Rockwell Automation 1763 User Manual

MicroLogix 1100 Programmable Controllers

Bulletin 1763 Controllers and 1762 Expansion I/O

User Manual

Important User Information

WARNING

IMPORTANT

ATTENTION

SHOCK HAZARD

BURN HAZARD

Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from your local Rockwell Automation sales office or online at http://literature.rockwellautomation.com

) describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited.

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.

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

Identifies information about practices or circumstances that can lead to: personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.

Labels may be on or inside the equipment, such as a drive or motor, to alert people that dangerous voltage may be present.

Labels may be on or inside the equipment, such as a drive or motor, to alert people that surfaces may reach dangerous temperatures.

Rockwell Automation, DeviceNet, ModBus, Allen-Bradley, SLC 5/02, SLC 5/03, PLC-5, MicroLogix, SLC 500, RSLogix, RSLinx, and RSLogix 500 are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

Publication 1763-UM001D-EN-P - March 2011

Summary of Changes

To help you find new and updated information in this release of the manual, we have included change bars as shown to the right of this paragraph.

Firmware Revision History

Features are added to the controllers through firmware upgrades. See the latest release notes, 1763-RN003 level you need. Firmware upgrades are not required, except to allow you access to the new features.

, to be sure that your controller’s firmware is at the

1 Publication 1763-UM001D-EN-P - March 2011

Summary of Changes 2

Notes:

Publication 1763-UM001D-EN-P - March 2011

Summary of Changes

Firmware Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Table of Contents Preface

Who Should Use this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Purpose of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Related Documentation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Common Techniques Used in this Manual. . . . . . . . . . . . . . . . . . . . . . 10

Chapter 1

Hardware Overview

Hardware Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Component Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

MicroLogix 1100 Memory Module and Built-in Real-Time Clock 12

1762 Expansion I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Communication Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Communication Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Chapter 2

Installing Your Controller

Agency Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Compliance to European Union Directives . . . . . . . . . . . . . . . . . . . . . 19

EMC Directive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Low Voltage Directive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Safety Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Hazardous Location Considerations. . . . . . . . . . . . . . . . . . . . . . . . 21

Disconnecting Main Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Safety Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Periodic Tests of Master Control Relay Circuit . . . . . . . . . . . . . . . 23

Power Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Isolation Transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Power Supply Inrush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Loss of Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Input States on Power Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Other Types of Line Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Preventing Excessive Heat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Master Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Using Emergency-Stop Switches . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Schematic (Using IEC Symbols) . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Schematic (Using ANSI/CSA Symbols). . . . . . . . . . . . . . . . . . . . . 29

Installing a Memory Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Using the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Connecting the Battery Wire Connector . . . . . . . . . . . . . . . . . . . . 32

Controller Mounting Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Controller and Expansion I/O Spacing . . . . . . . . . . . . . . . . . . . . . . . . 33

Mounting the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

DIN Rail Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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4 Table of Contents

Wiring Your Controller

Panel Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

1762 Expansion I/O Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Mounting 1762 Expansion I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

DIN Rail Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Panel Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Connecting Expansion I/O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Chapter 3

Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Wiring Recommendation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Wiring the Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Using Surge Suppressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Recommended Surge Suppressors . . . . . . . . . . . . . . . . . . . . . . . . . 45

Grounding the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Terminal Block Layouts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Terminal Groupings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Sinking and Sourcing Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . 50

1763-L16AWA, 1763-L16BWA, 1763-L16BBB and 1763-L16DWD

Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Controller I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Minimizing Electrical Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Wiring Your Analog Channels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Analog Channel Wiring Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . 53

Minimizing Electrical Noise on Analog Channels . . . . . . . . . . . . . 54

Grounding Your Analog Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Expansion I/O Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Digital Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Analog Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Communication Connections

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Chapter 4

Supported Communication Protocols. . . . . . . . . . . . . . . . . . . . . . . . . . 71

Default Communication Configuration . . . . . . . . . . . . . . . . . . . . . . . . 72

Using the Communications Toggle Functionality . . . . . . . . . . . . . . . . 72

Changing Communication Configuration . . . . . . . . . . . . . . . . . . . 73

Connecting to the RS-232 Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Making a DF1 Point-to-Point Connection. . . . . . . . . . . . . . . . . . . 77

Using a Modem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Connecting to a DF1 Half-Duplex Network . . . . . . . . . . . . . . . . . 80

Connecting to a DH-485 Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

DH-485 Configuration Parameters. . . . . . . . . . . . . . . . . . . . . . . . . 83

Recommended Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

DH-485 Communication Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Connecting the Communication Cable to the DH-485 Connector .

Using the LCD

Table of Contents 5

Grounding and Terminating the DH-485 Network . . . . . . . . . . . 87

Connecting the AIC+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Cable Selection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Recommended User-Supplied Components . . . . . . . . . . . . . . . . . 93

Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Install and Attach the AIC+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Powering the AIC+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Connecting to DeviceNet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Cable Selection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Connecting to Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Ethernet Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Chapter 5

Operating Principles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Startup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Main Menu and Default Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Operating Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Using Menus to Choose Values . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Selecting Between Menu Items . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Cursor Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Setting Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

I/O Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Viewing I/O Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Monitoring Bit File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Target Bit File Number (TBF) . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Monitoring a Bit File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Monitoring Integer File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Target Integer File Number (TIF) . . . . . . . . . . . . . . . . . . . . . . . . 117

Monitoring an Integer File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Using the Mode Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Controller Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Changing Mode Switch Position. . . . . . . . . . . . . . . . . . . . . . . . . . 125

Using a User Defined LCD Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

User Defined LCD Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Configuring Advanced Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Changing Key In Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Key In Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Changing Key In Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Using Communications Toggle Functionality . . . . . . . . . . . . . . . . . . 133

Viewing Ethernet Port Configuration. . . . . . . . . . . . . . . . . . . . . . . . . 133

Using Trim Pots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Trim Pot Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Changing Data Value of a Trim Pot . . . . . . . . . . . . . . . . . . . . . . . 135

Trim Pot Configuration in LCD Function File . . . . . . . . . . . . . . 137

Error Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Viewing System Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

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6 Table of Contents

Using Real-Time Clock and Memory Modules

Viewing Fault Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Chapter 6

Real-Time Clock Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Operation at Power-up and Entering a Run or

Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Writing Data to the Real-Time Clock. . . . . . . . . . . . . . . . . . . . . . 142

RTC Battery Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Memory Module Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

User Program , User Data and Recipe Back-up. . . . . . . . . . . . . . 143

Program Compare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Data File Download Protection . . . . . . . . . . . . . . . . . . . . . . . . . . 144

Memory Module Write Protection . . . . . . . . . . . . . . . . . . . . . . . . 144

Removal/Insertion Under Power . . . . . . . . . . . . . . . . . . . . . . . . . 144

Memory Module Information File . . . . . . . . . . . . . . . . . . . . . . . . 144

Program /Data Download . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Program /Data Upload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Online Editing

Specifications

Chapter 7

Overview of Online Editing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Online Editing Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Effects of Online Editing On Your System . . . . . . . . . . . . . . . . . . . . 149

System Impacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

Data Table File Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Online Edit Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Directions and Cautions for MicroLogix 1100 Online

Edit User. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Change the RSLinx "Configure CIP Option"

(OS Series A FRN 1,2, and 3 only) . . . . . . . . . . . . . . . . . . . . . . . . 150

A Download Before Starting Online Edit . . . . . . . . . . . . . . . . . . 151

Types of Online Editing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Edit Functions in Runtime Online Editing . . . . . . . . . . . . . . . . . 154

Edit Functions in Program Online Editing . . . . . . . . . . . . . . . . . 154

Appendix A

Expansion I/O Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Digital I/O Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Analog Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

Replacement Parts

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Appendix B

MicroLogix 1100 Replacement Kits . . . . . . . . . . . . . . . . . . . . . . . . . . 179

Lithium Battery (1763-BA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

Battery Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

Troubleshooting Your System

Table of Contents 7

Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

Appendix C

Understanding the Controller Indicator Status. . . . . . . . . . . . . . . . . . 185

Controller Status LED Indicators. . . . . . . . . . . . . . . . . . . . . . . . . 185

Status Indicators on the LCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

I/O Status Indicators on the LCD . . . . . . . . . . . . . . . . . . . . . . . . 187

Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Error Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Controller Error Recovery Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

Analog Expansion I/O Diagnostics and Troubleshooting . . . . . . . . 190

Module Operation and Channel Operation . . . . . . . . . . . . . . . . . 190

Power-up Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

Critical and Non-Critical Errors . . . . . . . . . . . . . . . . . . . . . . . . . . 191

Module Error Definition Table. . . . . . . . . . . . . . . . . . . . . . . . . . . 191

Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

Calling Rockwell Automation for Assistance . . . . . . . . . . . . . . . . . . . 194

Using Control Flash to Upgrade Your Operating System

Connecting to Networks via RS-232/RS-485 Interface

Appendix D

Preparing for Upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

Install ControlFlash Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

Prepare the Controller for Updating. . . . . . . . . . . . . . . . . . . . . . . 196

Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

Missing/Corrupt OS LED Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

Appendix E

RS-232 Communication Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

RS-485 Communication Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

DF1 Full-Duplex Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

DF1 Half-Duplex Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

DF1 Half-Duplex Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

Considerations When Communicating as a DF1 Slave

on a Multi-drop Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

Using Modems with MicroLogix™ Programmable Controllers . 203

DH-485 Communication Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

DH-485 Configuration Parameters. . . . . . . . . . . . . . . . . . . . . . . . 205

Devices that use the DH-485 Network . . . . . . . . . . . . . . . . . . . . 206

Important DH-485 Network Planning Considerations . . . . . . . . 206

Example DH-485 Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . 210

Modbus Communication Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

ASCII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

Appendix F

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8 Table of Contents

Connecting to Networks via Ethernet Interface

System Loading and Heat Dissipation

MicroLogix 1100 Controllers and Ethernet Communication . . . . . . 213

MicroLogix 1100 Performance Considerations . . . . . . . . . . . . . . . . . 214

MicroLogix 1100 and PC Connections to the

Ethernet Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

Ethernet Network Topology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

Connecting an Ethernet switch on the Ethernet Network . . . . . 216

Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

Ethernet Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Duplicate IP address Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

Configuring the Ethernet Channel on the MicroLogix 1100. . . . . . . 221

Configuration Using RSLogix 500 Programming Software . . . . . . . . 222

Configuration Via BOOTP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

Using the Rockwell BOOTP/DHCP Utility . . . . . . . . . . . . . . . . 224

Using a DHCP Server To Configure Your Processor . . . . . . . . . . . . 226

Using Subnet Masks and Gateways. . . . . . . . . . . . . . . . . . . . . . . . . . . 226

Manually Configuring Channel 1 for Controllers on Subnets . . . 228

MicroLogix 1100 Embedded Web Server Capability . . . . . . . . . . . . . 229

Appendix G

System Loading Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

System Loading Example Calculations . . . . . . . . . . . . . . . . . . . . 232

System Loading Worksheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

Current Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

Calculating Heat Dissipation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

Glossary

Index

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Preface

Read this preface to familiarize yourself with the rest of the manual. It provides information concerning:

• who should use this manual

• the purpose of this manual

• related documentation

• conventions used in this manual

• Rockwell Automation support

Who Should Use this Manual

Purpose of this Manual

Use this manual if you are responsible for designing, installing, programming, or troubleshooting control systems that use MicroLogix™™ 1100 controllers.

You should have a basic understanding of electrical circuitry and familiarity with relay logic. If you do not, obtain the proper training before using this product.

This manual is a reference guide for MicroLogix™ 1100 controllers and expansion I/O. It describes the procedures you use to install, wire, and troubleshoot your controller. This manual:

• explains how to install and wire your controllers

• gives you an overview of the MicroLogix™ 1100 controller system

Refer to publication 1763-RM001, MicroLogix 1100 Programmable Controllers Instruction Set Reference Manual for the MicroLogix 1100 instruction set and for application examples to show the instruction set in use. Refer to your RSLogix 500 programming software user documentation for more information on programming your MicroLogix™ 1100 controller.

9 Publication 1763-UM001D-EN-P - March 2011

Common Techniques Used in this Manual

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A glossary of industrial automation terms and abbreviations.

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.

Hardware Overview

ESC OK

Side View

Top View

Chapter

Hardware Features

The Bulletin 1763, MicroLogix 1100 programmable controller contains a power supply, input and output circuits, a processor, an isolated combination RS-232/485 communication port, and an Ethernet port. Each controller supports 18 I/O points (10 digital inputs, 2 analog inputs, and 6 discrete outputs).

The hardware features of the controller are shown below.

Hardware Features

Feature Description Feature Description

1 Output Terminal Block 7 LCD Keypad

2 Battery Connector 8 Status LED indicators 3 Bus Connector Interface to Expansion I/O 9

4 Battery 10 DIN Rail Latches 5 Input Terminal Block 11 RS-232/485 Communication Port

6 LCD 12 Ethernet Port

(1)

Shipped with controller.

(2)

Optional equipment.

(ESC, OK, Up, Down, Left, Right)

Memory Module Port Cover Memory Module

(Channel 0, isolated)

(Channel 1)

(2)

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(1)

-or-

12 Hardware Overview

Controller Input Power and Embedded I/O

Catalog Number Description

Input Power Digital Inputs Analog Inputs Digital Outputs

1763-L16AWA 120/240V AC (10) 120V AC (2) voltage input

(6) relay

0...10V DC

1763-L16BWA 120/240V AC (6) 24V DC

(4) high-speed 24V DC

1763-L16BBB 24V DC (6) 24V DC

(4) high-speed 24V DC

1763-L16DWD 12...24V DC (6) 12...24V DC

(4) high-speed 12/24V

(1)

The 4 high-speed inputs (inputs 0 through 3) can be used individually for pulse catch/latching inputs or combined as a high speed counter. Refer to Digital Input Specifications on page 157 and the MicroLogix 1100 Instruction Set Reference Manual, publication 1763-RM001, for more information.

Component Descriptions

MicroLogix 1100 Memory Module and Built-in Real-Time Clock

(2) voltage input

(1)

0...10V DC (2) voltage input

(1)

0...10V DC (2) voltage input

0...10V DC

All individually isolated (6) relay

All individually isolated (2) relay (isolated)

(2) 24V DC FET (2) high-speed 24V DC FET

(6) relay

All individually isolated

The controller has a built-in real-time clock to provide a reference for applications that need time-based control.

The controller is shipped with a memory module port cover in place. You can order a memory module, 1763-MM1, as an accessory. The memory module provides optional backup of your user program and data, and is a means to transport your programs between controllers.

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The program and data in your MicroLogix 1100 is non-volatile and is stored when the power is lost to the controller. The memory module provides additional backup that can be stored separately. The memory module does not increase the available memory of the controller.

1763-MM1 Memory Module

TIP

1762 Expansion I/O 1762 Expansion I/O Connected to MicroLogix 1100 Controller

1762 Expansion I/O

Hardware Overview 13

1762 expansion I/O can be connected to the MicroLogix 1100 controller, as shown below.

A maximum of four I/O modules, in any combination, can be connected to a controller. See Appendix G to determine how much heat a certain combination generates.

1762 Expansion I/O

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14 Hardware Overview

Expansion I/O

Catalog Number Description

Digital 1762-IA8 8-Point 120V AC Input Module 1762-IQ8 8-Point Sink/Source 24V DC Input Module 1762-IQ16 16-Point Sink/Source 24V DC Input Module 1762-IQ32T 32-Point Sink/Source 24V DC Input Module 1762-OA8 8-Point 120/240V AC Triac Output Module 1762-OB8 8-Point Sourcing 24V DC Output Module 1762-OB16 16-Point Sourcing 24V DC Output Module 1762-OB32T 32-Point Sourcing 24V DC Output Module 1762-OV32T 32-Point Sinking 24V DC Output Module 1762-OW8 8-Point AC/DC Relay Output Module 1762-OW16 16-Point AC/DC Relay Output Module 1762-OX6I 6-Point Isolated AC/DC Relay Output Module 1762-IQ8OW6 8-Point Sink/Source 24V DC Input and 6-Point AC/DC Relay

Output Module Analog 1762-IF4 4-Channel Voltage/Current Analog Input Module 1762-OF4 4-Channel Voltage/Current Analog Output Module 1762-IF2OF2 Combination 2-Channel Input 2-Channel Output

Voltage/Current Analog Module Temperature 1762-IR4 4-Channel RTD/Resistance Input Module 1762-IT4 4-Channel Thermocouple/mV Input Module

Communication Cables

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Use only the following communication cables with the MicroLogix 1100 controllers. These cables are required for Class I Div. 2 applications.

• 1761-CBL-AM00 Series C or later

• 1761-CBL-AP00 Series C or later

• 1761-CBL-PM02 Series C or later

• 1761-CBL-HM02 Series C or later

• 2707-NC9 Series C or later

• 1763-NC01 Series A or later

Hardware Overview 15

ATTENTION

UNSUPPORTED CONNECTION

Do not connect a MicroLogix 1100 controller to another MicroLogix family controller such as MicroLogix 1000, MicroLogix 1200, MicroLogix 1500, or the network port of a 1747-DPS1 Port Splitter using a 1761- CBL-AM00 (8-pin mini-DIN to 8-pin mini-DIN) cable or equivalent.

This type of connection will cause damage to the RS-232/485 communication port (Channel 0) of the MicroLogix 1100 and/or the controller itself. The communication pins used for RS-485 communications on the MicroLogix 1100 are alternately used for 24V power on the other MicroLogix controllers and the network port of the 1747-DPS1 Port Splitter.

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16 Hardware Overview

Programming

Communication Options

Programming the MicroLogix 1100 controller is done using RSLogix 500, Revision 7.0 or later. To use all of the latest features, RSLogix 500 programming software must be version 7.20.00 or later. Communication cables for programming are available separately from the controller and software.

The MicroLogix 1100 controllers provide two communications ports, an isolated combination RS-232/485 communication port (Channel 0) and an Ethernet port (Channel 1).

The isolated Channel 0 port on the MicroLogix 1100 can be connected to the following:

• operator interfaces, personal computers, etc. using DF1 Full Duplex

point-to-point

• a DH-485 network

• a DF1 Radio Modem network

• a DF1 half-duplex network as an RTU Master or RTU Slave

• a Modbus network as an RTU Master or RTU Slave

• an ASCII network

• a DeviceNet network as a slave or peer using a DeviceNet Interface

(catalog number 1761-NET-DNI)

• an Ethernet network using the Ethernet Interface module (catalog

number 1761-NET-ENI, or 1761-NET-ENIW)

(1)

When connecting to a DH-485 network, DF1 half-duplex network

or a Modbus network, the MicroLogix 1100 can be connected directly via Channel 0 (without an Advanced Interface Converter, catalog number 1761-NET-AIC). The Channel 0 combo port provides both RS-232 and RS-485 isolated connections. The appropriate electrical interface is selected through your choice of communication cable. The existing MicroLogix 1761 communication cables provide an interface to the RS-232 drivers. The 1763-NC01 cable provides an interface to the RS-485 drivers (for DH-485,

(1)

Modbus RTU Master, RTU slave networks, DF1 half-duplex Master

(1)

DF1 half-duplex Slave

and

The controller may also be connected to serial devices, such as bar code readers, weigh scales, serial printers, and other intelligent devices, using ASCII. See Default Communication Configuration on page 72 for the configuration settings for Channel 0. MicroLogix 1100 can be connected directly to RS-485

(1)

network via channel 0, using ASCII

(1)

OS Series B FRN4 or later.

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Hardware Overview 17

The MicroLogix 1100 supports Ethernet communication via the Ethernet communication Channel 1. You can connect your controller to a local area network that provides communication between various devices at 10 Mbps or 100 Mbps. This port supports CIP explicit messaging (message exchange) only. The controller cannot be used for CIP implicit messaging (real-time I/O messaging). The controller also includes an embedded web server which allows viewing of not only module information, TCP/IP configuration, and diagnostic information, but also includes the data table memory map and data table monitor screen using a standard web browser.

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

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18 Hardware Overview

Notes:

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Chapter

Installing Your Controller

This chapter shows you how to install your controller. The only tools you require are a flat or Phillips head screwdriver and drill. Topics include:

• agency certifications

• compliance to European Union Directives

• installation considerations

• safety considerations

• power considerations

• preventing excessive heat

• master control relay

• installing a memory module

• using the battery

• controller mounting dimensions

• controller and expansion I/O spacing

• mounting the controller

• mounting 1762 expansion I/O

• connecting 1762 expansion I/O

Agency Certifications

Compliance to European Union Directives

19 Publication 1763-UM001D-EN-P - March 2011

• UL Listed Industrial Control Equipment for use in Class I, Division 2,

Hazardous Locations, Groups A, B, C, D

• C-UL Listed Industrial Control Equipment for use in Canada

• CE marked for all applicable directives

• C-Tick marked for all applicable acts

This product has the CE mark and is approved for installation within the European Union and EEA regions. It has been designed and tested to meet the following directives.

20 Installing Your Controller

EMC Directive

This product is tested to meet Council Directive 89/336/EEC Electromagnetic Compatibility (EMC) and the following standards, in whole or in part, documented in a technical construction file:

• EN 61000-6-4

EMC - Part 6-4: Generic Standards - Emission Standard for Industrial Environments

• EN 61000-6-2

EMC - Part 6-2: Generic Standards - Immunity for Industrial Environments

This product is intended for use in an industrial environment.

Low Voltage Directive

Installation Considerations

This product is tested to meet Council Directive 73/23/EEC Low Voltage, by applying the safety requirements of EN 61131-2 Programmable Controllers, Part 2 - Equipment Requirements and Tests.

For specific information required by EN 61131-2, see the appropriate sections in this publication, as well as the following Allen-Bradley publications:

• Industrial Automation Wiring and Grounding Guidelines for Noise Immunity,

publication 1770-4.1

• Guidelines for Handling Lithium Batteries, publication AG-5.4

• Automation Systems Catalog, publication B115

Most applications require installation in an industrial enclosure (Pollution

(1)

Degree 2 Category II

) to reduce the effects of electrical interference (Over Voltage

(2)

) and environmental exposure. Locate your controller as far as possible from power lines, load lines, and other sources of electrical noise such as hard-contact switches, relays, and AC motor drives. For more information on proper grounding guidelines, see the Industrial Automation Wiring and Grounding Guidelines publication 1770-4.1.

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(1)

Pollution Degree 2 is an environment where normally only non-conductive pollution occurs except that occasionally temporary conductivity caused by condensation shall be expected.

(2)

Overvoltage Category II is the load level section of the electrical distribution system. At this level, transient voltages are controlled and do not exceed the impulse voltage capability of the products insulation.

Installing Your Controller 21

ATTENTION

WARNING

Electrostatic discharge can damage semiconductor devices inside the controller. Do not touch the connector pins or other sensitive areas.

Vertical mounting of the controller is not supported due to heat build-up considerations.

Be careful of metal chips when drilling mounting holes for your controller or other equipment within the enclosure or panel. Drilled fragments that fall into the controller or I/O modules could cause damage. Do not drill holes above a mounted controller if the protective debris shields are removed or the processor is installed.

Safety Considerations

Safety considerations are an important element of proper system installation. Actively thinking about the safety of yourself and others, as well as the condition of your equipment, is of primary importance. We recommend reviewing the following safety considerations.

Hazardous Location Considerations

This equipment is suitable for use in Class I, Division 2, Groups A, B, C, D or non-hazardous locations only. The following WARNING statement applies to use in hazardous locations.

EXPLOSION HAZARD

• Substitution of components may impair suitability for

Class I, Division 2.

• Do not replace components or disconnect equipment

unless power has been switched off.

• Do not connect or disconnect components unless

power has been switched off.

• This product must be installed in an enclosure. All

cables connected to the product must remain in the enclosure or be protected by conduit or other means.

• All wiring must comply with N.E.C. article 501-10(b).

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22 Installing Your Controller

WARNING

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

Communication Cables for Class I, Division 2 Hazardous Locations

1761-CBL-AM00 Series C or later 1761-CBL-AP00 Series C or later 1761-CBL-PM02 Series C or later 1761-CBL-HM02 Series C or later 2707-NC9 Series C or later 1763-NC01 Series A or later

Disconnecting Main Power

Explosion Hazard

Do not replace components, connect equipment, or disconnect equipment unless power has been switched off.

The main power disconnect switch should be located where operators and maintenance personnel have quick and easy access to it. In addition to disconnecting electrical power, all other sources of power (pneumatic and hydraulic) should be de-energized before working on a machine or process controlled by a controller.

Safety Circuits

Explosion Hazard

Do not connect or disconnect connectors while circuit is live.

Circuits installed on the machine for safety reasons, like overtravel limit switches, stop push buttons, and interlocks, should always be hard-wired directly to the master control relay. These devices must be wired in series so that when any one device opens, the master control relay is de-energized, thereby removing power to the machine. Never alter these circuits to defeat their function. Serious injury or machine damage could result.

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Installing Your Controller 23

Power Distribution

There are some points about power distribution that you should know:

• The master control relay must be able to inhibit all machine motion by

removing power to the machine I/O devices when the relay is de-energized. It is recommended that the controller remain powered even when the master control relay is de-energized.

• If you are using a DC power supply, interrupt the load side rather than

the AC line power. This avoids the additional delay of power supply turn-off. The DC power supply should be powered directly from the fused secondary of the transformer. Power to the DC input and output circuits should be connected through a set of master control relay contacts.

Periodic Tests of Master Control Relay Circuit

Any part can fail, including the switches in a master control relay circuit. The failure of one of these switches would most likely cause an open circuit, which would be a safe power-off failure. However, if one of these switches shorts out, it no longer provides any safety protection. These switches should be tested periodically to assure they will stop machine motion when needed.

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24 Installing Your Controller

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 to reduce the electrical noise that enters the controller and is often used as a step-down transformer to reduce line voltage. Any transformer used with the controller must have a sufficient power rating for its load. The power rating is expressed in volt-amperes (VA).

Power Supply Inrush

During power-up, the MicroLogix 1100 power supply allows a brief inrush current to charge internal capacitors. Many power lines and control transformers can supply inrush current for a brief time. If the power source cannot supply this inrush current, the source voltage may sag momentarily.

The only effect of limited inrush current and voltage sag on the MicroLogix 1100 is that the power supply capacitors charge more slowly. However, the effect of a voltage sag on other equipment should be considered. For example, a deep voltage sag may reset a computer connected to the same power source. The following considerations determine whether the power source must be required to supply high inrush current:

• The power-up sequence of devices in a system.

• The amount of the power source voltage sag if the inrush current

cannot be supplied.

• The effect of voltage sag on other equipment in the system.

If the entire system is powered-up at the same time, a brief sag in the power source voltage typically will not affect any equipment.

Loss of Power Source

The power supply is designed to withstand brief power losses without affecting the operation of the system. The time the system is operational during power loss is called program scan hold-up time after loss of power. The duration of the power supply hold-up time depends on the type and state of the I/O, but is typically between 10 milliseconds and 3 seconds. When the duration of power loss reaches this limit, the power supply signals the processor that it can no longer provide adequate DC power to the system.

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Installing Your Controller 25

TIP

This is referred to as a power supply shutdown. The processor then performs an orderly shutdown of the controller.

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.

Preventing Excessive Heat

For most applications, normal convective cooling keeps the controller within the specified operating range. Ensure that the specified temperature range is maintained. Proper spacing of components within an enclosure is usually sufficient for heat dissipation.

In some applications, a substantial amount of heat is produced by other equipment inside or outside the enclosure. In this case, place blower fans inside the enclosure to assist in air circulation and to reduce “hot spots” near the controller.

Additional cooling provisions might be necessary when high ambient temperatures are encountered.

Do not bring in unfiltered outside air. Place the controller in an enclosure to protect it from a corrosive atmosphere. Harmful contaminants or dirt could cause improper operation or damage to components. In extreme cases, you may need to use air conditioning to protect against heat build-up within the enclosure.

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26 Installing Your Controller

ATTENTION

TIP

Master Control Relay

A hard-wired master control relay (MCR) provides a reliable means for emergency machine shutdown. Since the master control relay allows the placement of several emergency-stop switches in different locations, its installation is important from a safety standpoint. Overtravel limit switches or mushroom-head push buttons are wired in series so that when any of them opens, the master control relay is de-energized. This removes power to input and output device circuits. Refer to the figures on pages 28 and 29.

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

If you are using an external DC power supply, interrupt the DC output side rather than the AC line side of the supply to avoid the additional delay of power supply turn-off.

The AC line of the DC output power supply should be fused.

Connect a set of master control relays in series with the DC power supplying the input and output circuits.

Place the main power disconnect switch where operators and maintenance personnel have quick and easy access to it. If you mount a disconnect switch inside the controller enclosure, place the switch operating handle on the outside of the enclosure, so that you can disconnect power without opening the enclosure.

Whenever any of the emergency-stop switches are opened, power to input and output devices should be removed.

When you use the master control relay to remove power from the external I/O circuits, power continues to be provided to the controller’s power supply so that diagnostic indicators on the processor can still be observed.

The master control relay is not a substitute for a disconnect to the controller. It is intended for any situation where the operator must quickly de-energize I/O devices only. When inspecting or installing terminal connections, replacing output fuses, or working on equipment within the enclosure, use the disconnect to shut off power to the rest of the system.

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Installing Your Controller 27

TIP

Do not control the master control relay with the controller. Provide the operator with the safety of a direct connection between an emergency-stop switch and the master control relay.

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 emergency-stop switches.

• Install emergency-stop switches and the master control relay in your

system. Make certain that relay contacts have a sufficient rating for your application. Emergency-stop switches must be easy to reach.

• In the following illustration, input and output circuits are shown with

MCR protection. However, in most applications, only output circuits require MCR protection.

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

In most applications input circuits do not require MCR protection; however, if you need to remove power from all field devices, you must include MCR contacts in series with input power wiring.

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28 Installing Your Controller

Disconnect

Isolation Transformer

Emergency-Stop Push Button

Fuse

MCR

230V AC I/O

Circuits

Operation of either of these contacts will remove power from the external I/O circuits, stopping machine motion.

Fuse

Overtravel Limit Switch

MCR

Stop

Start

Line Terminals: Connect to terminals of Power Supply (1763-L16AWA, 1763-L16BWA).

115V AC or 230V AC I/O Circuits

230V AC

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

Suppressor Cat. No. 700-N24

MCR

Suppr.

24V DC I/O Circuits

(Lo)

(Hi)

DC Power Supply. Use IEC 950/EN 60950

115V AC or 230V AC

Line Terminals: Connect to 24V DC terminals of Power Supply (1763-L16BBB).

Schematic (Using IEC Symbols)

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+ 226 hidden pages