Because of the variety of uses for the products described in this publication, those
responsible for the application and use of this control equipment must satisfy
themselves that all necessary steps have been taken to assure that each application
and use meets all performance and safety requirements, including any applicable
laws, regulations, codes, and standards.
The illustrations, charts, sample programs and layout examples shown in this guide
are intended solely for purposes of example. Since there are many variables and
requirements associated with any particular installation, Allen-Bradley does not
assume responsibility or liability (to include intellectual property liability) for actual
use based on the examples shown in this publication.
Allen-Bradley publication SGI-1.1, Safety Guidelines for the Application,
Installation, and Maintenance of Solid-State Control (available from your local
Allen-Bradley office), describes some important dif
equipment and electromechanical devices that should be taken into consideration
when applying products such as those described in this publication.
Reproduction of the contents of this copyrighted publication, in whole or in part,
without written permission of Allen-Bradley Company, Inc., is prohibited.
Throughout this manual, we use notes to make you aware of safety considerations:
ferences between solid-state
Identifies information about practices or circumstances that can lead to
personal injury or death, property damage, or economic loss.
Attention statements help you to:
•identify a hazard
•avoid the hazard
•
recognize the consequences
Note Identifies information that is critical for successful application and
understanding of the product.
SLC 500, SLC 5/01, SLC 5/02, SLC 5/03, SLC 5/04, MicroLogix, DTAM, DTAM Micro, PanelView, RediPANEL, Dataliner, DH+, and
Data Highway Plus are trademarks of Rockwell Automation.
PLC-2, PLC-5 are registered trademarks of Rockwell Automation.
A.I. Series and WINtelligent LINX are trademarks of Rockwell Software Inc.
information below summarizes the changes to this manual since the last
printing as Publication 1761-6.3 — December 1997.
To help you find new information and updated information in this release of the
manual, we have included change bars as shown to the right of this paragraph.
New Information
The
table below lists sections that document new features and additional
information about existing features, and shows where to find this new information.
For This New InformationSee
Power supply inrushpage 1–13
Summary of Changes
Updated Information
Changes from the previous release of this manual that require you to reference
information differently are as follows:
•The DeviceNet communications information has been updated; see chapter 3,
Connecting the System.
•For updated information on automatic protocol switching, see chapter 3,
Connecting the System.
•The MicroLogix 1000 programmable controllers’ VA ratings and power supply
inrush specifications have been updated; see appendix A, Hardware Reference.
•The DF1 Full-Duplex and DH-485 configuration parameters have been updated;
see appendix D, Understanding Communication Protocols.
soc–i
MicroLogix 1000 Programmable Controllers User Manual
Preface
Notes:
soc–ii
Preface
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
•
conventions used in this manual
•Allen-Bradley support
P–1
MicroLogix 1000 Programmable Controllers User Manual
Preface
Who Should Use this Manual
Use this manual if you are responsible for designing, installing, programming, or
troubleshooting control systems that use MicroLogix 1000 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 1000 controllers. It describes the
procedures you use to install, wire, program, and troubleshoot your controller. This
manual:
•explains how to install and wire your controllers
•gives you an overview of the MicroLogix 1000 controller system
•provides the MicroLogix 1000 controllers’ instruction set
•
contains application examples to show the instruction set in use
P–2
See your programming software user manual for information on programming your
MicroLogix 1000 controller. For information on using the Hand-Held Programmer
with the MicroLogix 1000 controllers, see the MicroLogix 1000 with Hand-HeldProgrammer (HHP) User Manual, Publication 1761-6.2.
Contents of this Manual
TabChapterTitleContents
Preface
Preface
Describes the purpose, background, and scope
of this manual. Also specifies the audience for
whom this manual is intended.
Hardware
Programming
Programming
1
2
3Connecting the System
4Programming Overview
5Using Analog
6Using Basic Instructions
7
8
9
10
11
12
13
Installing Your
Controller
Wiring Your ControllerProvides wiring guidelines and diagrams.
Using Comparison
Instructions
Using Math Instructions
Using Data Handling
Instructions
Using Program Flow
Control Instructions
Using Application
Specific Instructions
Using High-Speed
Counter Instructions
Using the Message
Instruction
Provides controller installation procedures and
system safety considerations.
Gives information on wiring your controller
system for the DF1 protocol or DH-485 network.
Provides an overview of principles of machine
control, a section on file organization and
addressing, and a program development model.
Provides information on I/O image file format,
I/O configuration, input filter and update times,
and conversion of analog data.
Describes how to use ladder logic instructions
for relay replacement functions, counting, and
timing.
Describes how to use the instructions to
compare values of data in your ladder logic
program.
Describes how to use the ladder logic
instructions that perform basic math functions.
Describes how to perform data handling
instructions, including move and logical
instructions and FIFO and LIFO instructions.
Describes the ladder logic instructions that affect
program flow and execution.
Describes the bit shift, sequencer and STI
related instructions.
Describes the four modes of the high-speed
counter and its related instructions.
Provides a general overview of the types of
communication, and explains how to establish
network communication using the message
instruction.
Troubleshooting14
Troubleshooting Your
System
Explains how to interpret and correct problems
with your MicroLogix 1000 controller system.
P–3
MicroLogix 1000 Programmable Controllers User Manual
Rfc
Preface
TabContentsTitleChapter
Appendix AHardware Reference
Appendix B
Appendix C
Reference
Appendix D
Programming
Reference
Valid Addressing Modes
and File Types for
Instruction Parameters
Understanding the
Communication
Protocols
Provides physical, electrical, environmental, and
functional specifications.
Explains the system status file and provides
instruction execution times.
Provides a listing of the instructions along with
their parameters and valid file types.
Contains descriptions of the DF1 protocol and
DH-485 network.
Appendix E
Appendix F
Application Example
Programs
Optional Analog Input
Software Calibration
Glossary
Provides advanced application examples for the
high-speed counter, sequencer, bit shift, and
message instructions.
Explains how to calibrate your controller using
software offsets.
Contains definitions for terms and abbreviations
that are specific to this product.
P–4
Related Documentation
The following documents contain additional information concerning Allen-Bradley
products. To obtain a copy, contact your local Allen-Bradley office or distributor.
Preface
ForRead this Document
A procedural manual for technical personnel
who use the Allen-Bradley Hand-Held
Programmer (HHP) to monitor and develop
control logic programs for the MicroLogix 1000
controller.
Information on mounting and wiring the
Information on mounting and wiring the
MicroLogix 1000 controllers, including a
mounting template for easy installation
The procedures necessary to install and
connect the AIC+ and DNI
A description on how to install and connect an
AIC+. This manual also contains information
on network wiring.
Information on how to install, configure, and
commission a DNI
In-depth information on grounding and wiring
Allen-Bradley programmable controllers
A description of important differences between
solid-state programmable controller products
and hard-wired electromechanical devices
MicroLogix 1000 with Hand-Held
Programmer (HHP) User Manual
Advanced Interface Converter (AIC+)
and DeviceNet Interface (DNI)
Installation Instructions
Advanced Interface Converter (AIC+)
User Manual
DeviceNet Interface User Manual
Allen-Bradley Programmable Controller
Grounding and Wiring Guidelines
Application Considerations for
Solid-State Controls
Document
Number
1761-6.2
1761-5.1.2
1761-5.1.3
1761-5.11
1761-6.4
1761-6.5
1770-4.1
SGI-1.1
An article on wire sizes and types for
grounding electrical equipment
A complete listing of current documentation,
including ordering instructions. Also indicates
whether the documents are available on
CD-ROM or in multi-languages.
A glossary of industrial automation terms and
abbreviations
Information on understanding and applying
MicroLogix 1000 controllers
Published by
National Electrical Code
Allen-Bradley Publication IndexSD499
Allen-Bradley Industrial Automation
Glossary
MicroMentor1761-MMB
the National
Fire Protection
Association of
Boston, MA.
AG-7.1
P–5
MicroLogix 1000 Programmable Controllers User Manual
Preface
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.
Allen-Bradley Support
Allen-Bradley offers support services worldwide, with over 75 Sales/Support
Offices, 512 authorized Distributors and 260 authorized Systems Integrators located
throughout the United States alone, plus Allen-Bradley representatives in every
major country in the world.
Local Product Support
Contact your local Allen-Bradley representative for:
•
sales and order support
•product technical training
•warranty support
•
support service agreements
Technical Product Assistance
If
you need to contact Allen-Bradley for technical assistance, please review the
information in the Tr
representative.
oubleshooting
chapter first. Then call your local Allen-Bradley
Your Questions or Comments on this Manual
If you find a problem with this manual, or you have any suggestions for how this
manual could be made more useful to you, please contact us at the address below:
Allen-Bradley Company, Inc.
Control and Information Group
T
echnical Communication, Dept. 602V
P
.O. Box 2086
Milwaukee, WI 53201-2086
or visit our internet page at:
http://www.ab.com/micrologix
P–6
, T122
Installing Your Controller
1
Installing Your Controller
This chapter shows you how to install your controller system. The only tools you
require are a Flat head or Phillips head screwdriver and drill. T
•compliance to European Union Directives
•hardware overview
•master control relay
•sur
•
•
•
•controller spacing
•mounting the controller
ge suppressors
safety considerations
power considerations
preventing excessive heat
opics include:
Hardware
1–1
MicroLogix 1000 Programmable Controllers User Manual
Preface
Compliance to European Union Directives
If this product has the CE mark it is approved for installation within the European
Union and EEA regions. It has been designed and tested to meet the following
directives.
EMC Directive
This product is tested to meet Council Directive 89/336/EEC Electromagnetic
Compatibility (EMC) and the following standards, in whole or in part, documented
in a technical construction file:
•EN 50081-2
EMC – Generic Emission Standard, Part 2 – Industrial Environment
•EN 50082-2
EMC – Generic Immunity Standard, Part 2 – Industrial Environment
This product is intended for use in an industrial environment.
1–2
Hardware Overview
The MicroLogix 1000 programmable controller is a packaged controller containing
a power supply, input circuits, output circuits, and a processor. The controller is
available in 10 I/O, 16 I/O and 32 I/O configurations, as well as an analog version
with 20 discrete I/O and 5 analog I/O.
The catalog number for the controller is composed of the following:
Installing Your Controller
10
Bulletin Number
Base Unit
Unit I/O Count: 20
Input Signal:
A = 120V ac
B = 24V dc
1761-L20AWA-5A
Analog I/O
Analog Circuits:
Inputs = 4
Outputs = 1
Power Supply:
A = 120/240V ac
B = 24V dc
Output Type:
W = Relay
B = MOSFET
A = Triac
Hardware
The hardware features of the controller are:
1
2
3
4
5
6
7
8
9
3
POWER
RUN
FAULT
FORCE
IN
OUT
1
Input terminals
2
dc output terminals (or not used)
3
Mounting hole
Input LEDs
4
Status LEDs
5
6
RS-232 communication channel
7
Output LEDs
8
Power supply line power
9
Ground screw
Output terminals
10
20142
1–3
MicroLogix 1000 Programmable Controllers User Manual
Preface
Master Control Relay
A hard-wired master control relay (MCR) provides a reliable means for emergency
controller shutdown. Since the master control relay allows the placement of several
emer
gency-stop switches in dif
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
figure on page 1–6.
ferent locations, its installation is important from a
Note If
Never alter these cir
machine damage could result.
you ar
e using an external dc output power supply
rather than the ac line side of the supply to avoid the additional delay of power
supply turn-off.
The external ac line of the dc output power supply should be fused.
Connect a set of master contr
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 emer
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’
diagnostic indicators on the processor can still be observed.
cuits to defeat their function, since serious injury and/or
, interrupt the dc output side
ol r
elays in series with the dc power supplying the
gency-stop switches are opened, power to input and
s power supply so that
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-ener
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.
NoteDo
with the safety of a dir
master contr
1–4
not contr
ol the master contr
ect connection between an emer
ol r
elay.
ol r
elay with the contr
gize I/O devices
oller. Pr
gency-stop switch and the
ovide the operator
Using Emergency-Stop Switches
When using emergency-stop switches, adhere to the following points:
•Do not program emergency-stop switches in the controller program. Any
emergency-stop switch should turn off all machine power by turning off the
master control relay.
•
Observe all applicable local codes concerning the placement and labeling of
emer
gency-stop switches.
•Install emer
Make certain that relay contacts have a suf
Emer
gency-stop switches and the master control relay in your system.
gency-stop switches must be easy to reach.
•In the following illustration, input and output circuits are shown with MCR
protection. However
protection.
Installing Your Controller
ficient rating for your application.
, in most applications, only output circuits require MCR
Hardware
1–5
MicroLogix 1000 Programmable Controllers User Manual
L1L2
Preface
The following illustrations show the Master Control Relay wired in a grounded
system.
NoteThe
illustrations only show output cir
applications input cir
r
emove power fr
om all field devices, you must include MCR contacts in series with
input power wiring.
Schematic (Using IEC Symbols)
230V ac
Disconnect
Isolation
Transformer
230V ac
X1
Fuse
X2
Operation of either of these contacts will
remove power from the adapter external I/O
circuits, stopping machine motion.
Emergency-Stop
Push Button
cuits do not r
Overtravel
Limit Switch
cuits with MCR pr
equire MCR pr
Stop
otection. In most
otection; however
Fuse
Master Control Relay (MCR)
Start
Cat. No. 700-PK400A1
, if you need to
MCR
Suppressor
Cat. No. 700-N24
MCR
230V ac
I/O Circuits
1–6
(Lo)(Hi)
erminals: Connect to 230V ac
Line T
terminals of Power Supply
MCR
Suppr.
230V ac
I/O Circuits
24V dc
I/O Circuits
MCR
MCR
dc Power Supply
Use IEC 950/EN 60950
—
.
Line terminals: Connect to 24V dc
terminals of Power Supply
.
+
.
Schematic (Using ANSI/CSA Symbols)
L1L2
230V ac
Disconnect
Fuse
Installing Your Controller
MCR
230V ac
Output
Circuits
Isolation
Transformer
115V ac
X1
Fuse
Operation of either of these contacts will
remove power from the adapter external I/O
X2
circuits, stopping machine motion.
(Lo)(Hi)
Line T
terminals of Power Supply
Emergency-Stop
Push Button
erminals: Connect to 1
.
Overtravel
Limit Switch
15V ac
Stop
Master Control Relay (MCR)
Cat. No. 700-PK400A1
.
+
Suppressor
Cat. No. 700-N24
1
15V ac
Output
Circuits
MCR
.
Start
MCR
MCR
dc Power Supply
Use N.E.C. Class 2
for UL Listing.
—
Line terminals: Connect to 24V dc
terminals of Power Supply
MCR
Suppr.
24V dc
Output
Circuits
Hardware
1–7
MicroLogix 1000 Programmable Controllers User Manual
Preface
Using Surge Suppressors
Inductive
load devices such as motor starters and solenoids require the use of some
type of surge suppression to protect the controller output contacts. Switching
inductive loads without sur
ge suppression can
significantly reduce the lifetime of
relay contacts. By adding a suppression device directly across the coil of an
inductive device, you will prolong the life of the switch contacts. Y
ou will also
reduce the effects of voltage transients caused by interrupting the current to that
inductive device, and will prevent electrical noise from radiating into system wiring.
The following diagram shows an output with a suppression device. We recommend
that you locate the suppression device as close as possible to the load device.
+
dc or L1
ac
or dc
Outputs
VAC/VDC
OUT 0
OUT
OUT 2
OUT 3
OUT
OUT 5
OUT 6
OUT 7
COM
1
4
Snubber
dc COM or L2
If you connect a micro controller FET output to an inductive load, we recommend
that you use an 1N4004 diode for sur
ge suppression, as shown in the illustration that
follows.
1–8
Relay
or Solid State
dc Outputs
VAC/VDC
OUT 0
OUT
OUT 2
OUT 3
OUT
OUT 5
OUT 6
OUT 7
COM
+24V
dc
1
4
24V dc common
IN4004 Diode
Installing Your Controller
Suitable sur
an RC network, or an Allen-Bradley sur
components must be appropriately rated to suppress the switching transient
characteristic of the particular inductive device. See the table on page 1–10 for
recommended suppressors.
Output Device
Varistor
If you connect a micro controller triac output to control an inductive load, we
recommend that you use varistors to suppress noise. Choose a varistor that is
appropriate for the application. The suppressors we recommend for triac outputs
when switching 120V ac inductive loads are a Harris MOV
LA10A, or an Allen-Bradley MOV, catalog number 599-K04 or 599-KA04.
Consult the varistor manufacturer’s data sheet when selecting a varistor for your
application.
For inductive dc load devices, a diode is suitable. An 1N4004 diode is acceptable
for most applications. A sur
page 1–10 for recommended suppressors.
ge suppression methods for inductive ac load devices include a varistor
ge suppressor
Surge Suppression for Inductive ac Load Devices
Output DeviceOutput DeviceOutput Device
RC Network
, all shown below. These
Surge
Suppressor
, part number V175
ge suppressor can also be used. See the table on
,
Hardware
As shown in the illustration below
, these sur
ge suppression circuits connect directly
across the load device. This reduces arcing of the output contacts. (High transient
can cause arcing that occurs when switching of
Surge Suppression for Inductive dc Load Devices
—
Output Device
Output Device
(A surge suppressor can also be used.)
Diode
f an inductive device.)
+
1–9
MicroLogix 1000 Programmable Controllers User Manual
Preface
Recommended Surge Suppressors
We recommend the Allen-Bradley sur
ge suppressors shown in the following table
for use with Allen-Bradley relays, contactors, and starters.
DeviceCoil Voltage
Bulletin 509 Motor Starter
Bulletin 509 Motor Starter
Bulletin 100 Contactor
Bulletin 100 Contactor
Bulletin 709 Motor Starter120V ac1401-N10
Bulletin 700 Type R, RM Relaysac coilNone Required
Bulletin 700 Type R Relay
Bulletin 700 Type RM Relay
Bulletin 700 Type R Relay
Bulletin 700 Type RM Relay
Bulletin 700 Type R Relay
Bulletin 700 Type RM Relay
Bulletin 700 Type R Relay
Bulletin 700 Type RM Relay
Bulletin 700 Type R Relay
Bulletin 700 Type RM Relay
Bulletin 700 Type N, P, or PK Relay150V max, ac or DC700-N24
120V ac
240V ac
120V ac
240V ac
12V dc
12V dc
24V dc
24V dc
48V dc
48V dc
115-125V dc
115-125V dc
230-250V dc
230-250V dc
Suppressor Catalog
599-K04
599-KA04
199-FSMA1
199-FSMA2
700-N22
700-N28
700-N10
700-N13
700-N16
700-N17
700-N11
700-N14
700-N12
700-N15
Number
1–10
Miscellaneous electromagnetic devices
limited to 35 sealed VA
150V max, ac or DC700-N24
Safety Considerations
Safety considerations are an important element of proper system installation.
Actively thinking about the safety of yourself and others, as well as the condition of
your equipment, is of primary importance. We recommend reviewing the following
safety considerations.
Disconnecting Main Power
Explosion Hazard — Do not replace components or disconnect equipment
unless power has been switched off and the area is known to be
non-hazardous.
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.
Installing Your Controller
Hardware
Safety Circuits
Explosion Hazard — Do not connect or disconnect connectors while circuit is
live unless ar
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
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.
ea is known to be non-hazardous.
. These devices must be wired in series so that when any one device
1–11
MicroLogix 1000 Programmable Controllers User Manual
Preface
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.
•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 is connected through a
set of master control relay contacts.
Periodic Tests of Master Control Relay Circuit
Any part can fail, including the switches in a master control relay circuit. The
failure of one of these switches would most likely cause an open circuit, which
would be a safe power-off failure. However
no longer provides any safety protection. These switches should be tested
periodically to assure they will stop machine motion when needed.
, if one of these switches shorts out, it
1–12
Power Considerations
The following explains power considerations for the micro controllers.
Isolation Transformers
You may want to use an isolation transformer in the ac line to the controller. This
type of transformer provides isolation from your power distribution system and is
often used as a step down transformer to reduce line voltage. Any transformer used
with the controller must have a sufficient power rating for its load. The power
rating is expressed in volt-amperes (VA).
Power Supply Inrush
The MicroLogix power supply does not require or need a high inrush current.
However, if the power source can supply a high inrush current, the MicroLogix
power supply will accept it. There is a high level of inrush current when a large
capacitor on the input of the MicroLogix is charged up quickly.
If the power source cannot supply high inrush current, the only effect is that the
MicroLogix input capacitor char
determine whether the power source needs to supply a high inrush current:
•power
•power source sag if it cannot source inrush current
•the effect of the voltage sag on other equipment
-up sequence of devices in system
ges up more slowly
Installing Your Controller
. The following considerations
If the power source cannot provide high inrush current when the entire system in an
application is powered, the MicroLogix powers-up more slowly. If part of an
application’
powered, the source voltage may sag while the MicroLogix input capacitor is
charging. A power source voltage sag can affect other equipment connected to the
same power source. For example, a voltage sag may reset a computer connected to
the same power source.
s system is already powered and operating when the MicroLogix is
1–13
MicroLogix 1000 Programmable Controllers User Manual
Preface
Loss of Power Source
The
power supply is designed to withstand brief power losses without af
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 20 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.
fecting the
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.
Hardware
1–14
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