Set Ready, Carrier Detect and Data
Terminal Ready) are supported by any MicroLogix 1200
controllers.
Understanding the Communication Protocols
E-7
Dial-Up Phone Modems
Some dial-up phone line modems support point-to-point Full-Duplex
communications. A MicroLogix 1200 controller, on the receiving end of the
dial-up connection, can be configured for DF1 Full-Duplex protocol with or
without handshaking. The modem connected to the MicroLogix controller
should support auto-answer. The MicroLogix 1200 supports ASCII out
communications. Therefore, it can cause a modem to initiate or disconnect a
phone call.
Leased-Line Modems
Leased-line modems are used with dedicated phone lines that are typically
leased from the local phone company. The dedicated lines may be in a
point-to-point topology supporting Full-Duplex communications between
two modems or in a multi-drop topology supporting Half-Duplex
communications between three or more modems.
Radio Modems
Radio modems may be implemented in a point-to-point topology supporting
either Half-Duplex or Full-Duplex communications, or in a multi-drop
topology supporting Half-Duplex communications between three or more
modems.
Line Drivers
Line drivers, also called short-haul modems, do not actually modulate the serial
data, but rather condition the electrical signals to operate reliably over long
transmission distances (up to several miles). Line drivers are available in
Full-Duplex and Half-Duplex models. Allen-Bradley’s AIC+ Advanced
Interface Converter is a Half-Duplex 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-UM001A-US-P
E-8
Understanding the Communication Protocols
DH485 Communication
Protocol
The information in this section describes the DH485 network functions,
network architecture, and performance characteristics. It will also help you
plan and operate a MicroLogix on a DH485 network.
DH485 Network Description
The DH485 protocol defines the communication between multiple devices
that coexist on a single pair of wires. DH485 protocol uses RS-485
Half-Duplex 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.
The DH485 network offers:
•
•
•
•
•
interconnection of 32 devices
multi-master capability
token passing access control
the ability to add or remove nodes without disrupting the network
maximum network segment of 1219 m (4000 ft)
The DH485 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 DH485 network.
DH485 Token Rotation
A node holding the token can send a message onto the network. Each node is
allowed a fixed number of transmissions (based on the Token Hold Factor)
each time it receives the token. After a node sends a message, it passes the token
to the next device.
The allowable range of node addresses is 0 to 31. There must be at least one
initiator on the network such as a MicroLogix controller, or an SLC 5/02™ or
higher processor.
Publication 1762-UM001A-US-P
Understanding the Communication Protocols
E-9
DH485 Configuration Parameters
When MicroLogix communications are configured for DH485, the following
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
1 to 4
Refer to Software Considerations on page E-12 for tips on setting the
parameters listed above.
Devices that use the DH485 Network
In addition to the MicroLogix 1200 controllers, the devices shown in the
following table also support the DH485 network.
Table E.4 Allen-Bradley Devices that Support DH485 Communication
Catalog Number Description
Bulletin 1761
MicroLogix 1000
Controllers
Bulletin 1764
MicroLogix 1500
Bulletin 1747
Processors
1746-BAS
SLC 500
Processors
BASIC Module
1785-KA5
DH+TM/DH485
Gateway
2760-RB
Flexible Interface
Module
1784-KTX, -KTXD
PC DH485 IM
1784-PCMK
PCMCIA IM
Installation
Series C or
higher
Series A or
higher
SLC Chassis
Function
These controllers support DH485 communications.
Publication
1761-6.3
These controllers support DH485 communications.
1764-6.1
These processors support a variety of I/O requirements and
functionality.
SLC Chassis Provides an interface for SLC 500 devices to foreign devices.
Program in BASIC to interface the 3 channels (2 RS232 and 1
DH485) to printers, modems, or the DH485 network for data
collection.
(1771) PLC
Provides communication between stations on the PLC-5® (DH+)
Chassis
and SLC 500 (DH485) networks. Enables communication and data
transfer from PLC® to SLC 500 on DH485 network. Also enables
programming software programming or data acquisition across
DH+ to DH485.
(1771) PLC
Provides an interface for SLC 500 (using protocol cartridge
Chassis
2760-SFC3) to other A-B PLCs and devices. Three configurable
channels are available to interface with Bar Code, Vision, RF,
Dataliner™, and PLC systems.
IBM XT/AT Provides DH485 using RSLinx.
Computer
Bus
PCMCIA slot Provides DH485 using RSLinx.
in computer
and
Interchange
1747-6.2
1746-6.1
1746-6.2
1746-6.3
1785-6.5.5
1785-1.21
1747-KE
2760-ND001
1784-6.5.22
1784-6.5.19
Publication 1762-UM001A-US-P
E-10
Understanding the Communication Protocols
Table E.4 Allen-Bradley Devices that Support DH485 Communication
Catalog Number Description
1747-PT1
Hand-Held
Terminal
DTAM, DTAM Plus,
1747-DTAM,
2707-L8P1, -L8P2, and DTAM Micro
Operator
-L40P1, -L40P2,
Interfaces
-V40P1, -V40P2,
-V40P2N,
-M232P3, and
-M485P3
PanelView 550 and
2711-K5A2,
PanelView 900
-B5A2, -K5A5,
Operator Terminals
-B5A5, -K5A1,
-B5A1, -K9A2,
-T9A2, -K9A5,
-T9A5, -K9A1, and
-T9A1
Installation Function
NA
Provides hand-held programming, monitoring, configuring, and
troubleshooting capabilities for SLC 500 processors.
Panel Mount Provides electronic operator interface for SLC 500 processors.
Panel Mount Provides electronic operator interface for SLC 500 processors.
Publication
1747-NP002
1747-ND013
2707-800,
2707-803
2711-802,
2711-816
NA = Not Applicable
Important DH485 Network Planning Considerations
Carefully plan your network configuration before installing any hardware.
Listed below are some 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.
When 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. The following sections help you understand and plan the
network.
Publication 1762-UM001A-US-P
Understanding the Communication Protocols
E-11
Number of Devices and Length of Communication Cable
The maximum length of the communication cable is 1219m (4000 ft). This is
the total cable distance from the first node to the last node in a segment.
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WKH $GYDQFHG ,QWHUIDFH &RQYHUWHU $,& 8VHU 0DQXDO SXEOLFDWLRQ Planning Cable Routes
Follow these guidelines to 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.
• If you must run the cable across power feed lines, run the cable at right
angles to the lines.
• If 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.
• If 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 less than 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-UM001A-US-P
E-12
Understanding the Communication Protocols
Running the communication cable through conduit provides extra
protection from physical damage and 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.
– Use plastic connectors to couple between aluminum and ferromagnetic
conduit. Make an 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 let the conduit touch the plug on the cable.
– Arrange the cables loosely within the conduit. The conduit should
contain only serial communication cables.
– Install the conduit so that it meets all applicable codes and
environmental specifications.
For more information on planning cable routes, see Industrial Automation
Wiring and Grounding Guidelines, publication Number 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:
• number of nodes on the network
• addresses of those nodes
• baud rate
The following sections explain network considerations and describe ways to
select parameters for optimum network performance (speed). See your
programming software’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.
Publication 1762-UM001A-US-P
Understanding the Communication Protocols
E-13
Setting Node Addresses
The 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. The valid range for the MicroLogix 1200 controllers is 1-31
(controllers cannot be node 0). The default setting is 1. The node address is
stored in the controller Communications Status file (CS0:5/0 to CS0:5/7).
Setting Controller Baud Rate
The best network performance occurs at the highest baud rate, which is 19200.
This is the default baud rate for a MicroLogix 1200 device on the DH485
network. All devices must be at the same baud rate. This rate is stored in the
controller Communications Status file (CS0:5/8 to CS0:5/15).
Setting Maximum Node Address
Once you have an 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 should be set to the same maximum node
address.
Example DH485 Connections
The following network diagrams provide examples of how to connect
MicroLogix 1200 controllers to the DH485 network using the Advanced
Interface Converter (AIC+, catalog number 1761-NET-AIC). For more
information on the AIC+, see the Advanced Interface Converter and DeviceNet
Interface Installation Instructions, Publication 1761-5.11.
Publication 1762-UM001A-US-P
E-14
Understanding the Communication Protocols
DH485 Network with a MicroLogix 1200 Controller
MicroLogix
1200
connection from port 1 or
port 2 to MicroLogix
1761-CBL-AP00 or
1761-CBL-PM02
1761-CBL-AM00 or
1761-CBL-HM02
(3)
connection from port 1
or port 2 to PC
1761-CBL-AP00 or
1761-CBL-PM02
AIC+
(2)
TERM
A
B
COM
SHLD
CHS GND
TX
TX
TX
PWR
AIC+
DC SOURCE
CABLE
(1)
EXTERNAL
(3)
(2)
TERM
A
B
COM
+24V dc user supply
SHLD
CHS GND
TX
TX
1747-CP3 or
1761-CBL-AC00
TX
PWR
DC SOURCE
CABLE
(1)
EXTERNAL
+24V dc user supply
DH485
(1) DB-9 RS-232 port
(2) mini-DIN 8 RS-232 port
(3) RS-485 port
NOTE
Series C or higher cables are required.
Typical 3-Node Network
PanelView 550
A-B
PanelView
MicroLogix 1200
1761-CBL-AM00
or 1761-CBL-HM02
RJ45 port
AIC+
1761-CBL-AS09
or 1761-CBL-AS03
TERM
A
B
COM
SHLD
CHS GND
TX
TX
TX
PWR
DC SOURCE
CABLE
EXTERNAL
1747-CP3 or 1761-CBL-AC00
NOTE
Publication 1762-UM001A-US-P
This 3-node network is not expandable.
Understanding the Communication Protocols
E-15
Networked Operator Interface Device and MicroLogix Controllers
AIC+
AIC+
TERM
TERM
A
B
COM
COM
SHLD
SHLD
CHS GND
TX
A-B
A
B
TX
TX
PWR
TX
DC SOURCE
TX
PWR
DC SOURCE
CABLE
CABLE
EXTERNAL
EXTERNAL
SLC 5/04
PanelView 550
DH485 Network
AIC+
AIC+
AIC+
TERM
TERM
A
B
TX
PWR
TX
DC SOURCE
TX
PWR
TX
MicroLogix 1000
TX
PWR
TX
PWR
CABLE
EXTERNAL
MicroLogix 1200
TX
DC SOURCE
CABLE
EXTERNAL
Personal
Computer
CHS GND
TX
DC SOURCE
CABLE
EXTERNAL
SHLD
CHS GND
TX
DC SOURCE
CABLE
COM
SHLD
CHS GND
TX
B
COM
SHLD
CHS GND
A
B
COM
SHLD
TERM
A
B
COM
TX
AIC+
TERM
A
TX
PanelView
CHS GND
TX
EXTERNAL
MicroLogix 1500
MicroLogix Remote Packet Support
MicroLogix 1200 controllers can respond and initiate with communications
(or commands) that do not originate on the local DH485 network. This is
useful in installations where communication is needed between the DH485
and DH+ networks.
The example below shows how to send messages from a PLC device or a PC on
the DH+ network to a MicroLogix controller on the DH485 network. This
method uses an SLC 5/04 processor bridge connection.
When using this method (as shown in the following illustration):
• PLC-5 devices can send read and write commands to MicroLogix 1200
controllers.
• MicroLogix 1200 controllers can respond to MSG instructions received.
• The MicroLogix 1200 controllers can initiate MSG instructions to
devices on the DH+ network.
• PC can send read and write commands to MicroLogix 1200 controllers.
• PC can do remote programming of MicroLogix 1200 controllers.
Publication 1762-UM001A-US-P
E-16
Understanding the Communication Protocols
AIC+
AIC+
TERM
TERM
A
A-B
A
B
B
COM
COM
SHLD
SHLD
CHS GND
PanelView
CHS GND
TX
TX
TX
TX
TX
PWR
TX
PWR
DC SOURCE
DC SOURCE
CABLE
CABLE
EXTERNAL
EXTERNAL
SLC 5/04
PanelView 550
DH485 Network
AIC+
AIC+
AIC+
AIC+
TERM
TERM
TERM
A
A
A
B
B
B
COM
COM
COM
SHLD
SHLD
SHLD
TERM
CHS GND
CHS GND
CHS GND
A
B
COM
TX
TX
TX
TX
TX
TX
SHLD
CHS GND
TX
TX
PWR
TX
DC SOURCE
PWR
TX
DC SOURCE
CABLE
TX
PWR
DC SOURCE
CABLE
CABLE
TX
PWR
DC SOURCE
EXTERNAL
EXTERNAL
CABLE
EXTERNAL
EXTERNAL
MicroLogix 1000
MicroLogix 1200
MicroLogix 1500
SLC 5/04
DH+ Network
SLC 5/04
Publication 1762-UM001A-US-P
PLC-5
Understanding the Communication Protocols
Modbus Communication
Protocol
E-17
Modbus is a Half-Duplex, master-slave communications protocol. The
Modbus network master reads and writes coils and registers.
Modbus protocol allows a single master to communicate with a maximum of
255 slave devices.
For more information on the MicroLogix 1200 configuration parameters for
Modbus Slave RTU (Remote Terminal Unit transmission mode) protocol, rHIHU
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Table E.5 Modbus to MicroLogix Memory Map
Modbus Addressing
Description
Valid MicroLogix Addressing
File Type
Data File Number Address
0001 to 4096
Read/Write Modbus Coil Data space
Bit (B) or Integer (N)
3 to 255
bits 0 to 4095
10001 to 14096
Read-Only Modbus Contact Data space
Bit (B) or Integer (N)
3 to 255
bits 0 to 4095
30001 to 30256
Read-Only Modbus Input Register space Bit (B) or Integer (N)
3 to 255
words 0 to 255
30501 to 30532
Modbus Communication Parameters
Communication
Status Files
2
words 0 to 31
31501 to 31566
Read-Only System Status File space
Status (S)
2
words 32 to 65
40001 to 40256
Read/Write Modbus Holding Register
space
Bit (B) or Integer (N)
3 to 255
words 0 to 255
41501 to 41566
Read/Write System Status File space
Status (S)
2
words 0 to 65
Publication 1762-UM001A-US-P
E-18
Understanding the Communication Protocols
Publication 1762-UM001A-US-P
Appendix
F
System Loading and Heat Dissipation
System Loading Limitations
When you connect MicroLogix accessories and expansion I/O, an electrical
load is placed on the controller power supply. This section shows how to
calculate the load and validate that the system will not exceed the capacity of
the controller power supply.
The following example is provided to illustrate system loading validation. The
system validation procedure accounts for the amount of 5V dc and 24V dc
current consumed by controller, expansion I/O, 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 the real-time clock
modules has already 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 MicroLogix Accessories
Catalog Number
Device Current Requirements Calculated Current
at 5V dc (mA) at 24V dc (mA) at 5V dc (mA)
at 24V dc (mA)
(1)
0
120
0
120
1761-NET-AIC when powered by the base unit communications
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.
1
Publication 1762-UM001A-US-P
F-2
System Loading and Heat Dissipation
Table F.2 Calculating the Current for Expansion I/O
Catalog Number(1)
n
Number of
Modules
1762-IA8
1762-OW8
1762-IQ8
1762-IF2OF2
2
2
Total Modules (4 maximum):
4
A
B
Device Current Requirements (max)
at 5V dc (mA)
at 24V dc (mA)
50
0
80
90
50
0
40
105
nxA
nxB
Calculated Current
at 5V dc (mA) at 24V dc (mA)
100
0
160
180
Subtotal 2:
260
180
(1) Refer to your expansion I/O Installation Instructions for Current Requirements not listed in this table.
Validating the System
The example systems shown in the tables below are verified to be acceptable
configurations. The systems are valid because:
•
•
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Table F.3 Validating Systems Using 1762-24AWA
Maximum Allowable Values
Calculated Values
Current:
400 mA at 5V dc
Current (Subtotal 1 + Subtotal 2 from page F-1.):
350 mA at 24V dc
0 mA + 260 mA = 260 mA at 5V dc
System Loading:
System Loading:
10.4 Watts
= (260 mA x 5V) + (300 mA x 24V)
= (1300 mW) + (7200 mW)
= 8500 mW
= 8.50 Watts
Publication 1762-UM001A-US-P
120 mA + 180 mA = 300 mA at 24V dc
System Loading and Heat Dissipation
F-3
Table F.4 Validating Systems using 1762-24BWA
Maximum Allowable Values
Calculated Values
Current for Devices Connected to the +24V dc
User Supply:
Sum of all sensor currents and/or 1761-NET-AIC connected to the +24V dc user supply
(AIC+ selector switch in the down position(1)):
350 mA at 24V dc
150 mA at 24V dc (example sensor value)
Current for MicroLogix Accessories and
Expansion I/O:
Current Values (Subtotal 1 + Subtotal 2 from page F-1.):
400 mA at 5V dc
0 mA + 260 mA = 260 mA at 5V dc
350 mA at 24V dc
120 mA + 180 mA = 300 mA at 24V dc
System Loading:
System Loading:
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 AIC+ is powered by an external source.
System Loading Worksheet
The tables below are provided for system loading validation. See “System
Loading Example Calculations (24-Point Controller)” on page F-1.
Current Loading
Table F.5 Calculating the Current for MicroLogix Accessories
Catalog Number
1761-NET-AIC(1) when powered by the base unit
communications port, selector switch in the up position
Subtotal 1:
Device Current Requirements
at 5V dc (mA) at 24V dc (mA)
0
120
Calculated Current
at 5V dc (mA) at 24V 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 I/O
1762-IA8
1762-OW8
1762-IQ8
1762-IF2OF2
A
B
Device Current Requirements
at 5V dc (mA)
at 24V dc (mA)
50
0
80
90
50
0
40
105
Total Modules (4 maximum):
Subtotal 2:
Catalog Number(1)
n
Number of
Modules
nxA
nxB
Calculated Current
at 5V dc (mA) at 24V dc (mA)
(1) Refer to your expansion I/O Installation Instructions for Current Requirements not listed in this table.
Publication 1762-UM001A-US-P
F-4
System Loading and Heat Dissipation
Validating the System
The example systems shown in the tables below are verified to be acceptable
configurations. The systems are valid because:
•
•
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Table F.7 Validating Systems using 1762-24AWA
Maximum Allowable Values
Calculated Values
Current:
400 mA at 5V dc
Current (Subtotal 1 + Subtotal 2 from page F-1.):
350 mA at 24V dc
System Loading:
System Loading:
10.4 Watts
Table F.8 Validating Systems using 1762-24BWA
Maximum Allowable Values
Current for Devices Connected to the +24V dc User
Supply:
Calculated Values
Sum of all sensor currents and/or 1761-NET-AIC connected to the +24V dc user
supply (AIC+ selector switch in the down position(1)):
350 mA at 24V dc
mA at 24V dc
Current for MicroLogix Accessories and Expansion
I/O:
400 mA at 5V dc
Current Values (Subtotal 1 + Subtotal 2 from page F-1.):
350 mA at 24V dc
mA at 5 V dc
mA at 24V dc
System Loading:
System Loading:
12 Watts
= (________ mA x 24V) + (________ mA x 5V) + (________ mA x 24V)
= __________ mW + __________ mW + __________ mW
= __________ mW
= __________ W
(1) No current is consumed from the controller when the AIC+ is powered by an external source.
Publication 1762-UM001A-US-P
System Loading and Heat Dissipation
F-5
System Loading Example Calculations (40-Point Controller)
Current Loading
Table F.9 Calculating the Current for MicroLogix Accessories
Catalog Number
Device Current Requirements
at 5V dc (mA)
at 24V dc (mA)
1761-NET-AIC(1) when powered by the base unit communications 0
port, selector switch in the up position
Subtotal 1:
120
Calculated Current
at 5V dc (mA) at 24V dc
(mA)
0
120
0
120
(1) This is an optional accessory. Current is consumed only if the accessory is installed.
Table F.10 Calculating the Current for Expansion I/O
Catalog Number(1)
n
Number of
Modules
1762-IA8
1762-OW8
1762-IQ8
1762-IF2OF2
2
3
1
Total Modules (6 maximum):
6
A
B
Device Current Requirements (max)
at 5V dc (mA)
at 24V dc (mA)
50
0
80
90
50
0
40
105
nxA
nxB
Calculated Current
at 5V dc (mA) at 24V dc (mA)
100
0
240
270
50
0
Subtotal 2:
390
270
(1) Refer to your expansion I/O Installation Instructions for Current Requirements not listed in this table.
Publication 1762-UM001A-US-P
F-6
System Loading and Heat Dissipation
Validating the System
The example systems shown in the tables below are verified to be acceptable
configurations. The systems are valid because:
•
•
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Table F.11 Validating Systems using 1762-40AWA
Maximum Allowable Values
Calculated Values
Current:
600 mA at 5V dc
Current (Subtotal 1 + Subtotal 2 from page F-1.):
500 mA at 24V dc
0 mA + 390 mA = 390 mA at 5V dc
System Loading:
System Loading:
15 Watts
= (390 mA x 5V) + (390 mA x 24V)
= (1950 mW) + (9360 mW)
= 11,310 mW
= 11.31 Watts
120 mA + 270 mA = 390 mA at 24V dc
Table F.12 Validating Systems using 1762-40BWA
Maximum Allowable Values
Calculated Values
Current for Devices Connected to the +24V dc
User Supply:
Sum of all current sensors and/or 1761-NET-AIC connected to the +24V dc user supply
(AIC+ selector switch in the down position(1)):
500 mA at 24V dc
150 mA at 24V dc (example sensor value)
Current for MicroLogix Accessories and
Expansion I/O:
Current Values (Subtotal 1 + Subtotal 2 from page F-1.):
600 mA at 5V dc
0 mA + 390 mA = 390 mA at 5V dc
500 mA at 24V dc
120 mA + 270 mA = 390 mA at 24V dc
System Loading:
System Loading:
16 Watts
= (150 mA x 24V) + (390 mA x 5V) + (390 mA x 24V)
= (3600 mW) + (1950 mW) + (9360 mW)
= 14.910 mW
= 14.91 Watts
(1) No current is consumed from the controller when the AIC+ is powered by an external source.
Publication 1762-UM001A-US-P
System Loading and Heat Dissipation
System Loading Worksheet
F-7
The tables 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
1761-NET-AIC(1) when powered by the base unit
communications port, selector switch in the up position
Subtotal 1:
Device Current Requirements
at 5V dc (mA) at 24V dc (mA)
0
120
Calculated Current
at 5V dc (mA) at 24V dc (mA)
(1) This is an optional accessory. Current is consumed only if the accessory is installed.
Table F.14 Calculating the Current for Expansion I/O
1762-IA8
1762-OW8
1762-IQ8
1762-IF2OF2
A
B
Device Current Requirements
at 5V dc (mA)
at 24V dc (mA)
50
0
80
90
50
0
40
105
Total Modules (6 maximum):
Subtotal 2:
Catalog Number(1)
n
Number of
Modules
nxA
nxB
Calculated Current
at 5V dc (mA) at 24V dc (mA)
(1) Refer to your expansion I/O Installation Instructions for Current Requirements not listed in this table.
Publication 1762-UM001A-US-P
F-8
System Loading and Heat Dissipation
Validating the System
The example systems shown in the tables below are verified to be acceptable
configurations. The systems are valid because:
•
•
&DOFXODWHG &XUUHQW 9DOXHV 0D[LPXP $OORZDEOH &XUUHQW 9DOXHV
&DOFXODWHG 6\VWHP /RDGLQJ 0D[LPXP $OORZDEOH 6\VWHP /RDGLQJ
Table F.15 Validating Systems using 1762-40AWA
Maximum Allowable Values
Calculated Values
Current:
600 mA at 5V dc
Current (Subtotal 1 + Subtotal 2 from page F-1.):
500 mA at 24V dc
System Loading:
System Loading:
15 Watts
Table F.16 Validating Systems using 1762-40BWA
Maximum Allowable Values
Current for Devices Connected to the +24V dc User
Supply:
Calculated Values
Sum of all sensor currents and/or 1761-NET-AIC connected to the +24V dc user
supply (AIC+ selector switch in the down position(1)):
400 mA at 24V dc
mA at 24V dc
Current for MicroLogix Accessories and Expansion I/
O:
500 mA at 5V dc
Current Values (Subtotal 1 + Subtotal 2 from page F-1.):
500 mA at 24V dc
mA at 5 V dc
mA at 24V dc
System Loading:
System Loading:
16 Watts
= (________ mA x 24V) + (________ mA x 5V) + (________ mA x 24V)
= __________ mW + __________ mW + __________ mW
= __________ mW
= __________ W
(1) No current is consumed from the controller when the AIC+ is powered by an external source.
Publication 1762-UM001A-US-P
System Loading and Heat Dissipation
Calculating Heat
Dissipation
Catalog Number
1762-24AWA
1762-24BWA
1762-40AWA
1762-40BWA
F-9
Use the following table when you need to determine the heat dissipation for
installation in an enclosure. Use the following table. For System Loading, take
the value from the table on page F-4:
Heat Dissipation
Equation or Constant
14W + (0.4 x System Loading)
16W + (0.4 x System Loading)
17.5W + (0.4 x System Loading)
20W + (0.4 x System Loading)
Calculation
14W + (0.4 x ______ W)
16W + (0.4 x ______ W)
17.5W + (0.4 x ______ W)
20W + (0.4 x ______ W)
Sub-Total
Add Sub-Totals to determine Heat Dissipation
Publication 1762-UM001A-US-P
F-10
System Loading and Heat Dissipation
Publication 1762-UM001A-US-P
Glossary
The following 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,
I:1/0 is the memory address for the data located in the Input file location
word1, bit 0.
AIC+ Advanced Interface Converter
A device that provides a communication link between various networked
devices. (Catalog Number 1761-NET-AIC.)
application
1) A machine or process monitored and controlled by a controller.
2) The use of computer- or processor-based routines for specific purposes.
baud rate
The speed of communication between devices. All devices must communicate
at the same baud rate on a network.
bit
The smallest storage location in memory that contains either a 1 (ON) or a 0
(OFF).
block diagrams
A schematic drawing.
Boolean operators
Logical operators such as AND, OR, NAND, NOR, NOT, and Exclusive-OR
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 a ladder program.
communication scan
A 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.
1
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2
Glossary
control profile
The means by which a controller determines which outputs turn on under
what conditions.
counter
1) An electro-mechanical relay-type device that counts the occurrence of some
event. May 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.
The software counter can be given a preset count value to count up or down
whenever the counted event occurs.
CPU (Central Processing Unit)
The decision-making and data storage section of a programmable controller.
data table
The part of processor memory that contains I/O values and files where data is
monitored, manipulated, and changed for control purposes.
DIN rail
Manufactured according to Deutsche Industrie Normenausshus (DIN)
standards, a metal railing designed to ease installation and mounting of your
controller.
download
Data 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 I/O
Embedded I/O is the controller’s on-board I/O.
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 I/O
Expansion I/O is I/O that is connected to the controller via a bus or cable.
MicroLogix 1200 controllers use Bulletin 1762 expansion I/O.
false
The status of an instruction that does not provide a continuous logical path on
a ladder rung.
Publication 1762-UM001A-US-P
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
received simultaneously (contrast with half-duplex).
half-duplex
A communication link in which data transmission is limited to one direction at
a time.
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 as a push button or a switch, that supplies signals through input
circuits to the controller.
inrush current
The temporary 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. The input 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.
I/O (Inputs and Outputs)
Consists of input and output devices that provide and/or receive data from the
controller.
Publication 1762-UM001A-US-P
4
Glossary
jump
Change in normal sequence of program execution, by executing an instruction
that alters the program counter (sometimes called a branch). In ladder
programs a JUMP (JMP) instruction causes execution to jump to a labeled
rung.
ladder logic
A program written in a format resembling a ladder-like diagram. The program
is used by a programmable controller to control devices.
least significant bit (LSB)
The digit (or bit) in a binary word (code) that carries the smallest value of
weight.
LED (Light Emitting Diode)
Used as status indicator for processor functions and inputs and outputs.
LIFO (Last-In-First-Out)
The 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. General term for digital circuits and
programmed instructions to perform required decision making and
computational functions.
Master Control Relay (MCR)
A mandatory hard-wired relay that can be de-energized by any series-connected
emergency stop switch. Whenever the MCR is de-energized, its contacts open
to de-energize all application I/O devices.
mnemonic
A simple and easy to remember term that is used to represent a complex or
lengthy set of information.
modem
Modulator/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 = +5V, 1 = 0V). Positive is
more conventional (for example, 1 = +5V, 0 = 0V).
Publication 1762-UM001A-US-P
Glossary
5
network
A series of stations (nodes) connected by some type of communication
medium. A network may be made up of a single link or multiple links.
nominal input current
The current 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. (They 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 is logic “1” when evaluated.
off-delay time
The OFF 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
Describes devices not under direct communication.
offset
The steady-state deviation of a controlled variable from a fixed point.
off-state leakage current
When 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 when the switch is in the off state. This 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
The ON delay time is a measure of the time 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.
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6
Glossary
online
Describes 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 be in the On state. For
outputs, the allowable range of user-supplied voltage.
output device
A device, such as a pilot light or a motor starter coil, that receives data from the
controller.
processor
A Central Processing Unit. (See CPU.)
processor file
The set of program and data files used by the controller to control output
devices. Only one processor file may be stored in the controller at a time.
program file
The area within a processor file that contains the ladder logic program.
program mode
When the controller is not executing the processor file and all outputs are
de-energized.
program scan
A part of the controller’s operating cycle. During 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
The packaging of information that is transmitted across a network.
read
To acquire data from a storage place. For example, the processor READs
information from the input data file to solve the ladder program.
relay
An electrically operated device that mechanically switches electrical circuits.
relay logic
A 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.
Publication 1762-UM001A-US-P
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
This is an executing mode during which the controller scans or executes the
ladder program, monitors input devices, energizes output devices, and acts on
enabled I/O forces.
rung
Ladder logic is comprised of a set of rungs. A rung contains input and output
instructions. During Run mode, the inputs 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 a
personal computer; OR to save a program to a computer hard disk.
scan time
The time required for the controller to execute the instructions in the program.
The scan 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 I/O device and controller I/O
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 I/O device and controller I/O
circuit — typically, a sourcing device or circuit provides a path to the source,
high, or positive side of power supply.
status
The condition of a circuit or system, represented as logic 0 (OFF) or 1 (ON).
terminal
A point on an I/O module that external I/O devices, such as a push button or
pilot light, are wired to.
Publication 1762-UM001A-US-P
8
Glossary
throughput
The 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
Data is transferred to a programming or storage device from another device.
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 WRITEs the
information from the output data file to the output modules.
Publication 1762-UM001A-US-P
Index
Numerics
1762-24AWA wiring diagram 3-10
1762-24BWA sinking wiring diagram 3-11
1762-24BWA sourcing wiring diagram 3-11, 3-12, 3-13
1762-IA8 wiring diagram 3-14
1762-IF2OF2 terminal block layout 3-16
1762-IF2OF2 wiring 3-16
1762-IQ8 wiring diagram 3-15
1762-OW8 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
AIC+ 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
communication
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
Modbus E-17
communication scan G-1
communications toggle push button
using 4-2
component descriptions 1-2
1762 expansion I/O 1-2
communication cables 1-3
memory module 1-2
real-time clock 1-2
configuration errors C-6
connecting expansion I/O 2-20
connecting the system
AIC+ 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 network 4-6
contacting Rockwell 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-UM001A-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 parameters 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
download G-2
DTE (Data Terminal Equipment) G-2
E
Electronics Industries Association (EIA) E-1
EMC 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-UM001A-US-P
expansion I/O mounting 2-18, 2-19
mounting on DIN rail 2-18
expansion I/O wiring 3-14
1762-IA8 wiring diagram 3-14
1762-IF2OF2 terminal block layout 3-16
1762-IF2OF2 wiring 3-16
1762-IQ8 wiring diagram 3-15
1762-OW8 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 protection 2-8
high byte G-3
I
I/O (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
Index
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
Master 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
Modbus 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 MicroLogix 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
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
O
offline G-5
offset G-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-UM001A-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
Rockwell 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
S
safety circuits 2-5
safety considerations 2-4
disconnecting main power 2-5
hazardous location 2-4
master control relay circuit
periodic tests 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
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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
B
Cover
Publication 1762-UM001A-US-P - January 2000 2
PN 40072-078-01(A)
© 2000 Rockwell International Corporation. Printed in the U.S.A.
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