1200 Micrologix Manual

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1200 Micrologix Manual

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 ) describes some important differences between solid state equipment and hard-wired electromechanical devices. MicroMentor 1761-MMB Information on the MicroLogix 1200 Controllers instruction set. MicroLogix 1200 and 1500 1762-RM001 Programmable Controllers Instruction Set Reference Manual Information on mounting and wiring the MicroLogix 1200. The hardware features of the controller are:. You can order a memory module, real-time clock, or memory module and real-time clock as an accessory. Communication cables for programming are not included with the software. 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. The only tools you require are a flat or Phillips head screwdriver and drill.Be careful of metal chips when drilling mounting ATTENTION holes for your controller or other equipment within the enclosure or panel.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. It is recommended that the controller remain powered even when the master control relay is de-energized. 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.http://ibarugi.com/fckeditor/userfiles/cdl-driving-manual-colorado.xml

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. 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. Provide the operator with the safety of a direct connection between an emergency-stop switch and the master control relay.Publication 1762-UM001D-EN-P - March 2004. Specifically, this equipment is intended for use in clean, dry environments (Pollution degree 2 ) and to circuits not exceeding Over Voltage Category II (IEC 60664-1). 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. 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-IN006. 2. Secure the template to the mounting surface. (Make sure your controller is spaced properly. The following illustration shows the location of the end anchors.In Class I, Division 2 applications, all modules must be mounted in direct contact with each other as shown on page 2-19. Then loosen the terminal screw. Using Surge Suppressors Because of the potentially high current surges that occur when switching inductive load devices, such as motor starters and solenoids, the use of some type of surge suppression to protect and extend the operating life of the controllers output contacts is required. These components must be appropriately rated to suppress the switching transient characteristic of the particular inductive device. Controllers with dc inputs can be wired as either sinking or sourcing inputs.http://grandaygun.com/cirali/cdl-drivers-manual-tn.xml

(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. Refer to pages 3-12 through 3-16 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 input group’s COM terminal. Refer to MicroLogix 1200 and 1500 Programmable Controllers Instruction Set Reference Manual, publication number 1762-RM001. Refer to MicroLogix 1200 and 1500 Programmable Controllers Instruction Set Reference Manual, publication number 1762-RM001. You can access the switches through the ventilation slots on the top of the module. See Default Communication Configuration on page 4-2 for the configuration settings. For more information on MicroLogix 1200 communications, refer to the MicroLogix 1200 and MicroLogix 1500 Programmable Controllers Instruction Set Reference Manual, publication number 1762-RM001. The Default Communications (DCOMM) LED operates to show when the controller is in the default communications mode (settings shown on page 4-2). Descriptions of these methods follow. All devices connected to the RS-232 channel must be. The recommended protocol for this configuration is DF1 Full-Duplex. See Appendix F, System Loading and Heat Dissipation. Network MicroLogix DH-485 Network MicroLogix 1200 connection from port 1 or port 2 to MicroLogix Channel 0 1761-CBL-AM00 PC to port 1 or 1761-CBL-HM02. In the 1761-CBL-PM02 cable, pins 4 and 6 are jumpered together within the DB-9 connector. This connection must be made whether or not an external 24V dc supply is used.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.

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. 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-RM001. 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. 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). The module continues to convert the analog input up to the maximum full scale range. The model provides Model common questions you might ask to help troubleshoot your system. Refer to the recommended pages within the model for further help. Identify the error code and Is the error Start. When a fault condition is detected, the analog outputs are reset to zero. 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. Refer to the MicroLogix 1200 and 1500 Programmable Controllers Instruction Set Reference Manual, publication 1762-RM001 for more information. 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.

RS-232 is an Electronics Industries Association (EIA) Interface standard that specifies the electrical and mechanical characteristics for serial binary communication. It provides you with a variety of system configuration possibilities. MicroLogix 1200 can act as the master or as a slave on a Half-Duplex network.The following sections help you understand and plan the network. 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. This is the default baud rate for a MicroLogix 1200 device on the DH-485 network. All devices must be at the same baud rate.For more information on configurating your MicroLogix 1200 controller for Modbus protocol, refer to the MicroLogix 1200 and 1500 Programmable Controllers Instruction Set Reference Manual, publication 1762-RM001. For more information about the Modbus protocol, see the Modbus Protocol Specifications (available from ). This section shows how to calculate the load and validate that the system will not exceed the capacity of the controller power supply. 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.LIFO (Last-In-First-Out) The order that data is entered into and retrieved from a file.A network may be made up of a single link or multiple links.During the scan the ladder program is executed and the output data file is updated based on the program and the input data file.A rung contains input and output instructions. At, you can Support find technical manuals, a knowledge base of FAQs, technical and application notes, sample code and links to software service packs, and a MySupport feature that you can customize to make the best use of these tools.

Use Trim Pots Trim Pot Operation Trim Pot Information Function File Error Conditions 6 -Connect to Networks via RS-232 Interface RS-232 Communication Interface DF1 Full-duplex Protocol Example DF1 Full-duplex Connections DF1 Half-duplex Protocol Example DF1 Half-duplex Connections Use Modems with MicroLogix 1200 Programmable Controllers DH-485 Communication Protocol Devices that use the DH-485 Network Important DH-485 Network Planning Considerations Hardware Considerations Number of Devices and Length of Communication Cable Planning Cable Routes Software Considerations Number of Nodes Setting Node Addresses Setting Controller Baud Rate Setting Maximum Node Address Example DH-485 Connections DH-485 Network with a MicroLogix 1200 Controller Typical 3-Node Network Networked Operator Interface Device and MicroLogix Controllers MicroLogix Remote Packet Support Modbus Communication Protocol ASCII F -. System Loading and Heat Dissipation System Loading Limitations System Current Loading Example Calculations (24-point Controller) Validate the System System Loading Worksheet Current Loading System Current Loading Example Calculations (40-point Controller) Validate the System System Loading Worksheet Current Loading Calculating Heat Dissipation Glossary Index Numerics A B C D E F G H I J L M N O P R S T U W Back CoverBecause of this differ ence, and also bec ause of the wide v ariety of u ses for solid state equipmen t, all persons responsible for appl ying this equipment must satisfy themselv es that each intended application of this equipment is acceptable. In no event will R ockw ell Automation, Inc.The ex amples and diag ram s in this manual ar e included sol ely for illustrativ e purposes. Because of th e many v ariables a nd requir ements asso ciated with any particular installation, Roc kwell A utomation, Inc.Reproduction of the contents of this manu al, in whole or in part, without written per mission of R ockwell A utomation, Inc.

WARNING Identifies infor mation about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injur y or death, proper ty damage, or economic loss. IMPORTANT Identifies infor mation that is critical for successful application and understanding of the product. ATTENTION Identifies infor mation about practices or circumstances that can le ad to personal injur y or death, proper ty damage, or economic loss. BURN HAZARD Labels may be located on or inside the dri ve to alert people that surfaces may be dang erous temperatures. The table below lists the sections that document new features and additional or updated information on existing features. Firmware Revision History F eatures are added to the co ntrollers thro ugh firmware upg rades. See the latest release notes, 1762 -RN001, to be sure that your cont roller’ s fir mware is at the level y o u need. Fir mware upg rades are not required, except to allow y ou access to the new features. For this informatio n: See Updated list of communication cables. 1-4, 2-4, 4-4 Updated list of warnings for Hazardous Location considerations 2-4 Updated list of cables for Cable Selection Guide. 4-13 Removed catalog 1761-NET -DNI 1-4, Chapter 4 Added Relay Output life to Specifications. A-3 Added Relay Life Chart to Specifications. A-4 Y ou should h av e a basic understandin g of electrical circuitr y and fam iliarity with relay logic. If you do not, obtain the proper train ing before using this product. It describes the proced ures you use to install, wire, and troubleshoot your cont roller. Re fer to your RSLogix 500 pr ogramming software user documentation for more infor mation on prog rammi ng your MicroLogix 1200 controller. T o ob tain a copy, contact your local R ockwell A utomation office or distributor.

Resource Descriptio n MicroLogix 1200 and 1500 Programmable Controllers Instruction Set Reference Manual, publication 1762-RM001 Information on the MicroLogix 1200 Controllers instruction set. MicroLogix 1200 Programmable Controllers Installation Instructions, publication 1762-IN006 Information on mounting and wiring the MicroLogix 1200 Controllers, including a mounting template for easy installation. This manual also contains information on network wiring. DeviceNet Interface User Manual, publication 1761-UM005 Information on how to install, configure, and commission a DNI. DF1 Protocol and Command Set Reference Manual, publication 1770-6.5.16 Information on DF1 open protocol. Modbus Protocol Specifications available from www.modbus.org Information about the Modbus protocol. Allen-Bradley Programmable Controller Grounding and Wiring Guidelines, publication 1770-4.1 In-depth information on grounding and wiring Allen-Bradley programmable controllers. Application Considerations for Solid-State Controls, publication SGI-1.1 A description of important differenc es between solid-state programmable controller products and hard-wired electromechanical devices. National Electrical Code - Published by the National Fire Protection Association of Boston, MA. An article on wire sizes and types for grounding electrical equipment. Allen-Bradley Industrial Automation Glossary, publication AG-7.1 A glossary of industrial automation terms and abbreviations. Communication cables for prog ramming are not included with the software. Communication Options The MicroLogix 1200 can be connected to a personal computer. It can also be connected to a DH-485 network, or a Mo dbus netw ork as an RTU Master or RTU Sla ve using an Adva nced Inte rface Converter (ca talog number 1761-NET -AIC). The controller can also be connected to DF1 Half-duplex netw orks as an RTU Master or RTU Sla ve. Series B controllers may also be connected to serial de vices using ASCII.

See Chapter 4 Comm unication Connections for more information on connecting to the available communication options. This por t suppor ts DF1 full-duplex protocol only. T he controller cannot initiate messag es through this por t. It can only respond to messages sent to it. A ll communication par ameters are fixed and cannot be changed by a user. See Default Communication Co nfiguration on pag e 4-2 for the configura tion settings. It ha s been designed an d tested to meet the following directi ves. Loca te your controller as far as possible from pow e r lines, load lines, and other sources of electrical noise such as hard-contact switches, relays, and A C motor drives. F or more infor mation on proper g rounding guidelines, see the Industrial A u tomation Wiring and Grounding Guidelines publication 1770-4.1. (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 t he electrical distribution system. At this level, transient voltages are controlled and do not exceed the impulse voltage capability of the products insulation. Activ ely thinking about the safet y of yourself and others, as well as the condition of your equipment, is of primar y im port ance. W e recommend reviewing the following safety considerations. Hazardous Location Considerations T his eq uip me nt is su ita bl e fo r u se i n Cl as s I, Divi sio n 2, Gr oup s A, B, C, D o r non-hazardous locations only. T he following W ARNING statement applies to use in hazardous locations. ATTENTION V er tical mounting of the controlle r is not recommended due to heat b uild-up cons iderations. ATTENTION Be careful of metal chip s when drilling mounting holes for your controller or other equipment within the enclosure or panel.

Do not drill holes abov e a mounted controller if the protectiv e debris shields are remov ed or the processor is installed. Communication Cable s for Class I, Division 2 Hazardous Locatio ns 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 1761-CBL-PH02 series A or later 1761-CBL-AH02 series A 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 In addition to disconnecting electrical p ow e r, all ot her sources of power (pneumatic and hy draulic) sho uld be de-energized before working on a machine or process controlled by a controller. Safety Circuits Circuits instal led on the machine for safety reasons, like o ver trav el limit switches, stop push buttons, and interl oc ks, should alwa ys be hard-wired directly to the master control rela y. Th ese devices must be wired in series so that when any o ne device open s, the master contro l relay is de-energized, thereby removing power to the machine. Never alter these c ircuits to defeat their function. Serious injur y or machine damage could result. This a voids the additional delay of power supply turn-off. The dc power su pply should be pow ered directly from the fused secondar y of the transfor mer. Po wer to the dc input and output circuits should be conne cted thro ugh a set of master control rela y contacts. WARNING Explosion Hazard Do not replace components or disc onnect equipment unless pow er has been switc hed off. WARNING Explosion Hazard Do not connect or disconn ect connectors while circuit is liv e. The failure of one of these switches w ould most likely cause an open circuit, which w ould be a safe power -off failure. How ever, if one of these switc hes shorts out, it no longer provides any safety protection. These switches should be tested periodically to assure they w ill stop mach ine mo tion when needed.

Power Considerations The following explains power considerations for the micro controllers. Isolation T ransformers Y ou may want to use an isolation transfor m er in the ac line to the controller. This type of tran sfor mer provides isolation from your pow er dist ribution system to reduce the electrical noise th at enters the controller and is often used as a step -down transfor mer to reduce line voltage. Any transfor mer used with the controller must ha ve a sufficient pow er rating for its load. The power rating is expressed in volt-amperes (V A). Power Supply Inrush During power -up, the MicroLogix 1200 po wer supply allows a brief inr ush curr ent to charge inter nal capacit ors. Many power lines and control transfor mers can supply inr ush cur rent for a brief time. If the power source cannot supply this inr ush current, the source voltage may sag momentarily. The only effect of limited inr ush cu rrent an d voltage sag on the MicroLogix 1200 is that the po wer supply capacitors c harg e more slowly. Howev er, the effect of a voltag e sag on othe r equipment should be considered. F or example, a deep voltage sag m ay reset a computer connected to the same power source. If the entire system is po wered-up at the same time, a brief sag in the po wer source voltage typically will not affect any equipment. When the duration of power loss reac hes this limit, the power supply signals the processor that it can no longer pro vide adequate dc pow e r to the system. This is referred to as a power supply shut do wn. T he processor then perfor ms an orderly shutdown of the controller. Input States on Power Down The power supply hold-up time as descri bed abov e is g enerally longer than the turn-on and turn-off times of the inputs. Understanding this concept is impor tant. The user prog ram should be written to take this effe ct into account. Other T ypes of Line Conditions Occasionally the pow e r sour ce to the syst em can be temporarily interr upted.

It is also possible that the voltage level may drop substantially below the nor mal line vo ltage rang e for a period of time. Bo th of these conditions are considered to be a loss of po wer for the system. Prevent Excessive Heat F or most applic ations, no r mal convectiv e cooling keeps th e controller within the specified operating range. Ensure that the specified temperature range is maintained. Proper spacing of compone nts within an enclosure is usually sufficient for heat dissipation. In some applications, a substantial amount of heat is produced by other equipment insid e or outside th e enclosure. In this case, p lace blo wer fans inside the enclosure to assist in air circ ulation and to reduce “hot spots” near the controller. Additional cooling provisions might be necessar y when high ambient temperatures are encountered. Sinc e the master control relay allo ws the placement of several emergency- stop sw itches in different locations, its installation is impor tant from a safety standpoint. Over trav el limit switches or mushroom-head push buttons are wired in series so that when any of them opens, the master control relay is de-e nergized. T his remov es power to input and output device circuits. Refer to the figures on page s 2-10 and 2-11. Place the main power disconnect switch where operators and maintenance personnel hav e quick and easy access to it. If you mount a disconnect switch inside the controller e nclosure, place the switch operating handle on the outside of the enclosure, so that you can disconnect power without opening the enclo sure. Whenever any of the emergency-stop switches are opened, pow er to input and output devices should be removed. TIP Do not bring in unfiltered outside air. Place the controller in an enclosure to protect it from a corrosive atmosphere. Har mful contaminants or dir t could cause improper ope ration or damage to components.

In extreme cases, you ma y need to use air conditioning to protect ag ainst hea t build-up within the enclosure. TIP If you are using an external dc power supply, inter r upt the dc outp ut side rather than the ac line side of the supply to av oid the additional delay of pow er supply tur n-off. The ac line of the dc output power supply should be fused. Connect a set of maste r control relays in serie s with the dc power supplying the input and output circuits. W hen inspecting or installing ter minal connections, replacing output fuses, or working on equipment within the enclosure, use the disconnect to shut off pow er to the rest of the system. Make certain that rela y contacts hav e a sufficient rating for your application. How ever, in most applications, only output circuits require MCR protection. The following illustrations show the Mast er Control R elay wired in a g rounded system. TIP Do not control the master control relay with the controller. Provide the oper ator with the safety of a direct connec tion between an emer gency-st op switch and the master control relay. TIP In most applications inpu t circuits do not require MCR protection; h ow eve r, if you need t o remov e pow er from all field devices, you must include MCR contacts in ser ies with input po wer wiring. Use NEC Class 2 for UL Listing. Overtravel Limit Switch Specifically, this equipment is intended for use in clean, dr y environ m ents (P ollution degree 2 (1) ) and to circuits not exceeding Over V oltag e Categ or y II (2) (IEC 60664-1). (3) (1) Pollution Degree 2 is an environment where, normally, only non-conductive pollution occurs except that occasionally a temporary conductivity c aused 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 V oltage Category II are International Electrote chnical Commission (IEC) desig nations. ATTENTION Do not remo ve the protecti ve debris shield until after the controller and all othe r equipment in the pa nel near the controller are mounted and wiring is complete. Once wiring is complete, remove protectiv e debris shield. Fa ilure to remov e shield before operating can cause o verheating. ATTENTION Electrostatic discharge can damage semiconductor devices inside the controller. Do not touch the connector pins or other sensitiv e areas. TIP F or environments with greater vibration and shock concer ns, use th e panel mounting method described on page 2-16, rather than DIN rail mountin g. debris shield A flat-blade screwdriv er is required for remov al of the controller. The controller can be mounte d to EN50022-35x7.5 or EN50022-35x15 DIN rails. DIN rail mounting dimensions are shown below. Refer to the mounting template inside the back cov er of t his document.) 2. Close the DIN latch, if it is open. 3. Hook the top slot over the DIN rail. 4. While pressing t he controller down against th e top of the rail, snap the bottom of the contro ller into position. 5. Leav e the protective debris shield a ttac hed until you are finished wiring the controller and any other devices. T o remov e your controller from the DIN rail: 1. Place a flat-blade screwdri ver in the DIN rail la tch at the bo ttom of the controller. 2. Holding the controller, pr y downward on the latch until the latc h locks in the open position. 3. R epeat ste ps 1 and 2 for the second DIN rail latch. 4. Unhook the top of the DIN rail slot from the rail. 27.5 mm (1.08 in.) 27.5 mm (1.08 in.) 90 mm (3.5 in.) The latch momentarily ope ns and locks into place. Debris that falls into the module could cause damage when the module is under pow er. The following illustration shows the location of th e end anchors.

Mount on Panel Use the dimensional template show n below to mount the mo dule. Mounting screws are required on ev er y module. TIP F or environments with greater vibration and shock concerns, use the panel mounting me thod described below, instead of DIN rail mounting.Do not pull on the ribbon cable. When you remov e or inser t a module with pow er applied, an electrical arc may occur. W or n contacts may create electrical resistance, reducing product reliability. Pull Loop In Class I, Division 2 applications, all modules m ust be mounted in direct contact with e ach other as shown on page 2-19.ATTENTION Before you install and wi re any device, disconnect pow er to the controller system. ATTENTION Calculate the maximum possible current in each powe r and common wire. Obser ve all electrical codes dictating the maximum cu r rent allo wable for each wire size. Cur rent abov e the maximum ratings may cause wiring to o v erheat, which can cause damag e. United States Only: If th e controller is installed within a potentially haz ardous environment, all wiring must comply with th e requirements stated in the National Electrical Code 501-4 (b). In addition t o labeling, use colored insulation to identify wiri ng based on signal characteristic s. F or example, you ma y use blue for dc wiring and red for ac wi ring. Wire without Spade Lugs When wiring without spade lugs, it is re commended to keep the finger-safe cov ers in place. Loosen the ter minal scre w and route the wires through th e opening in the fing er-safe cov er. Tighten t he ter minal screw making sure the pressure plate secures the wire. TIP Do not r un signal or communication wiring a nd pow er wiring in the same conduit.Then loosen the ter minal screw.