Grieve Corporation 1761-CBL-AM00 Installation 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.literature.rockwellautomation.com 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

IMPORTANT

ATTENTION

SHOCK HAZARD

BURN HAZARD

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.

Identifies information that is critical for successful application and understanding of the product.

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

Labels may be located on or inside the drive to alert people that dangerous voltage may be present.

Labels may be located on or inside the drive to alert people that surfaces may be dangerous temperatures.

Summary of Changes

This table 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.

This table lists the sections that document new features and additional or updated information about existing features.

For This Information See Page

Expansion I/O, 1762-IQ8OW6

• wire diagram

• specifications

• system loading and heat dissipation

• 3-22

• A-20

• Appendix F

1 Publication 1762-UM001E-EN-P - February 2006

Summary of Changes 2

Publication 1762-UM001E-EN-P - February 2006

Preface

Hardware Overview

Install Your Controller

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 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

Program the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

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

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

Chapter 2

Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

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

Disconnect 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

Prevent Excessive Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

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

Use Emergency-Stop Switches . . . . . . . . . . . . . . . . . . . 2-9

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

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

Install a Memory Module or Real-time Clock . . . . . . . . . . . 2-12

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

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

Mount 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

Wire Your Controller

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

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

Mount on Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

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

Chapter 3

Wire Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Wire without Spade Lugs . . . . . . . . . . . . . . . . . . . . . . . 3-2

Wire with Spade Lugs . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Use Surge Suppressors . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

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

Ground the Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

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

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

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

Sinking and Sourcing Wiring Diagrams . . . . . . . . . . . . . . . 3-11

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

Minimize Electrical Noise . . . . . . . . . . . . . . . . . . . . . . . 3-17

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

Discrete Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . 3-18

Analog Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Communication Connections

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Chapter 4

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

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

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

Use the Communications Toggle Push Button . . . . . . . . . . 4-3

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

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

Use a Modem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

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

Connect to a DF1 Half-duplex Network . . . . . . . . . . . . 4-8

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

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

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

Connect the Communication Cable to the DH-485

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

Ground and Terminate the DH-485 Network. . . . . . . . . 4-12

Connect the AIC+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Use Trim Pots

Use Real-time Clock and Memory Modules

Table of Contents iii

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

Recommended User-supplied Components . . . . . . . . . . 4-16

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

Install and Attach the AIC+. . . . . . . . . . . . . . . . . . . . . . 4-18

Apply Power to the AIC+ . . . . . . . . . . . . . . . . . . . . . . . 4-18

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

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

Chapter 5

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

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

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

Chapter 6

Real-time Clock Operation. . . . . . . . . . . . . . . . . . . . . . . . . 6-1

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

Write 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

Specifications

1762 Replacement Parts

Troubleshoot Your System

Appendix A

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

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

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

Analog Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-13

Combination Module DC-Input/Relay Output . . . . . . . A-21

Appendix B

MicroLogix 1200 RTB Replacement Kit. . . . . . . . . . . . . . . . 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

Interpret LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

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

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

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

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Table of Contents iv

Use Control Flash to Upgrade Your Operating System

Connect to Networks via RS-232 Interface

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

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

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

Critical and Noncritical Errors . . . . . . . . . . . . . . . . . . . . C-5

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

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

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

Appendix D

Prepare 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

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

DF1 Full-duplex Protocol . . . . . . . . . . . . . . . . . . . . . . . . . E-1

DF1 Half-duplex Protocol . . . . . . . . . . . . . . . . . . . . . . . . . E-2

Use 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

System Loading and Heat Dissipation

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Appendix F

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

System Current Loading Example Calculations

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

Validate the System . . . . . . . . . . . . . . . . . . . . . . . . . . . F-2

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

Current Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-4

System Current Loading Example Calculations

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

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

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

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

Glossary

Index

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

Who Should Use This Manual

Purpose of 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.

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.

1 Publication 1762-UM001E-EN-P - February 2006

P-2 Preface

Common Techniques Used in This Manual

Publication 1762-UM001E-EN-P - February 2006

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.

Hardware Overview

Chapter

Hardware Features

Side View

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.

Figure 1.1 Hardware Features of the Controller

Top Vie w

COM

Table 1.1 Hardware Features

Feature Description Feature Description

1 Terminal Blocks

7 Terminal Doors and Labels (Removable Terminal Blocks on 40-point controllers only.)

2 Bus Connector Interface to Expansion I/O 8 Trim Pots

3 Input LEDs 9 Communications Toggle Push Button

4 Output LEDs 10

5 Communication Port/

11 DIN Rail Latches

Memory Module Port Cover Memory Module and/or Real-Time Clock

(1)

-or-

(2)

Channel 0

6 Status LEDs 12 Programmer/HMI Port

(Equipped with 1762-LxxxxxR controllers only)

(1) Shipped with controller.

(2) Optional equipment.

1 Publication 1762-UM001E-EN-P - February 2006

1-2 Hardware Overview

Table 1.2 Controller Input Power and Embedded I/O

Catalog Number Description

Input Power Inputs Outputs

1762-L24AWA, 1762-L24AWAR 120/240V ac (14) 120V ac (10) relay 1762-L24BWA, 1762-L24BWAR 120/240V ac (10) 24V dc

(4) fast 24V dc

1762-L24BXB, 1762-L24BXBR 24V dc (10) 24V dc

(4) fast 24V dc 1762-L40AWA, 1762-L40AWAR 120/240V ac (24) 120V ac (16) relay 1762-L40BWA, 1762-L40BWAR 120/240V ac (20) 24V dc

(4) fast 24V dc 1762-L40BXB, 1762-L40BXBR 24V dc (20) 24V dc

(4) fast 24V dc

(10) relay

(5) relay, (4) 24V dc FET (1) high-speed 24V dc FET

(16) relay

(8) relay, (7) 24V dc FET (1) high-speed 24V dc FET

Component Descriptions

These sections provide component descriptions for:

• MicroLogix 1200 Memory Module and/or Real-time Clock

• 1762 Expansion I/O

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.

Publication 1762-UM001E-EN-P - February 2006

Table 1.3 Memory Module and/or Real-time Clock

Catalog Number Description

1762-MM1 Memory Module only

1762-RTC Real-time Clock only

1762-MM1RTC Memory Module and Real-Time Clock

Hardware Overview 1-3

1762 Expansion I/O

1762 expansion I/O can be connected to the MicroLogix 1200 controller, as shown below.

TIP

A maximum of six I/O modules, in certain combinations, may be connected to a controller. See Appendix F, System Loading and Heat Dissipation, to determine valid combinations.

1762 Expansion I/O 1762 Expansion I/O Connected to MicroLogix 1200 Controller

Table 1.4 Expansion I/O

Catalog Number Descriptions

1762-IA8 8-point 120V ac Input

1762-IQ8 8-point Sink/Source 24V dc Input

1762-IQ16 16-point Sink/Source 24V dc Input

1762-OA8 8-point AC Triac Output

1762-OB8 8-point Sourcing 24V dc Output

1762-OB16 16-point Sourcing 24V dc Output

1762-OW8 8-point AC/DC Relay Output

1762-OW16 16-point AC/DC Relay Output

1762-OX6I 6-point Isolated Relay Output

1762-IF2OF2 2-channel Analog Voltage/Current Input

2-channel Analog Voltage/Current Output

1762-IF4 4-channel Analog Voltage/Current Input

1762-OF4 4-channel Analog Voltage/Current Output

1762-IR4 RTD/Resistance Input

1762-IT4 Thermocouple/mV Input

1762-IQ8OW6 DC-input/Relay-output Combination Module

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1-4 Hardware Overview

Communication Cables

Program the Controller

Use only the following communication cables with the MicroLogix 1200 controllers.

• 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 A or later

• 2702-NC9 series B or later

• 2707-NC10 series B or later

• 2707-NC11 series B or later

You program the MicroLogix 1200 programmable controller using RSLogix 500, revision 4 or later. You must use revision 4.5 or later of RSLogix 500 in order to use the new features of the series B MicroLogix 1200 controllers, including the full ASCII instruction set. Communication cables for programming are not included with the software.

MicroLogix 1200

Catalog Number

1762-L24AWA 1762-L24BWA 1762-L40AWA 1762-L40BWA

1762-L24BXB 1762-L40BXB

Firmware Revision History

Features are added to the controllers through firmware upgrades. Use the listing below to be sure that your controller’s firmware is at the level you need. Firmware upgrades are not required, except to give you access to the new features.

(1)

OS Revision Letter

OS Series Letter

A A FRN1 March 2000 Initial product release.

A B FRN2 May 2000 The trim pots (trimming potentiometers) on the controller

B A FRN3 November 2000 MicroLogix 1200 controllers now offer:

B A FRN3 November 2000 Initial product release. Supports all the features listed above for

OS Firmware Release No.

Release Date Enhancement

operated in reverse of the ladder logic. Corrected.

• Full ASCII (read/write)

• PTO Controlled Stop

• PWM Ramping

• RTC and String Messaging

• Static Data File Protection

• Comms Reset Pushbutton Bit

the 1762-L24xWA and 1762-L40xWA controllers.

Publication 1762-UM001E-EN-P - February 2006

Hardware Overview 1-5

MicroLogix 1200

Catalog Number

1762-L24AWA 1762-L24BWA 1762-L24BXB 1762-L40AWA 1762-L40BWA 1762-L40BXB

OS Series Letter

Revision Letter

OS Firmware Release No.

(2)

FRN4

Release Date Enhancement

June 2001 MicroLogix 1200 controllers now offer:

• Floating Point (F) Data File for use with: compare instructions (EQU, GEQ, GRT, LEQ, LES, LIM, NEQ); math instructions (ABS, ADD, CLR, DIV, MUL, NEG, SQR, SUB); move instruction (MOV); file instructions (CPW, FLL); and the message (MSG) instruction

• Programmable Limit Switch (PLS) File for use with HSC

(1)

• RTA - Real Time Clock Adjust

• GCD - Gray Code

• CPW - Copy Word

• ABS - Absolute Value

FRN5

FRN6

(3)

March 2002 Internal firmware revision; no user functionality change.

September 2002 MicroLogix 1200 Controllers now offer:

• The Floating Point (F) Data File can now be used with the Scale with Parameters (SCP)

• Modbus Memory Mapping Enhancements

1762-L24AWA 1762-L24BWA 1762-L24BXB 1762-L40AWA 1762-L40BWA 1762-L40BXB

C D FRN7 April 2003 MicroLogix 1200 Controllers now offer:

• DF1 Half-duplex Master Driver

• DF1 Radio Modem Driver

• Enhanced DF1 Broadcast Support

• ASCII Clear Buffer (ACL) instruction enhancement

C E FRN8 November 2003 MicroLogix 1200 Controllers now offer:

• Modbus Master Protocol

• PTO Independent Accel/Decel profiles

1762-L24AWAR 1762-L24BWAR 1762-L24BXBR

C E FRN8 March 2004 MicroLogix 1200 Controllers now offer:

• Additional communications port called the Programmer/HMI Port

1762-L40AWAR 1762-L40BWAR 1762-L40BXBR

There are operating system firmware flash upgrades and downgrades available for MicroLogix 1200 controllers from the MicroLogix website (www.ab.com/micrologix

). Any controller may be upgraded to the latest release by using these tools. Issues regarding

downgrading are discussed below.

(1) OS = Operating System.

(2) For users of RSLogix 500 Programming Software version 4.5 - MicroLogix 1200 series C revision A controllers with FRN4 firmware may be downgraded for compatibility

with this version of software using the ControlFlash FRN3 tool available on the MicroLogix website. Your controller may be later upgraded using the FRN5 (which replaces the FRN4 ControlFlash upgrade, and is a functional equivalent) or higher ControlFlash tool.

(3) For users of RSLogix 500 Programming Software version 4.5 - MicroLogix 1200 series C revision B controllers with FRN5 or later firmware may be downgraded for

compatibility with this version of software using the ControlFlash FRN 3.1 tool available on the MicroLogix website. Your controller may be later upgraded using the FRN5 (which replaces the FRN 4 ControlFlash upgrade, and is a functional equivalent) or higher ControlFlash tool.

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1-6 Hardware Overview

Communication Options

The MicroLogix 1200 can be connected to a personal computer. It can also be connected to a DH-485 network, or a Modbus network as an RTU Master or RTU Slave 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 DF1 Half-duplex networks as an RTU Master or RTU Slave. Series B controllers may also be connected to serial devices using ASCII.

See Chapter 4 Communication Connections for more information on connecting to the available communication options.

The 1762-LxxxxxR controllers provide an additional communication port called the Programmer/HMI Port. This port supports DF1 full-duplex protocol only. The controller cannot initiate messages through this port. It can only respond to messages sent to it. All communication parameters are fixed and cannot be changed by a user.

See Default Communication Configuration on page 4-2 for the configuration settings.

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Install Your Controller

This chapter shows you how to install your controller.

Topics include:

• required tools

• agency certifications

• compliance to European Union Directives

• installation considerations

• safety considerations

• power considerations

• preventing excessive heat

• master control relay

• install the memory module and/or real-time clock

• controller mounting dimensions

• controller and expansion I/O spacing

• mount the controller

• mount 1762 expansion I/O

• connect 1762 expansion I/O

Chapter

Required Tools

Agency Certifications

Compliance to European Union Directives

1 Publication 1762-UM001E-EN-P - February 2006

You need a screwdriver and a drill.

• 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

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.

2-2 Install Your Controller

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

Installation Considerations

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 B113

Most applications require installation in an industrial enclosure

(1)

(Pollution Degree 2 (Over Voltage Category II

) to reduce the effects of electrical interference

(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.

Publication 1762-UM001E-EN-P - February 2006

(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.

Install Your Controller 2-3

Safety Considerations

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.

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).

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2-4 Install Your Controller

Use only the following communication cables in Class I, Division 2 hazardous locations.

Communication Cables for Class I, Division 2 Hazardous Locations

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 A or later

2707-NC9 series B or later

2707-NC10 series B or later

2707-NC11 series B or later

Disconnect 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.

Publication 1762-UM001E-EN-P - February 2006

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.

Install Your Controller 2-5

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.

Power Considerations

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.

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).

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2-6 Install Your Controller

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.

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.

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Install Your Controller 2-7

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.

Prevent 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.

TIP

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.

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2-8 Install Your Controller

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 2-10 and 2-11.

ATTENTION

Never alter these circuits to defeat their function since serious injury and/or machine damage could result.

TIP

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.

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Install Your Controller 2-9

TIP

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.

Use 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.

TIP

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.

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2-10 Install Your Controller

Schematic (Using IEC Symbols)

Isolation Transformer

115V ac

or 230V ac

230V ac

Disconnect

Fuse

Operation of either of these contacts will remove power from the external I/O

circuits, stopping machine motion.

Emergency-Stop Push Button

(Lo)

Line Terminals: Connect to terminals of Power Supply (1762-L24AWA, 1762-L24BWA, 1762-L40AWA, 1762-L40BWA, 1762-L24AWAR, 1762-L24BWAR, 1762-L40AWAR, and 1762-L40BWAR).

(Hi)

Overtravel Limit Switch

Fuse

Stop

Line Terminals: Connect to 24V dc terminals of Power Supply (1762-L24BXB, 1762-L40BXB, 1762-L24BXBR, and 1762-L40BXBR).

Start

MCR

dc Power Supply. Use IEC 950/EN 60950

MCR

Master Control Relay (MCR) Cat. No. 700-PK400A1

Suppressor Cat. No. 700-N24

MCR

Suppr.

MCR

115V ac or 230V ac I/O Circuits

MCR

230V ac I/O

Circuits

24V dc I/O Circuits

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Schematic (Using ANSI/CSA Symbols)

Install Your Controller 2-11

Disconnect

Isolation Transformer

230V ac

115V ac or 230V ac

Fuse

MCR

Master Control Relay (MCR) Cat. No. 700-PK400A1

Suppressor Cat. No. 700-N24

MCR

Suppr.

115V ac or 230V ac I/O Circuits

MCR

230V ac Output Circuits

24 V dc I/O Circuits

Operation of either of these contacts will remove power from the external I/O

circuits, stopping machine motion.

Emergency-Stop Push Button

(Lo)

Line Terminals: Connect to terminals of Power Supply (1762-L24AWA, 1762-L24BWA, 1762-L40AWA, 1762-L40BWA, 1762-L24AWAR, 1762-L24BWAR, 1762-L40AWAR, and 1762-L40BWAR).

Overtravel Limit Switch

(Hi)

Fuse

Stop

Start

MCR

dc Power Supply. Use NEC Class 2 for UL

Listing

Line Terminals: Connect to 24V dc terminals of Power Supply (1762-L24BXB, 1762-L40BXB, 1762-L24BXBR, and 1762-L40BXBR).

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2-12 Install Your Controller

Install a Memory Module or Real-time Clock

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.

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Controller Mounting Dimensions

Install Your Controller 2-13

1762-L24AWA, 1762-L24BWA, 1762-L24BXB 1762-L24AWAR, 1762-L24BWAR, 1762-L24BXBR

1762-L40AWA, 1762-L40BWA, 1762-L40BXB 1762-L40AWAR, 1762-L40BWAR, 1762-L40BXBR

Table 2.1 Controller Dimensions

Dimension 1762-L24AWA

1762-L24AWAR

1762-L24BWA 1762-L24BWAR

1762-L24BXB 1762-L24BXBR

1762-L40AWA 1762-L40AWAR

1762-L40BWA 1762-L40BWAR

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.)

1762-L40BXB 1762-L40BXBR

Controller and Expansion I/O Spacing

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, and adjacent equipment, as shown below.

Top

Side Side

MicroLogix

1200

1762 I/O

Bottom

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2-14 Install Your Controller

Mount the Controller

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 Over Voltage Category II

ATTENTION

Do not remove the protective debris shield until after

(2)

(IEC 60664-1).

(1)

) and to circuits not exceeding

(3)

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 devices inside the controller. Do not touch the connector pins or other sensitive areas.

TIP

For environments with greater vibration and shock concerns, use the panel mounting method described on page 2-16, rather than DIN rail mounting.

(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.

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