Rockwell Automation 1761 User Manual

Allen-Bradley

MicroLogix 1000 Programmable Controllers

(Bulletin

1761 Controllers)

User Manual

Important User Information

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.

able of Contents

Preface P–1.

1 Installing Your Controller 1–1.

2 Wiring Your Controller 2–1.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Who

Should Use this Manual Purpose of this Manual Common T

Allen-Bradley Support P–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compliance to European Union Directives 1–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hardware Overview 1–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Master Control Relay Using Sur Safety Considerations Power Considerations Preventing Excessive Heat

Controller Spacing 1–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting the Controller 1–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Grounding

Sinking and Sourcing Circuits 2–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iring Recommendations

W Wiring Diagrams, Discrete Input and Output V Analog Cable Recommendation

Minimizing Electrical Noise on Analog Controllers 2–21. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring Y

Analog Voltage and Current Input and Output Ranges 2–23. . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring Your Controller for High–Speed Counter Applications 2–24. . . . . . . . . . . . . . . . . . . .

echniques Used in this Manual

ge Suppressors

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Guidelines

our Analog Channels

P–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

P–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

P–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hardware

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

oltage Ranges

2–7. . . . . . . . . . . . . . . . . . . . . .

2–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Connecting the System 3–1.

Connecting the DF1 Protocol 3–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting to a DH-485 Network 3–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting the AIC+

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

toc–i

MicroLogix 1000 Programmable Controllers User Manual

Preface

Establishing Communication 3–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DeviceNet Communications

Programming

3–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Programming Overview 4–1.

Principles of Machine Control 4–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Understanding File Organization 4–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Understanding How Processor Files are Stored and Accessed Addressing Data Files

Applying Ladder Logics to Your Schematics 4–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Developing Your Logic Program – A Model 4–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Using Analog 5–1.

I/O Image 5–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I/O Configuration 5–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Input Filter and Update Times 5–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Converting Analog Data 5–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 Using Basic Instructions 6–1.

About

the Basic Instructions

Bit Instructions Overview 6–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Examine if Closed (XIC) 6–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Examine if Open (XIO) 6–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Output Energize (OTE) 6–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Output Latch (OTL) and Output Unlatch (OTU) 6–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

One-Shot Rising (OSR) 6–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Timer Instructions Overview 6–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Timer On-Delay (TON) 6–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Timer Off-Delay (TOF) 6–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Retentive Timer (RTO) 6–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Counter Instructions Overview 6–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Count Up (CTU) 6–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Count Down (CTD) 6–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reset (RES) 6–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Basic Instructions in the Paper Drilling Machine Application Example 6–21. . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4–6. . . . . . . . . . . . . . . . . . . . . .

4–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 Using Comparison Instructions 7–1.

About the Comparison Instructions 7–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Comparison Instructions Overview 7–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

toc–ii

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

able of Contents

Equal (EQU) 7–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Not Equal (NEQ) 7–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Less Than (LES) 7–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Less Than or Equal (LEQ) 7–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Greater Than (GRT) 7–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Greater Than or Equal (GEQ) 7–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Masked Comparison for Equal (MEQ) 7–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Limit Test (LIM) 7–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Comparison Instructions in the Paper Drilling Machine Application Example 7–8. . . . . . . . .

8 Using Math Instructions 8–1.

About

the Math Instructions

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Math Instructions Overview 8–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Add (ADD) 8–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Subtract (SUB) 8–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32-Bit Addition and Subtraction 8–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Multiply (MUL) 8–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Divide (DIV) 8–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Double Divide (DDV) 8–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clear (CLR) 8–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Square Root (SQR) 8–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Scale Data (SCL) 8–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Math Instructions in the Paper Drilling Machine Application Example 8–14. . . . . . . . . . . . .

9 Using Data Handling Instructions 9–1.

About the Data Handling Instructions 9–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Convert to BCD (TOD) 9–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Convert from BCD (FRD) 9–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Decode 4 to 1 of 16 (DCD) 9–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Encode 1 of 16 to 4 (ENC) 9–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Copy File (COP) and Fill File (FLL) Instructions 9–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Move and Logical Instructions Overview 9–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Move (MOV) Masked Move (MVM)

And (AND) 9–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Or (OR) 9–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exclusive Or (XOR) 9–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Not (NOT) 9–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Negate (NEG) 9–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIFO and LIFO Instructions Overview 9–23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIFO Load (FFL) and FIFO Unload (FFU) 9–25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIFO Load (LFL) and LIFO Unload (LFU) 9–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

toc–iii

MicroLogix 1000 Programmable Controllers User Manual

Preface

Data Handling Instructions in the Paper Drilling Machine Application Example 9–28. . . . . .

10 Using Program Flow Control Instructions 10–1.

About the Program Flow Control Instructions 10–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Jump (JMP) and Label (LBL) 10–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Jump to Subroutine (JSR), Subroutine (SBR), and Return (RET) 10–4. . . . . . . . . . . . . . . . . .

Master Control Reset (MCR)

Temporary End (TND) 10–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Suspend (SUS) 10–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Immediate Input with Mask (IIM) 10–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Immediate Output with Mask (IOM) 10–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

w C

Program Flo A

pplication Example 10–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ontrol Instruction

11 Using Application Specific Instructions 11–1.

s i

n the Paper Drillin

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

About the Application Specific Instructions 11–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bit Shift Instructions Overview 11–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bit Shift Left (BSL) 11–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bit Shift Right (BSR) 11–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sequencer Instructions Overview 11–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sequencer Output (SQO) and Sequencer Compare (SQC) 11–7. . . . . . . . . . . . . . . . . . . . . . . .

Sequencer Load (SQL) 11-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selectable Timed Interrupt (STI) Function Overview 11–15. . . . . . . . . . . . . . . . . . . . . . . . . .

Selectable Timed Disable (STD) and Enable (STE) 11–18. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selectable Timed Start (STS) 11–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Interrupt Subroutine (INT) 11–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Application Specific Instructions in the Paper Drilling Machine

Application Example 11–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

g M

achine

12 Using High-Speed Counter Instructions 12–1.

About the High-Speed Counter Instructions 12–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High-Speed Counter Instructions Overview 12–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High-Speed Counter (HSC) 12–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High-Speed Counter Load (HSL) 12-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High-Speed Counter Reset (RES) 12–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High-Speed Counter Reset Accumulator (RAC) 12–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High-Speed Counter Interrupt Enable (HSE) and Disable (HSD) 12–23. . . . . . . . . . . . . . . . .

Update High-Speed Counter Image Accumulator (OTE) 12–24. . . . . . . . . . . . . . . . . . . . . . . .

What Happens to the HSC When Going to REM Run Mode High-Speed Counter Instructions in the Paper Drilling Machine

Application Example 12–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

toc–iv

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12–25. . . . . . . . . . . . . . . . . . . . .

able of Contents

13 Using the Message Instruction 13–1.

Types of Communication 13–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Message Instruction (MSG)

Timing Diagram for a Successful MSG Instruction 13–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MSG Instruction Error Codes 13–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Application Examples that Use the MSG Instruction 13–12. . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting

14 Troubleshooting Your System 14–1.

Understanding the Controller LED Status 14–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Controller Error Recovery Model 14–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Identifying Controller Faults 14–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Calling Allen-Bradley for Assistance

Reference

A Hardware Reference A–1.

Controller Specifications A–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Controller Dimensions A–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement Parts

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B Programming Reference B–1.

Controller Status File B–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instruction Execution T

C Valid Addressing Modes and File Types for Instruction Parameters C–1.

Available File Types C–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

vailable Addressing Modes

D Understanding the Communication Protocols D–1.

RS-232 Communication Interface D–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DF1 Full-Duplex Protocol D–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DF1 Half-Duplex Slave Protocol D–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DH-485 Communication Protocol D–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

imes and Memory Usage

. . . . . . . . . . . . . . . . . . . . . . . . . . .

B–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . .

C–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

toc–v

MicroLogix 1000 Programmable Controllers User Manual

Preface

E Application Example Programs E–1.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paper Drilling Machine Application Example E–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Time Driven Sequencer Application Example E–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Event Driven Sequencer Application Example E–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bottle Line Example E–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pick and Place Machine Example E–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RPM Calculation Application Example

On/Off Circuit Application Example E–34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spray Booth Application Example E–36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjustable Timer Application Example E–41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F Optional Analog Input Software Calibration F–1.

Calibrating an Analog Input Channel F–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Glossary G–1.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E–28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

toc–vi

Summary of Changes

The

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 Information See

Power supply inrush page 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

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-Held Programmer (HHP) User Manual, Publication 1761-6.2.

Contents of this Manual

Tab Chapter Title Contents

Preface

Describes the purpose, background, and scope of this manual. Also specifies the audience for whom this manual is intended.

Hardware

Programming

1 2 3 Connecting the System

4 Programming Overview

5 Using Analog

6 Using Basic Instructions

Installing Your Controller

Wiring Your Controller Provides 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.

Troubleshooting 14

Troubleshooting Your System

Explains how to interpret and correct problems with your MicroLogix 1000 controller system.

P–3

MicroLogix 1000 Programmable Controllers User Manual

Rf c

Preface

Tab ContentsTitleChapter

Appendix A Hardware 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

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

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

.O. Box 2086

Milwaukee, WI 53201-2086 or visit our internet page at:

http://www.ab.com/micrologix

P–6

, T122

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

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

8 9

POWER RUN FAULT FORCE

OUT

Input terminals

dc output terminals (or not used)

Mounting hole Input LEDs

Status LEDs

5 6

RS-232 communication channel

Output LEDs

Power supply line power

Ground screw Output terminals

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.

Note Do

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

L1 L2

Preface

The following illustrations show the Master Control Relay wired in a grounded system.

Note The

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

Fuse

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

dc Power Supply Use IEC 950/EN 60950

—

Line terminals: Connect to 24V dc terminals of Power Supply

Schematic (Using ANSI/CSA Symbols)

L1 L2

230V ac

Disconnect

Fuse

Installing Your Controller

MCR

230V ac Output Circuits

Isolation Transformer

115V ac

Fuse

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

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

15V ac Output Circuits

MCR

Start

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

or dc

Outputs

VAC/VDC

OUT 0

OUT OUT 2 OUT 3 OUT OUT 5

OUT 6 OUT 7

COM

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

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 Device Output 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

(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.

Device Coil Voltage

Bulletin 509 Motor Starter Bulletin 509 Motor Starter

Bulletin 100 Contactor Bulletin 100 Contactor

Bulletin 709 Motor Starter 120V ac 1401-N10 Bulletin 700 Type R, RM Relays ac coil None Required Bulletin 700 Type R Relay

Bulletin 700 Type RM Relay Bulletin 700 Type R Relay

Bulletin 700 Type RM Relay Bulletin 700 Type N, P, or PK Relay 150V max, ac or DC 700-N24

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 DC 700-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

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+ 392 hidden pages

Rockwell Automation 1761 User Manual

Important User Information

Table of Contents

Summary of Changes

New Information

Updated Information

Preface

Who Should Use this Manual

Purpose of this Manual

Common Techniques Used in this Manual

Allen-Bradley Support

Compliance to European Union Directives

Hardware Overview

Master Control Relay

Using Surge Suppressors

Safety Considerations

Power Considerations