Allen-Bradley MicroLogix 1200 User manual

MicroLogix™ 1200
Programmable
Controllers
Bulletin 1762 Controllers and
Expansion I/O
User Manual

Important User Information
Solid state equipment has operational characteristics differing from those of
electromechanical equipment. Safety Guidelines for the Application,
Installation and Maintenance of Solid State Controls (Publication SGI-1.1
available from your local Rockwell Automation sales office or online at
http://www.ab.com/manuals/gi) describes some important differences
between solid state equipment and hard-wired electromechanical devices.
Because of this difference, and also because of the wide variety of uses for
solid state equipment, all persons responsible for applying this equipment
must satisfy themselves that each intended application of this equipment is
acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for
indirect or consequential damages resulting from the use or application of
this equipment.
The examples and diagrams in this manual are included solely for illustrative
purposes. Because of the many variables and requirements associated with
any particular installation, Rockwell Automation, Inc. cannot assume
responsibility or liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to
use of information, circuits, equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without
written permission of Rockwell Automation, Inc. is prohibited.
Throughout this manual we use notes to make you aware of safety
considerations.
WARNING Identifies information about practices or circumstances
that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property
damage, or economic loss.
IMPORTANT Identifies information that is critical for successful
application and understanding of the product.
ATTENTION Identifies information about practices or circumstances
that can lead to personal injury or death, property
damage, or economic loss. Attentions help you:
•identify a hazard
•avoid a hazard
•recognize the consequence
SHOCK HAZARD Labels may be located on or inside the drive to alert
people that dangerous voltage may be present.
BURN HAZARD Labels may be located on or inside the drive to alert
people that surfaces may be dangerous temperatures.

1Publication 1762-UM001D-EN-P - March 2004
Summary of Changes
The information below summarizes the changes to this manual since
the last printing.
To help you find new and updated information in this release of the
manual, we have included change bars as shown to the right of this
paragraph.
The table below lists the sections that document new features and
additional or updated information about existing features.
For this information See
MicroLogix 1200 controllers with the
additional communications port
(Programmer/HMI Port)
•hardware features
•firmware revision history
•description
•new 6 catalog numbers
•application example
•specifications
page(s):
•1-1
•1-5
•1-6
•4-1
•4-1
•A-1
Programmer/HMI Port
•location
•configuration
•supported protocol
•no LED indicator provided
page(s):
•1-1
•4-2
•4-2
•C-1

Publication 1762-UM001D-EN-P - March 2004
Summary of Changes 2

iPublication 1762-UM001D-EN-P - March 2004
Table of Contents
Preface Who Should Use this Manual. . . . . . . . . . . . . . . . . . . . . . . P-1
Purpose of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
Related Documentation . . . . . . . . . . . . . . . . . . . . . . . . P-2
Common Techniques Used in this Manual . . . . . . . . . . . . . P-2
Chapter 1
Hardware Overview
Hardware Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Component Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
MicroLogix 1200 Memory Module and/or Real-Time Clock .
1-2
1762 Expansion I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Communication Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Firmware Revision History . . . . . . . . . . . . . . . . . . . . . . 1-4
Communication Options . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Chapter 2
Installing Your Controller
Agency Certifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Compliance to European Union Directives . . . . . . . . . . . . . 2-1
EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Installation Considerations. . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hazardous Location Considerations . . . . . . . . . . . . . . . 2-3
Disconnecting Main Power. . . . . . . . . . . . . . . . . . . . . . 2-4
Safety Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Power Distribution. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Periodic Tests of Master Control Relay Circuit . . . . . . . . 2-5
Power Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Isolation Transformers . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Power Supply Inrush . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Loss of Power Source. . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Input States on Power Down . . . . . . . . . . . . . . . . . . . . 2-7
Other Types of Line Conditions . . . . . . . . . . . . . . . . . . 2-7
Preventing Excessive Heat . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Master Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Using Emergency-Stop Switches . . . . . . . . . . . . . . . . . . 2-9
Schematic (Using IEC Symbols) . . . . . . . . . . . . . . . . . . 2-10
Schematic (Using ANSI/CSA Symbols). . . . . . . . . . . . . . 2-11
Installing a Memory Module and/or Real-Time Clock . . . . . 2-12
Controller Mounting Dimensions . . . . . . . . . . . . . . . . . . . . 2-13
Controller and
Expansion I/O Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Mounting the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
DIN Rail Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Panel Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
1762 Expansion I/O Dimensions . . . . . . . . . . . . . . . . . . . . 2-17

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Table of Contents ii
Mounting 1762
Expansion I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
DIN Rail Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Panel Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Connecting Expansion I/O . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Chapter 3
Wiring Your Controller
Wiring Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Wiring Recommendation . . . . . . . . . . . . . . . . . . . . . . . 3-1
Using Surge Suppressors . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Recommended Surge Suppressors . . . . . . . . . . . . . . . . 3-5
Grounding the Controller . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Terminal Block Layouts . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Terminal Groupings . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Sinking and Sourcing Wiring Diagrams . . . . . . . . . . . . . . . 3-10
1762-L24AWA, 1762-L24BWA, 1762-L24BXB, 1762-L24AWAR,
1762-L24BWAR and 1762-L24BXBR Wiring Diagrams. . . 3-11
1762-L40AWA, 1762-L40BWA, 1762-L40BXB ,
1762-L40AWAR, 1762-L40BWAR and 1762-L40BXBR Wiring
Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Controller I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Minimizing Electrical Noise. . . . . . . . . . . . . . . . . . . . . . 3-17
Expansion I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Discrete Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . 3-17
Analog Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Chapter 4
Communication Connections
Supported Communication Protocols . . . . . . . . . . . . . . . . . 4-1
Default Communication Configuration . . . . . . . . . . . . . . . . 4-2
Using the Communications Toggle Push Button . . . . . . . . . 4-2
Connecting to the RS-232 Port . . . . . . . . . . . . . . . . . . . . . . 4-4
Making a DF1 Point-to-Point Connection . . . . . . . . . . . 4-5
Using a Modem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Isolated Modem Connection. . . . . . . . . . . . . . . . . . . . . 4-6
Connecting to a DF1 Half-Duplex Network. . . . . . . . . . 4-8
Connecting to a DH-485 Network . . . . . . . . . . . . . . . . . . . 4-9
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
DH-485 Communication Cable . . . . . . . . . . . . . . . . . . . 4-9
Connecting the Communication Cable to the DH-485
Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Grounding and Terminating the DH-485 Network . . . . . 4-12
Connecting the AIC+. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Cable Selection Guide . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Recommended User-Supplied Components. . . . . . . . . . 4-16

Publication 1762-UM001D-EN-P - March 2004
Table of Contents iii
Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Installing and Attaching the AIC+ . . . . . . . . . . . . . . . . . 4-18
Powering the AIC+. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
DeviceNet Communications. . . . . . . . . . . . . . . . . . . . . . . . 4-20
Cable Selection Guide . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Chapter 5
Using Trim Pots
Trim Pot Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Trim Pot Information Function File . . . . . . . . . . . . . . . . 5-2
Error Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Chapter 6
Using Real-Time Clock and
Memory Modules
Real-Time Clock Operation . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Removal/Insertion Under Power. . . . . . . . . . . . . . . . . . 6-1
Writing Data to the Real-Time Clock. . . . . . . . . . . . . . . 6-2
RTC Battery Operation . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Memory Module Operation . . . . . . . . . . . . . . . . . . . . . . . . 6-3
User Program and Data Back-up. . . . . . . . . . . . . . . . . . 6-3
Program Compare . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Data File Download Protection. . . . . . . . . . . . . . . . . . . 6-4
Memory Module Write Protection . . . . . . . . . . . . . . . . . 6-4
Removal/Insertion Under Power. . . . . . . . . . . . . . . . . . 6-4
Appendix A
Specifications
Controller Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Expansion I/O Specifications . . . . . . . . . . . . . . . . . . . . . . . A-6
Discrete I/O Modules. . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Analog Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-12
Appendix B
Replacement Parts
MicroLogix 1200 Replacement Kits. . . . . . . . . . . . . . . . . . . B-1
Controller 40-Point Replacement Terminal Blocks . . . . . B-1
1762 Expansion I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Expansion I/O Replacement Doors. . . . . . . . . . . . . . . . B-2
Expansion I/O Replacement DIN Latches . . . . . . . . . . . B-2
Expansion I/O Replacement Door Labels . . . . . . . . . . . B-2
Appendix C
Troubleshooting Your System
Understanding the Controller LED Status . . . . . . . . . . . . . . C-1
Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Error Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Controller Error Recovery Model . . . . . . . . . . . . . . . . . . . . C-3
Analog Expansion I/O Diagnostics and Troubleshooting. . . C-4
Module Operation and Channel Operation . . . . . . . . . . C-4

Publication 1762-UM001D-EN-P - March 2004
Table of Contents iv
Power-up Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Critical and Non-Critical Errors . . . . . . . . . . . . . . . . . . . C-5
Module Error Definition Table . . . . . . . . . . . . . . . . . . . C-5
Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-7
Calling Rockwell Automation for Assistance . . . . . . . . . . . . C-8
Appendix D
Using Control Flash to Upgrade
Your Operating System
Preparing for Upgrade. . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Install ControlFlash Software . . . . . . . . . . . . . . . . . . . . D-1
Prepare the Controller for Updating . . . . . . . . . . . . . . . D-2
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Missing/Corrupt OS LED Pattern . . . . . . . . . . . . . . . . . . . . D-2
Appendix E
Connecting to Networks via
RS-232 Interface
RS-232 Communication Interface . . . . . . . . . . . . . . . . . . . . E-1
DF1 Full-Duplex Protocol . . . . . . . . . . . . . . . . . . . . . . . . . E-1
DF1 Half-Duplex Protocol . . . . . . . . . . . . . . . . . . . . . . . . . E-2
Using Modems with MicroLogix 1200 Programmable
Controllers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3
DH-485 Communication Protocol. . . . . . . . . . . . . . . . . . . . E-5
Devices that use the DH-485 Network . . . . . . . . . . . . . E-5
Important DH-485 Network Planning Considerations. . . E-6
Example DH-485 Connections . . . . . . . . . . . . . . . . . . . E-9
Modbus Communication Protocol . . . . . . . . . . . . . . . . . . E-12
ASCII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-12
Appendix F
System Loading and Heat
Dissipation
System Loading Limitations . . . . . . . . . . . . . . . . . . . . . . . . F-1
System Loading Example Calculations (24-Point Controller) .
F-1
System Loading Worksheet . . . . . . . . . . . . . . . . . . . . . . . . F-3
Current Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-4
System Loading Example Calculations (40-Point Controller) .
F-5
System Loading Worksheet . . . . . . . . . . . . . . . . . . . . . . . . F-7
Current Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-7
Calculating Heat Dissipation . . . . . . . . . . . . . . . . . . . . . . . F-9
Glossary
Index
Rockwell Automation Support . . . . . . . . . . . . . . . . . . . . . . 1-9
Installation Assistance . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
New Product Satisfaction Return. . . . . . . . . . . . . . . . . . 1-9

1Publication 1762-UM001D-EN-P - March 2004
Preface
Read this preface to familiarize yourself with the rest of the manual. It
provides information concerning:
•who should use this manual
•the purpose of this manual
•related documentation
•conventions used in this manual
•Rockwell Automation support
Who Should Use this
Manual
Use this manual if you are responsible for designing, installing,
programming, or troubleshooting control systems that use
MicroLogix™ 1200 controllers.
You should have a basic understanding of electrical circuitry and
familiarity with relay logic. If you do not, obtain the proper training
before using this product.
Purpose of this Manual
This manual is a reference guide for MicroLogix 1200 controllers and
expansion I/O. It describes the procedures you use to install, wire,
and troubleshoot your controller. This manual:
•explains how to install and wire your controllers
•gives you an overview of the MicroLogix 1200 controller system
Refer to Publication 1762-RM001, MicroLogix 1200 and 1500
Programmable Controllers Instruction Set Reference Manual for the
MicroLogix 1200 and 1500 instruction set and for application examples
to show the instruction set in use. Refer to your RSLogix 500
programming software user documentation for more information on
programming your MicroLogix 1200 controller.

Publication 1762-UM001D-EN-P - March 2004
P-2 Preface
Related Documentation
The following documents contain additional information concerning
Rockwell Automation products. To obtain a copy, contact your local
Rockwell Automation office or distributor.
Common Techniques Used
in this Manual
The following conventions are used throughout this manual:
•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.
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-RM001
Information on mounting and wiring the MicroLogix 1200
Controllers, including a mounting template for easy installation.
MicroLogix 1200 Programmable
Controllers Installation Instructions
1762-IN006
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 protocol. Modbus Protocol Specifications Available from
www.modbus.org
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