Rockwell Automation 1764-xxxx User Manual

Page 1

MicroLogix™ 1500 Programmable Controllers

Bulletin 1764

User Manual

Page 2

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 upon 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 differences between solid-state 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 part, without written permission of Rockwell Automation, is prohibited.

Throughout this publication, notes may be used to make you aware of safety considerations. The following annotations and their accompanying statements help you to identify a potential hazard, avoid a potential hazard, and recognize the consequences of a potential hazard:

WARNING

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.

!

ATTENTION

Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss.

!

IMPORTANT

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

MicroLogix, Compact I/O, and RSLogix are trademarks of Rockwell Automation.

Page 3

Summary of Changes

The information below summarizes the changes to this manual since the last printing.

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

The table below lists the sections that document new features and additional or updated information on existing features.

For this information: See

Series C support for up to 16 expansion I/O modules

List of controller series, OS FRN numbers, and RSLogix versions

Updated list of recommended surge suppressors

Ethernet Connectivity Page 4-23 Typical CPU hold-up time Page A-1 Updated system loading and heat

dissipation worksheets System loading graphs for 1769 power

supplies, including 1769-PA4 and 1769-PB4

Chapter 1

Page 1-5

Page 3-6

Appendix F

pages F-5 through F-7

iii Publication 1764-UM001B-EN-P - March 2002

Page 4

Summary of Changes iv

Publication 1764-UM001B-EN-P - March 2002

Page 5

Hardware Overview

Table of Contents

Preface

Who Should Use this Manual. . . . . . . . . . . . . . . . . . . . . . . P-1

Purpose of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1

Related Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1

Common Techniques Used in this Manual . . . . . . . . . . . . . P-3

Rockwell Automation Support . . . . . . . . . . . . . . . . . . . . . . P-3

Local Product Support . . . . . . . . . . . . . . . . . . . . . . . . . P-3

Technical Product Assistance . . . . . . . . . . . . . . . . . . . . P-3

Your Questions or Comments on this Manual . . . . . . . . P-4

Chapter 1

Hardware Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

MicroLogix 1500 Component Descriptions . . . . . . . . . . . . . 1-2

Base Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Processors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Data Access Tool (Catalog Number 1764-DAT) . . . . . . . 1-3

Memory Modules/Real-Time Clock . . . . . . . . . . . . . . . . 1-4

Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

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

Compact™ Expansion I/O . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Expansion Power Supply and Cables . . . . . . . . . . . . . . 1-7

System Requirements for Using Expansion Modules . . . 1-7

Adding an I/O Bank . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Addressing Expansion I/O . . . . . . . . . . . . . . . . . . . . . . 1-11

Expansion I/O Power Failure . . . . . . . . . . . . . . . . . . . . 1-11

Chapter 2

Installing Your Controller

v Publication 1764-UM001B-EN-P - April 2002

Agency Certifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

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

EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Installation Considerations. . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Hazardous Location Considerations . . . . . . . . . . . . . . . 2-3

Disconnecting Main Power. . . . . . . . . . . . . . . . . . . . . . 2-4

Safety Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Power Distribution. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Periodic Tests of Master Control Relay Circuit . . . . . . . . 2-5

Power Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Isolation Transformers . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Power Supply Inrush . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Loss of Power Source. . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Page 6

Table of Contents vi

Input States on Power Down . . . . . . . . . . . . . . . . . . . . 2-6

Other Types of Line Conditions . . . . . . . . . . . . . . . . . . 2-7

Preventing Excessive Heat. . . . . . . . . . . . . . . . . . . . . . . . . 2-7

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

Using Emergency-Stop Switches . . . . . . . . . . . . . . . . . . 2-9

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

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

Base Unit Mounting Dimensions . . . . . . . . . . . . . . . . . . . . 2-12

Controller Spacing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Mounting the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Using a DIN Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Base Unit Panel Mounting . . . . . . . . . . . . . . . . . . . . . . 2-16

Installing Controller Components. . . . . . . . . . . . . . . . . . . . 2-17

Prevent Electrostatic Discharge . . . . . . . . . . . . . . . . . . . 2-17

Processor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Data Access Tool (DAT). . . . . . . . . . . . . . . . . . . . . . . . 2-19

Memory Module/Real-Time Clock. . . . . . . . . . . . . . . . . 2-20

Compact I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Wiring Your Controller

Communication Connections

Chapter 3

Wiring Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Wiring Recommendation . . . . . . . . . . . . . . . . . . . . . . . 3-2

Using Surge Suppressors . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Recommended Surge Suppressors . . . . . . . . . . . . . . . . 3-6

Grounding the Controller . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Miswiring - 1764-28BXB Only. . . . . . . . . . . . . . . . . . . . 3-8

Terminal Block Layouts . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Terminal Groupings. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Sinking and Sourcing Input Circuits . . . . . . . . . . . . . . . . . . 3-10

1764-24AWA Wiring Diagram . . . . . . . . . . . . . . . . . . . . 3-11

1764-24BWA Wiring Diagram with Sinking Inputs . . . . . 3-12

1764-24BWA Wiring Diagram with Sourcing Inputs . . . . 3-13

1764-28BXB Wiring Diagram with Sinking Inputs . . . . . 3-14

1764-28BXB Wiring Diagram with Sourcing Outputs . . . 3-15

Controller I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Minimizing Electrical Noise. . . . . . . . . . . . . . . . . . . . . . 3-16

Transistor Output Transient Pulses . . . . . . . . . . . . . . . . 3-16

Chapter 4

Default Communication Configuration . . . . . . . . . . . . . . . . 4-1

Communications Toggle Push Button. . . . . . . . . . . . . . . . . 4-2

Connecting to the RS-232 Port . . . . . . . . . . . . . . . . . . . . . . 4-3

DF1 Full-Duplex Communication Parameters . . . . . . . . 4-3

Making a DF1 Full-Duplex Point-to-Point Connection . . 4-3

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Using Trim Pots and the Data Access Tool (DAT)

Table of Contents vii

Using a Modem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Isolated Modem Connection. . . . . . . . . . . . . . . . . . . . . 4-5

Connecting to a DF1 Half-Duplex Network. . . . . . . . . . 4-7

Connecting to a DH-485 Network . . . . . . . . . . . . . . . . . . . 4-10

DH-485 Configuration Parameters. . . . . . . . . . . . . . . . . 4-12

Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

DH-485 Communication Cable . . . . . . . . . . . . . . . . . . . 4-12

Communication Cable Connection to the

DH-485 Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Connecting the AIC+ . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Connecting to DeviceNet . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Cable Selection Guide . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Connecting to Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Ethernet Connections. . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

RS-232 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

Chapter 5

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

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

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

Data Access Tool (DAT) . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

DAT Keypad and Indicator Light Functions. . . . . . . . . . 5-2

Power-Up Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

DAT Function File . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Power Save Timeout (PST) Parameter. . . . . . . . . . . . . . 5-4

Understanding the DAT Display . . . . . . . . . . . . . . . . . . 5-5

Entering Bit Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Entering Integer Mode . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Monitoring and Editing. . . . . . . . . . . . . . . . . . . . . . . . . 5-6

F1 and F2 Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Working Screen Operation . . . . . . . . . . . . . . . . . . . . . . 5-7

Non-Existent Elements . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Controller Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Error Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Using Real-Time Clock and Memory Modules

Chapter 6

Real-Time Clock Operation . . . . . . . . . . . . . . . . . . . . . . . . 6-1

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

Real-Time Clock Function File . . . . . . . . . . . . . . . . . . . 6-1

Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Writing Data to the Real-Time Clock. . . . . . . . . . . . . . . 6-2

RTC Battery Operation . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Memory Module Operation . . . . . . . . . . . . . . . . . . . . . . . . 6-3

User Program and Data Back-Up . . . . . . . . . . . . . . . . . 6-3

Program Compare . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

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Page 8

Table of Contents viii

Specifications

Replacement Parts

Data File Download Protection. . . . . . . . . . . . . . . . . . . 6-4

Memory Module Write Protection . . . . . . . . . . . . . . . . . 6-5

Removal/Insertion Under Power. . . . . . . . . . . . . . . . . . 6-5

Memory Module Information File . . . . . . . . . . . . . . . . . 6-5

Appendix A

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

Choosing a Power Supply . . . . . . . . . . . . . . . . . . . . . . A-2

Transistor Output Transient Pulses . . . . . . . . . . . . . . . . A-8

Controller Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9

Compact I/O Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . A-9

Panel Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9

End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10

Appendix B

MicroLogix 1500 Replacement Kits. . . . . . . . . . . . . . . . . . . B-1

Lithium Battery (1747-BA) . . . . . . . . . . . . . . . . . . . . . . . . B-2

Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Battery Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

Disposing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4

Replacement Terminal Blocks . . . . . . . . . . . . . . . . . . . . . . B-5

Replacement Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6

Base Terminal Door (1764-RPL-TDR1) . . . . . . . . . . . . . B-6

Processor Access Door (1764-RPL-CDR1) . . . . . . . . . . . B-6

Base Comms Door

(included in 1764-RPL-DR) . . . . . . . . . . . . . . . . . . . . . . B-6

Trim Pots/Mode Switch Cover Door

(included in 1764-RPL-DR) . . . . . . . . . . . . . . . . . . . . . . B-6

Troubleshooting Your System

Publication 1764-UM001B-EN-P - April 2002

Appendix C

Understanding Controller LEDs . . . . . . . . . . . . . . . . . . . . . C-1

When Operating Normally . . . . . . . . . . . . . . . . . . . . . . C-2

When an Error Exists . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

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

Identifying Controller Faults . . . . . . . . . . . . . . . . . . . . . . . C-4

Automatically Clearing Faults . . . . . . . . . . . . . . . . . . . . C-4

Manually Clearing Faults Using the Fault Routine . . . . . C-4

Fault Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5

Calling Rockwell Automation for Assistance . . . . . . . . . . . . C-5

Page 9

Upgrading Your Operating System

Understanding Communication Protocols

Table of Contents ix

Appendix D

Preparing for Upgrade. . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

Performing the Upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . D-2

Missing/Corrupt OS LED Pattern . . . . . . . . . . . . . . . . . . . . D-2

Appendix E

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

DF1 Full-Duplex Protocol . . . . . . . . . . . . . . . . . . . . . . . . . E-1

DF1 Half-Duplex Protocol . . . . . . . . . . . . . . . . . . . . . . . . . E-2

DF1 Half-Duplex Operation . . . . . . . . . . . . . . . . . . . . . E-2

Considerations When Communicating as a DF1 Slave

on a Multi-drop Link . . . . . . . . . . . . . . . . . . . . . . . . . . E-3

Using Modems with MicroLogix 1500

Programmable Controllers . . . . . . . . . . . . . . . . . . . . . . . . . E-3

Dial-Up Phone Modems . . . . . . . . . . . . . . . . . . . . . . . . E-4

Leased-Line Modems . . . . . . . . . . . . . . . . . . . . . . . . . . E-4

Radio Modems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5

Line Drivers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5

DH-485 Communication Protocol. . . . . . . . . . . . . . . . . . . . E-5

DH-485 Network Description . . . . . . . . . . . . . . . . . . . . E-5

DH-485 Token Rotation . . . . . . . . . . . . . . . . . . . . . . . . E-6

DH-485 Configuration Parameters. . . . . . . . . . . . . . . . . E-6

Devices that Use the DH-485 Network . . . . . . . . . . . . . E-7

Important DH-485 Network Planning Considerations. . . E-8 Modbus RTU Slave Communication Protocol (MicroLogix 1764-LSP and 1764-LRP Series B and

later processors only) . . . . . . . . . . . . . . . . . . . . . . . . . . . E-13

ASCII Protocol (MicroLogix 1500 1764-LSP

and 1764-LRP Series B and later Processors only) . . . . . . . E-13

System Loading and Heat Dissipation

Appendix F

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

System Expansion Calculations . . . . . . . . . . . . . . . . . . . . . F-1

Selecting System Devices . . . . . . . . . . . . . . . . . . . . . . . F-2

Verifying the System Loading . . . . . . . . . . . . . . . . . . . . F-4

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

Glossary

Index

Publication 1764-UM001B-EN-P - April 2002

Page 10

Table of Contents x

Publication 1764-UM001B-EN-P - April 2002

Page 11

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 1500 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 1500 controllers. 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 1500 controller system

Refer to publication 1762-RM001, MicroLogix 1200 and MicroLogix 1500 Programmable Controllers Instruction Set Reference Manual for

the MicroLogix 1200 and 1500 instruction set and for application examples to show the instruction set in use. Refer to your programming software user documentation for more information on programming your MicroLogix 1500 controller.

Related Documentation

P-1 Publication 1764-UM001B-EN-P - April 2002

The documents listed on page P-2 contain additional information concerning Rockwell Automation products. If you would like a copy, you can:

• download a free electronic version from the internet:

www.ab.com/micrologix or www.theautomationbookstore.com

• purchase a printed manual by:

– contacting your local distributor or Rockwell Automation

representative

– visiting www.theautomationbookstore.com and placing your

order

– calling 1.800.963.9548 (USA/Canada)

or 001.330.725.1574 (Outside USA/Canada)

Page 12

Preface P-2

For Read this Document Document Number

A technical overview of the MicroLogix 1500 and related products

Information on the MicroLogix 1500 Controllers instruction set MicroLogix 1200 and 1500 Programmable

MicroLogix 1500 Programmable Controllers Technical Data

1764-TD001

1762-RM001

Controllers Instruction Set Reference Manual

Information on mounting and wiring the MicroLogix 1500 Base Units, including a mounting template for easy installation

MicroLogix 1500 Programmable Controllers Base Unit Installation Instructions

1764-IN001

An overview of Compact I/O Compact I/O System Overview 1769-SO001 More information on Compact I/O Power Supplies and Cables 1769 Compact I/O Power Supplies and

1769-TD001 Communication Bus Expansion Cables Technical Data

More information on Compact Analog I/O and Temperature Input Modules

Compact Analog I/O and Temperature Input Modules Technical Data

1769-TD004

Detailed information on using Compact I/O Analog Modules Compact I/O Analog Modules User Manual 1769-UM002 Detailed information on installing, configuring, and using

1769-IT6 Thermocouple/mV Input Modules Detailed information on installing, configuring, and using

1769-IR6 RTD/Resistance Input Modules Detailed information on installing, configuring, and using

1769-HSC High Speed Counter Modules A description on how to install and connect an AIC+. This

manual also contains information on network wiring.

Compact I/O 1769-IT6 Thermocouple/mV Input Module User Manual

Compact I/O 1769-IR6 RTD/Resistance Input Module User Manual

Compact 1769-HSC High Speed Counter Module User Manual

Advanced Interface Converter (AIC+) User Manual

1769-UM004

1769-UM005

1769-UM006

1761-6.4

Information on how to install, configure, and commission a DNI DeviceNet™ Interface User Manual 1761-6.5 Information on installing, connecting, and configuring an ENI Ethernet Interface User Manual 1761-UM001 Information on installing, configuring, and using a DeviceNet

Scanner Information on DF1 open protocol. DF1 Protocol and Command Set Reference

Compact™ I/O 1769-SDN DeviceNet Scanner User Manual

1761-UM009

1770-6.5.16 Manual

In-depth information on grounding and wiring Allen-Bradley programmable controllers

A description of important differences between solid-state programmable controller products and hard-wired

Allen-Bradley Programmable Controller Grounding and Wiring Guidelines

Application Considerations for Solid-State Controls

1770-4.1

SGI-1.1

electromechanical devices An article on wire sizes and types for grounding electrical

equipment A complete listing of current documentation, including ordering

National Electrical Code - Published by the National Fire Protection Association of Boston, MA.

Allen-Bradley Publication Index SD499

instructions. Also indicates whether the documents are available on CD-ROM or in multi-languages.

A glossary of industrial automation terms and abbreviations Allen-Bradley Industrial Automation Glossary AG-7.1

Publication 1764-UM001B-EN-P - April 2002

Page 13

Preface P-3

Common Techniques Used in this Manual

Rockwell Automation Support

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.

Rockwell Automation 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 Rockwell Automation representatives in every major country in the world.

Local Product Support

Contact your local Rockwell Automation representative for:

• sales and order support

• product technical training

• warranty support

• support service agreements

Technical Product Assistance

Before you contact Rockwell Automation for technical assistance, we suggest you please review the troubleshooting information contained in this publication first.

Publication 1764-UM001B-EN-P - April 2002

Page 14

Preface P-4

If the problem persists, call your local Rockwell Automation representative or contact Rockwell Automation in one of the following ways:

Phone United

States/Canada Outside United

States/Canada

Internet

⇒

1.440.646.5800

You can access the phone number for your country via the Internet:

1. Go to http://www.ab.com

2. Click on (http://support.automation.rockwell.com)

3. Under

Information

1. Go to http://www.ab.com

2. Click on (http://support.automation.rockwell.com)

Product Support

Support Centers

Product Support

, click on

Contact

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:

Rockwell Automation Automation Control and Information Group Technical Communication, Dept. A602V P.O. Box 2086 Milwaukee, WI 53201-2086

Publication 1764-UM001B-EN-P - April 2002

or visit our internet page at:

http://www.rockwellautomation.com

For the latest information on MicroLogix controllers, visit www.ab.c

om/micrologix

Page 15

Hardware Overview

Chapter

1

Hardware Features

The MicroLogix 1500 programmable controller is composed of a base unit, which contains a power supply, input and output circuits, and a processor. The controller is available with 24 or 28 points of embedded I/O. Additional I/O may be added using Compact™ I/O.

The hardware features of the controller are:

1

2

3

4

5

1

6

7

11

12

REM

RUN PROG

10

10

9

8

Feature Description Feature Description

1 Removable Terminal Blocks 7

2 Interface to Expansion I/O,

Removable ESD Barrier 3 Input LEDs 9 Battery 4 Output LEDs 10 Terminal Doors and Label 5 Communication Port 11

6 Status LEDs 12 Mode Switch, Trim Pots

(1) Optional.

1 Publication 1764-UM001B-EN-P - April 2002

8

Memory Module/Real-Time Clock

Replacement Battery

Data Access Tool

(1)

(1)

(1)

Page 16

1-2 Hardware Overview

MicroLogix 1500 Component Descriptions

A controller is composed of a processor (1764-LSP or enhanced 1764-LRP with RS-232 port) and one of the base units listed below. The FET transistor outputs are available on the 1764-28BXB base only.

Base Units

Catalog Number

1764-24AWA 120/240V ac (12) 120V ac (12) Relay, 2 isolated relays

1764-24BWA 120/240V ac (8) Standard 24V dc

1764-28BXB 24V dc (8) Standard 24V dc

Line Power Inputs Outputs High Speed I/O

n/a

(4) 20 kHz input

(8) 20 kHz input (2) 20 kHz output

(4) Fast 24V dc

(8) Fast 24V dc

per unit (12) Relay, 2 isolated relays

per unit (6) Relay, 2 isolated relays

per unit (4) Standard 24V dc FET (2) Fast 24V dc FET

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Page 17

Processors

Processor (Catalog Number 1764-LSP)

Processor (Catalog Number 1764-LRP)

Hardware Overview 1-3

Communications Port

• DTE (male) 9-pin D-shell

connector

• 30V dc isolation

Data Access Tool (Catalog Number 1764-DAT)

1764-DAT mounted on 1764-LSP processor.

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1-4 Hardware Overview

Memory Modules/Real-Time Clock

Memory module

mounted on 1764-LSP processor.

The following memory modules and real-time clock modules are available:

Catalog Number Function Memory Size

1764-RTC Real-Time Clock not applicable 1764-MM1 Memory Module 8K 1764-MM1RTC Memory Module and Real-Time Clock 8K

1764-MM2

1764-MM2RTC

(1) For 1764-LRP programs greater than 8k, use the 1764-MM2 or 1764-MM2RTC.

(1)

(1)

Memory Module 16K

Memory Module and Real-Time Clock 16K

Cables

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

Table 1.1 Cables for Use in Class I, Division 2 Hazardous Environment

1761-CBL-PM02 Series C or later 2707-NC8 Series B or later 1761-CBL-HM02 Series C or later 2707-NC9 Series B or later 1761-CBL-AM00 Series C or later 2707-NC10 Series B or later 1761-CBL-AP00 Series C or later 2707-NC11 Series B or later

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Hardware Overview 1-5

Programming

Programming the MicroLogix 1500 programmable controller is done using RSLogix™ 500, Rev. 4.0 or later. Certain features are only available when using the most current version of the software, as noted in System Requirements for Using Expansion Modules on page 1-7.

The following table lists the firmware release numbers, feature and functionality enhancements, and the required version of RSLogix 500 and RSLogix 500 Starter software.

Table 1.B Required Software Version by FRN Number

Controller Firmware

Release

Initial Release

Enhancement October

Series B Release

1764-LSP

Enhancement October

Available

for Sale

Date

February

1999

1999

March

2000

2000

Catalog Number

Series

AB

AC

BA

BB

Catalog Number

Revision

OS FRN

Number

2 Initial Release 3.01.00

3 Power Supply and Expansion Cable

4 String Data File Type,

5 PTO Controlled Stop,

Feature and Functionality

Changes

Compatibility

ASCII Instruction Set, Modbus RTU Slave Protocol, Ramping (when using PWM outputs), Static Data File Protection, RTC Messaging

Memory Module Program Compare Bit Enhancement

Required Version of RSLogix 500/RSLogix 500 Starter Software

3.01.00

4.00.00

4.50.00

1764-LRP

Series C Release

Initial Release

Enhancement October

Series C Release

September

2001

March

2000

2000

September

2001

CA

BA

BB

CA

6 Floating Point Data File Support,

Programmable Limit Switch (PLS), Real Time Clock Adjust (Copy Word), Absolute Value, Gray Code, Recipe, Message Instruction Support for 1769-SDN

4 Initial Release - Same Functionality as

1764-LSP

5 PTO Controlled Stop,

Memory Module Program Compare Bit Enhancement

6 Floating Point Data File Support,

Programmable Limit Switch (PLS), Real Time Clock Adjust (Copy Word), Absolute Value, Gray Code, Recipe, Message Instruction Support for 1769-SDN

Publication 1764-UM001B-EN-P - April 2002

5.10.00

4.00.00

4.50.00

5.10.00

Page 20

1-6 Hardware Overview

Communication Options

Compact™ Expansion I/O

The MicroLogix 1500 can be connected to a personal computer. It can also be connected to the DH-485 network using an Advanced Interface Converter (1761-NET-AIC), to an Ethernet network using an Ethernet Interface (1761-NET-ENI), or to a DeviceNet™ network using a DeviceNet Interface (1761-NET-DNI) or through the DeviceNet Scanner module (1769-SDN). The controller can also be connected to Modbus™ SCADA networks as an RTU slave. See Communication Connections on page 4-1 for more information on connecting to the available communication options.

The 1764-LRP processor provides an additional communication port. Each of the communications ports can be independently configured for any supported communication protocol. (Channel 0 is on the base unit and Channel 1 is on the 1764-LRP processor.)

Compact expansion I/O (Bulletin 1769) can be connected to the MicroLogix 1500 Controller. A maximum of either 8 or 16 expansion I/O modules can be used, depending upon your system. See System Requirements for Using Expansion Modules on page 1-7.

See System Loading and Heat Dissipation on page F-1 for more information on system configurations.

End Cap

An end cap terminator (catalog number 1769-ECR or 1769-ECL) must be used at the end of the group of I/O modules attached to the MicroLogix 1500 Controller. The end cap terminator is not provided with the base or processor units. It is required when using expansion I/O.

This illustration shows the right end cap (1769-ECR ). The left end cap (1769-ECL) is shown on page 1-10.

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Page 21

Hardware Overview 1-7

Expansion Power Supply and Cables

With Operating System Revision Number (FRN) 3 or higher, you can connect an additional bank of I/O to your controller. Using an expansion power supply increases the system’s capacity for adding expansion I/O modules. The additional I/O bank is connected to the controller via a specially designed cable. The additional I/O bank must include a power supply and an end cap.

TIP

Depending on the system configuration, each controller can support up to 16 expansion I/O modules. See the System Requirements for Using Expansion Modules below. Also see System Guidelines on page 1-9 for system limitations and illustrations of expansion I/O banks.

System Requirements for Using Expansion Modules

To support a maximum of 8 I/O modules in an additional I/O bank, you must have the following:

Table 1.3 Requirements to Support a Maximum of 8 I/O Modules

Product Catalog Number

MicroLogix 1500 Processor

MicroLogix 1500 Base Unit

Operating System Version

1764-LSP, Series A, Revision C or higher 1764-LSP, Series B or higher 1764-LRP, Series B or higher

1764-24AWA, Series A or higher 1764-24BWA, Series A or higher 1764-28BXB, Series A or higher

Firmware Revision Number (FRN) 3 or higher

1764-LSP, Series A RSLogix 500, Version 3.01.09 or higher,

(1)

Programming Software

1 Power Supply (optional)

1 Cable (optional) 1769-CRL1, 1769-CRL3, 1769-CRR1, 1769-CRR3 1 End Cap (required) 1769-ECL, 1769-ECR

(1) You can check the FRN by looking at word S:59 (Operating System FRN) in the Status File.

1764-LSP, Series B 1764-LRP, Series B

1764-LSP, Series C 1764-LRP, Series C

1769-PA2, 1769-PA4 1769-PB2, 1769-PB4

RSLogix 500, Version 4.00.00 or higher.

RSLogix 500, Version 5.00.00 or higher.

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Page 22

1-8 Hardware Overview

To support a maximum of 16 I/O modules in an additional I/O bank, you must have the following:

Table 1.4 Requirements to Support a Maximum of 16 I/O Modules

Product Catalog Number

MicroLogix 1500 Processor 1764-LSP, Series C or higher

1764-LRP, Series C or higher

MicroLogix 1500 Base Unit 1764-24AWA, Series B or higher

1764-24BWA, Series B or higher 1764-28BXB, Series B or higher

Operating System Version

Programming Software RSLogix 500, Version 5.10.00 or higher. 1 Power Supply (optional) 1769-PA2, 1769-PA4, 1769-PB2, 1769-PB4 1 Cable (optional) 1769-CRL1, 1769-CRL3, 1769-CRR1, 1769-CRR3 1 End Cap (required) 1769-ECL, 1769-ECR

(1) You can check the FRN by looking at word S:59 (Operating System FRN) in the Status File.

Firmware Revision Number (FRN) 6 or higher

(1)

IMPORTANT

If your processor is at an older revision, you must upgrade the operating system to FRN 3 or higher to use an expansion cable and power supply (or to FRN 6 or higher to allow up to 16 expansion modules). On the Internet, go to http://www.ab.com/micrologix to download the operating system upgrade. Navigate to MicroLogix 1500 for further instructions and downloads.

MicroLogix 1500 base units are not field upgradeable from Series A to Series B.

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Page 23

Hardware Overview 1-9

Adding an I/O Bank

System Guidelines

A maximum of one 1769 Expansion Cable can be used in a MicroLogix 1500 system, allowing for two banks of I/O modules (one connected directly to the controller, and the other connected via the cable). Each I/O bank requires its own power supply (Bank 1 uses the controller’s embedded power supply).

ATTENTION

!

ATTENTION

!

LIMIT OF ONE EXPANSION POWER SUPPLY

The expansion power supply cannot be connected directly to the controller. It must be connected using an expansion cable. Only one power supply (embedded in the base unit or an expansion power supply) may be used on an I/O bank. Exceeding these limitations may damage the power supply and result in unexpected operation.

REMOVE POWER

Remove system power before making or breaking cable connections. When you remove or insert a cable connector with power applied, an electrical arc may occur. An electrical arc can cause personal injury or property damage by:

• sending an erroneous signal to your system’s field

devices, causing unintended machine operation

• causing an explosion in a hazardous environment

Electrical arcing causes excessive wear to contacts on both the module and its mating connector.

IMPORTANT

Refer to your power supply and I/O module’s documentation for instructions on how to set up your system.

See the System Requirements for Using Expansion Modules on page 1-7 to determine the maximum number of expansion I/O modules you can use in your MicroLogix system.

Also see System Loading and Heat Dissipation on page F-1 for more information on system configurations.

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Page 24

1-10 Hardware Overview

The following illustrations show a MicroLogix 1500 with an expansion I/O bank.

Vertical Orientation

Expansion I/O Bank 1

1769-CRRx Expansion Cable

1769-ECL End Cap

(1) The x in this catalog number can be either a 1 or a 3 representing the length of the cable:

1 = 1 foot (305 mm) and 3 = 3.28 feet (1 meter).

(1)

Expansion I/O Bank 2

Horizontal Orientation

1769-ECR End Cap

Publication 1764-UM001B-EN-P - April 2002

Expansion I/O Bank 1

(1) The x in this catalog number can be either a 1 or a 3 representing the length of the cable:

1 = 1 foot (305 mm) and 3 = 3.28 feet (1 meter).

1769-CRLx Expansion Cable

(1)

Expansion I/O Bank 2

Page 25

Hardware Overview 1-11

Addressing Expansion I/O

The expansion I/O is addressed as slots 1 through 16 (the controller’s embedded I/O is addressed as slot 0). Power supplies and cables are not counted as slots. Modules are counted from left to right on each bank as shown in the illustrations below. For more information on addressing, refer to the MicroLogix 1200 and MicroLogix 1500 Programmable Controllers Instruction Set Reference Manual, publication 1762-RM001.

Vertical Orientation

Expansion

Embedded I/O = Slot 0

Slot 1

I/O Bank 1

Slot 2

Horizontal Orientation

Embedded I/O = Slot 0

Slot 1

Slot 2

Expansion I/O Bank 1 Expansion I/O Bank 2

Expansion I/O Power Failure

Expansion I/O Bank 2

Slot 3

Slot 4

Slot 3

Slot 5

Slot 4

Slot 5

Expansion I/O errors represent failures of the I/O bus or the modules themselves. The error codes are listed in the MicroLogix 1200 and

MicroLogix 1500 Programmable Controllers Instruction Set Reference Manual, publication 1762-RM001.

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Page 26

1-12 Hardware Overview

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Page 27

Chapter

2

Installing Your Controller

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

• agency certifications

• compliance to European Union Directives

• using in hazardous locations

• master control relay

• power considerations

• preventing excessive heat

• controller spacing

• mounting the controller

Agency Certifications

Compliance to European Union Directives

• UL 508

• C-UL under CSA C22.2 no. 142

• Class I, Division 2, Groups A, B, C, D

(UL 1604, C-UL under CSA C22.2 no. 213)

• CE compliant for all applicable directives

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.

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 Publication 1764-UM001B-EN-P - April 2002

Page 28

2-2 Installing Your Controller

Low Voltage Directive

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 B111

Installation Considerations

Most applications require installation in an industrial enclosure

(1)

(Pollution Degree 2 (Over Voltage Category II

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.

ATTENTION

) to reduce the effects of electrical interference

(2)

) and environmental exposure. Locate

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

!

ATTENTION

!

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

Publication 1764-UM001B-EN-P - April 2002

(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.

Page 29

Installing Your Controller 2-3

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.

WARNING

!

EXPLOSION HAZARD

• Substitution of components may impair suitability

for Class I, Division 2.

• Do not replace components or disconnect

equipment unless power has been switched off.

• Do not connect or disconnect components unless

power has been switched off, or the area is known to be non-hazardous.

• This product must be installed in an enclosure. All

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

• All wiring must comply with N.E.C. article

501-4(b).

WARNING

!

When installing any peripheral device (for example, push buttons, lamps) into a hazardous environment, ensure that they are Class I, Division 2 certified, or determined to be safe for the environment.

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Page 30

2-4 Installing Your Controller

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

Table 2.1 Cables for Use in Class I, Division 2 Hazardous Environment

1761-CBL-PM02 Series C or later 2707-NC8 Series B or later 1761-CBL-HM02 Series C or later 2707-NC9 Series B or later 1761-CBL-AM00 Series C or later 2707-NC10 Series B or later 1761-CBL-AP00 Series C or later 2707-NC11 Series B or later

Disconnecting Main Power

WARNING

EXPLOSION HAZARD

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

!

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

Safety Circuits

WARNING

EXPLOSION HAZARD

Do not connect or disconnect connectors while circuit is live.

Publication 1764-UM001B-EN-P - April 2002

!

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.

Page 31

Installing Your Controller 2-5

Power Distribution

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

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

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

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

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

Power Considerations

Periodic Tests of Master Control Relay Circuit

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

The following explains power considerations for the micro controllers.

Isolation Transformers

You may want to use an isolation transformer in the ac line to the controller. This type of transformer provides isolation from your power distribution system to reduce the electrical noise that enters the controller and is often used as a step-down transformer to reduce line voltage. Any transformer used with the controller must have a sufficient power rating for its load. The power rating is expressed in volt-amperes (VA).

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2-6 Installing Your Controller

Power Supply Inrush

During power-up, the MicroLogix 1500 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 1500 is that the power supply capacitors charge more slowly. However, the effect of a voltage sag on other equipment should be considered. For example, a deep voltage sag may reset a computer connected to the same power source. The following considerations determine whether the power source must be required to supply high inrush current:

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

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

current cannot be supplied.

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

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

Loss of Power Source

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

Input States on Power Down

Publication 1764-UM001B-EN-P - April 2002

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

Page 33

Installing Your Controller 2-7

power supply shuts down the system. Understanding this concept is important. Write the user program, taking 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.

TIP

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

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2-8 Installing Your Controller

Master Control Relay

A hard-wired master control relay (MCR) provides a reliable means for emergency machine shutdown. Since the master control relay allows the placement of several emergency-stop switches in different locations, its installation is important from a safety standpoint. Overtravel limit switches or mushroom-head push buttons are wired in series so that when any of them opens, the master control relay is de-energized. This removes power to input and output device circuits. Refer to the figures on pages 2-10 and 2-11.

ATTENTION

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

!

TIP

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

The ac line of the dc output power supply should be fused.

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

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

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

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

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

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Page 35

Installing Your Controller 2-9

equipment within the enclosure, use the disconnect to shut off power to the rest of the system.

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.

TIP

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

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Page 36

2-10 Installing Your Controller

L1

L2

230V ac

Disconnect

Schematic (Using IEC Symbols)

Fuse

MCR

230V ac I/O Circuits

Isolation Transformer

115V ac

X1

or 230V ac

Fuse

X2

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

Emergency-Stop Push Button

(Lo) (Hi)

Line Terminals: Connect to terminals of Power Supply (1764-24AWA and 1764-24BWA).

Overtravel Limit Switch

Stop

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

Start

MCR

MCR

dc Power Supply. Use IEC 950/EN 60950

_

+

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

MCR

Suppr.

115V ac or 230V ac I/O Circuits

24V dc

MCR

I/O Circuits

Suppressor Cat. No. 700-N24

Publication 1764-UM001B-EN-P - April 2002

Page 37

Schematic (Using ANSI/CSA Symbols)

Installing Your Controller 2-11

L1

230V ac

Disconnect

Isolation Transformer

115V ac or

X1 X2

230V ac

Fuse

L2

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

Emergency-Stop Push Button

Overtravel Limit Switch

Stop

Fuse

Start

MCR

MCR

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

MCR

115V ac or 230V ac I/O Circuits

MCR

Suppr.

230V ac Output Circuits

Suppressor Cat. No. 700-N24

(Lo) (Hi)

Line Terminals: Connect to 1764-24AWA or 1764-24BWA terminals.

dc Power Supply. Use NEC Class 2

_

+

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

MCR

24 V dc I/O Circuits

Publication 1764-UM001B-EN-P - April 2002

Page 38

2-12 Installing Your Controller

Base Unit Mounting Dimensions

A

Controller Spacing

B

(1)

Dimension

Height (A) DIN latch open: 138 mm (5.43 in.), DIN latch closed: 118 mm (4.65 in.) Width (B) 168 mm (6.62 in.) Depth (C) 87 mm (3.43 in.)

(1) See Controller Dimensions on page A-9 for more dimensional information.

1764-24AWA 1764-24BWA 1764-28BXB

C

The base unit is designed to be mounted horizontally, with the Compact™ expansion I/O extending to the right of the base unit. Allow 50 mm (2 in.) minimum of space on all sides for adequate ventilation, as shown below.

To p

Publication 1764-UM001B-EN-P - April 2002

Side

Controller

Compact I/O

Bottom

Compact I/O

Compact I/O

Compact I/O

Compact I/O

Side

End Cap

Page 39

Mounting the Controller

ATTENTION

!

Installing Your Controller 2-13

Do not remove protective debris strips until after the base and all other equipment in the panel near the base is mounted and wiring is complete. The debris strips are there to prevent drill fragments, wire strands and other dirt from getting into the controller. Once wiring is complete, remove protective debris strips and install processor unit. Failure to remove strips before operating can cause overheating.

Protective Debris Strips

ESD Barrier

ATTENTION

!

ATTENTION

!

Be careful of metal chips when drilling mounting holes for your controller or other equipment within the enclosure or panel. Drilled fragments that fall into the controller could cause damage. Do not drill holes above a mounted controller if the protective debris strips have been removed.

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

Publication 1764-UM001B-EN-P - April 2002

Page 40

2-14 Installing Your Controller

TIP

If additional I/O modules are required for the application, remove the ESD barrier to install expansion I/O modules. A maximum of 16 I/O modules may be connected to the base. (See page 1-7 for system requirements.) The I/O module’s current requirements and power consumption may further limit the number of modules connected to the base. See System Loading and Heat Dissipation on page F-1. An end cap terminator (catalog number 1769-ECR or 1769-ECL) is required at the end of the group of I/O modules attached to the base.

Using a DIN Rail

The base unit and expansion I/O DIN rail latches lock in the open position so that an entire system can be easily attached to or removed from the DIN rail. The maximum extension of the latch is 15 mm (0.67 in.) in the open position. A flat-blade screw driver is required for removal of the base unit. The base can be mounted to EN50022-35x7.5 or EN50022-35x15 DIN rails. DIN rail mounting dimensions are shown below.

Publication 1764-UM001B-EN-P - April 2002

B

A

DIN Rail Latch

Dimension Height

A DIN latch open: 138 mm (5.43 in.), DIN latch closed: 118 mm (4.65 in.) B 47.6 mm (1.875 in.) C 47.6 mm (1.875 in) DIN latch closed

54.7 mm (2.16 in.) DIN latch open

C

Page 41

Installing Your Controller 2-15

To install your base unit on the DIN rail:

1. Mount your DIN rail. (Make sure that the placement of the base

unit on the DIN rail meets the recommended spacing requirements, see Controller Spacing on page 2-12. Refer to the mounting template from the inside back cover of the MicroLogix

1500 Programmable Controller Base Units Installation Instructions, publication 1764-IN001.

2. Hook the top slot over the DIN rail.

3. While pressing the base unit down against the top of the rail,

snap the bottom of the base unit into position. Ensure DIN latches are in the up (secured) position.

4. Leave the protective debris strip attached until you are finished

wiring the base unit and any other devices.

To remove your base unit from the DIN rail:

1. Place a flat-blade screwdriver in the DIN rail latch at the bottom

of the base unit.

2. Holding the base unit, pry downward on the latch until the latch

locks in the open position. Repeat this procedure with the second latch. This releases the base unit from the DIN rail.

DIN Rail Latch

Publication 1764-UM001B-EN-P - April 2002

Page 42

2-16 Installing Your Controller

Base Unit Panel Mounting

Mount to panel using #8 or M4 screws.

Mounting Template

To install your base unit using mounting screws:

1. Remove the mounting template from the inside back cover of

the MicroLogix 1500 Programmable Controller Base Units Installation Instruction, publication 1764-IN001.

2. Secure the template to the mounting surface. (Make sure your

base unit is spaced properly, see Controller Spacing on page 2-12).

3. Drill holes through the template.

4. Remove the mounting template.

5. Mount the base unit.

6. Leave the protective debris strips attached until you are finished

wiring the base unit and any other devices.

Publication 1764-UM001B-EN-P - April 2002

Page 43

Installing Your Controller 2-17

Installing Controller Components

Prevent Electrostatic Discharge

ATTENTION

!

Electrostatic discharge can damage integrated circuits or semiconductors if you touch bus connector pins. Follow these guidelines when you handle any module:

• Touch a grounded object to discharge static

potential.

• Wear an approved wrist-strap grounding device.

• Do not touch the bus connector or connector

pins.

• Do not touch circuit components inside the

module.

• If available, use a static-safe work station.

When not in use, keep the module in its static-shield bag.

ATTENTION

!

Processor

Be sure the base unit is free of all metal fragments before removing protective debris strips and installing the processor unit. Failure to remove strips before operating can cause overheating.

Publication 1764-UM001B-EN-P - April 2002

Page 44

2-18 Installing Your Controller

1. Be sure base unit power is off.

2. Slide the processor into the base unit using the guide rails for

alignment.

3. Push until a click is heard. Be careful not to push on the

connector when installing the 1764-LRP processor.

IMPORTANT

It is critical that the processor is fully engaged and locked into place.

4. Make sure the actuator is pushed closed.

5. To remove the processor from the base unit, make sure base

unit power is off. Push the actuator to the open position until the processor is ejected slightly. Once the processor has been ejected, it can be removed from the base unit.

Publication 1764-UM001B-EN-P - April 2002

Page 45

Installing Your Controller 2-19

Data Access Tool (DAT)

1. Remove cover from processor.

2. Holding the DAT in the proper orientation (as shown), place the

DAT onto processor. Align DAT port on the processor with the plug on the DAT.

3. Firmly seat DAT on processor; make sure it seats into place.

Publication 1764-UM001B-EN-P - April 2002

Page 46

2-20 Installing Your Controller

4. To remove DAT, grasp using finger areas and pull upward.

Memory Module/Real-Time Clock

1. Remove the cover (or DAT if installed) from the processor as

shown below.

Publication 1764-UM001B-EN-P - April 2002

ATTENTION

!

Electrostatic discharge can damage semiconductor devices inside the base and processor units. Do not touch the connector pins or other sensitive areas.

Page 47

Installing Your Controller 2-21

2. Align connector on the memory module with the connector pins

on the processor.

3. Firmly seat the memory module in the processor making sure

the locking tabs click into place.

4. Replace the cover (or DAT if used).

Publication 1764-UM001B-EN-P - April 2002

Page 48

2-22 Installing Your Controller

Compact I/O

Attach and Lock Module (Module-to-Controller or Module-to-Module)

A Compact I/O module can be attached to the controller or an adjacent I/O module before or after mounting to the panel or DIN rail. The module can be detached and replaced while the system is mounted to a panel or DIN rail.

ATTENTION

!

ATTENTION

!

Remove power before removing or inserting an I/O module. When you remove or insert a module with power applied, an electrical arc may occur. An electrical arc can cause personal injury or property damage by:

• sending an erroneous signal to your system’s field

devices, causing the controller to fault

• causing an explosion in a hazardous environment

Electrical arcing causes excessive wear to contacts on both the module and its mating connector. Worn contacts may create electrical resistance, reducing product reliability.

When attaching I/O modules, it is very important that they are securely locked together to ensure proper electrical connection.

Publication 1764-UM001B-EN-P - April 2002

Page 49

Installing Your Controller 2-23

3

4

1

1

To attach and lock modules:

TIP

1. Disconnect power.

2. Check that the bus lever of the module to be installed is in the

unlocked (fully right) position.

3. Use the upper and lower tongue-and-groove slots (1) to secure

the modules together (or to a controller).

Remove ESD barrier when attaching I/O modules to a MicroLogix 1500 base unit.

2

6

5

4. Move the module back along the tongue-and-groove slots until

the bus connectors (2) line up with each other.

5. Push the bus lever back slightly to clear the positioning tab (3).

Use your fingers or a small screw driver.

6. To allow communication between the controller and module,

move the bus lever fully to the left (4) until it clicks. Ensure it is locked firmly in place.

ATTENTION

When attaching I/O modules, it is very important that the bus connectors are securely locked together to ensure proper electrical connection.

!

Publication 1764-UM001B-EN-P - April 2002

Page 50

2-24 Installing Your Controller

7. Attach an end cap terminator (5) to the last module in the

system by using the tongue-and-groove slots as before.

8. Lock the end cap bus terminator (6).

IMPORTANT

A 1769-ECR right end cap (or a 1769-ECL left end cap if I/O bank is located below the controller) must be used to terminate the end of the serial communication bus.

See Controller Dimensions on page A-9 for mounting dimensions.

Publication 1764-UM001B-EN-P - April 2002

Page 51

Chapter

Wiring Your Controller

This chapter describes how to wire your controller. Topics include:

• wiring requirements

• using surge suppressors

• grounding guidelines

• sinking and sourcing circuits

• wiring diagrams, input voltage ranges, and output voltage

ranges

• minimizing noise

3

Wiring Requirements

Wire Type

Solid Cu-90°C (194°F) #14 to #22 AWG 1.13 Nm (10 in-lb) rated Stranded Cu-90°C (194°F) #14 to #22 AWG

(1) Two wires maximum per terminal screw.

ATTENTION

!

Be careful when stripping wires. Wire fragments that fall into the controller could cause damage. Once wiring is complete, be sure the base unit is free of all metal fragments before removing protective debris strips and installing the processor unit. Failure to remove strips before operating can cause overheating.

Wire Size

(1)

Wiring Torque

1.3 Nm (12 in-lb) maximum

1 Publication 1764-UM001B-EN-P - April 2002

Page 52

3-2 Wiring Your Controller

Wiring Recommendation

ATTENTION

Before you install and wire any device, disconnect power to the controller system.

!

ATTENTION

!

• Allow for at least 50 mm. (2 in.) between I/O wiring ducts or

terminal strips and the controller.

• Route incoming power to the controller by a path separate from

the device wiring. Where paths must cross, their intersection should be perpendicular.

Calculate the maximum possible current in each power and common wire. Observe all electrical codes dictating the maximum current allowable for each wire size. Current above the maximum ratings may cause wiring to overheat, which can cause damage.

United States Only: If the controller is installed within a potentially hazardous environment, all wiring must comply with the requirements stated in the National Electrical Code 501-4 (b).

Publication 1764-UM001B-EN-P - April 2002

TIP

• Separate wiring by signal type. Bundle wiring with similar

electrical characteristics together.

• Separate input wiring from output wiring.

• Label wiring to all devices in the system. Use tape,

shrink-tubing, or other dependable means for labeling purposes. In addition to labeling, use colored insulation to identify wiring based on signal characteristics. For example, you may use blue for dc wiring and red for ac wiring.

Do not run signal or communications wiring and power wiring in the same conduit. Wires with different signal characteristics should be routed by separate paths.

Page 53

Wiring Your Controller 3-3

Wiring without Spade Lugs

When wiring without spade lugs, it is recommended to keep the finger-safe covers in place. Loosen the terminal screw and route the wires through the opening in the finger-safe cover. Tighten the terminal screw making sure the pressure plate secures the wire.

Finger-Safe Cover

terminal screw torque:

1.13 Nm (10 in-lbs) rated

1.3 Nm (12 in-lbs) max.

Wiring with Spade Lugs

The diameter of the terminal screw head is 5.5 mm (0.220 in.). The input and output terminals of the MicroLogix 1500 base unit are designed for a 6.35mm (0.25 in.) wide spade (standard for #6 screw for up to 14 AWG) or a 4 mm (metric #4) fork terminal.

When using spade lugs, use a small, flat-blade screwdriver to pry the finger-safe cover from the terminal blocks as shown below. Then loosen the terminal screw.

Finger-Safe

terminal screw torque:

1.13 Nm (10 in-lbs) rated

1.3 Nm (12 in-lbs) max.

Cover

Publication 1764-UM001B-EN-P - April 2002

Page 54

3-4 Wiring Your Controller

Using Surge Suppressors

Inductive load devices, such as motor starters and solenoids, require the use of some type of surge suppression to protect and extend the operating life of the controller’s output contacts. Switching inductive loads without surge suppression can significantly reduce the life expectancy of relay contacts. By adding a suppression device directly across the coil of an inductive device, you prolong the life of the output or relay contacts. You also reduce the effects of voltage transients and electrical noise from radiating into adjacent systems.

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.

ac or dc Outputs

+dc or L1

VAC/D Out 0 Out 1 Out 2

Out 3 Out 4

Out 5 Out 6

Out 7 COM

Suppression Device

dc COM or L2

If the outputs are dc, we recommend that you use an 1N4004 diode for surge suppression, as shown below.

+24V dc

VAC/D Out 0 Out 1

Relay or Solid State dc Outputs

Out 2 Out 3 Out 4

Out 5

Out 6

Out 7 COM

IN4004 Diode

24V dc common

Suitable surge suppression methods for inductive ac load devices include a varistor, an RC network, or an Allen-Bradley surge suppressor, all shown below. These components must be appropriately rated to suppress the switching transient characteristic of the particular inductive device. See the table on page 3-6 for recommended suppressors.

Publication 1764-UM001B-EN-P - April 2002

Page 55

Surge Suppression for Inductive ac Load Devices

Wiring Your Controller 3-5

Output Device

Varistor RC Network Surge

Output Device

If you connect an expansion I/O 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, part number V175 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. A 1N4004 diode is acceptable for most applications. A surge suppressor can also be used. See the table on page 3-6 for recommended suppressors.

As shown in the illustration below, these surge suppression circuits connect directly across the load device.

Output Device

Suppressor

Surge Suppression for Inductive dc Load Devices

_

Output Device

Diode

(A surge suppressor can also be used.)

+

Publication 1764-UM001B-EN-P - April 2002

Page 56

3-6 Wiring Your Controller

Recommended Surge Suppressors

Use the Allen-Bradley surge suppressors shown in the following table for use with relays, contactors, and starters.

Suppressor Device Coil Voltage Catalog Number

Bulletin 509 Motor Starter Bulletin 509 Motor Starter

Bulletin 100 Contactor Bulletin 100 Contactor

120V ac 240V ac

120V ac 240V ac

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

12V dc 12V dc

(1)

599-K04 599-KA04

199-FSMA1 199-FSMA2

199-FSMA9

(1)

(2) (2)

Grounding the Controller

Bulletin 700 Type R Relay Bulletin 700 Type RM Relay

Bulletin 700 Type R Relay Bulletin 700 Type RM Relay

Bulletin 700 Type R Relay Bulletin 700 Type RM Relay

Bulletin 700 Type R Relay Bulletin 700 Type RM Relay

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

Miscellaneous electromagnetic

24V dc 24V dc

48V dc 48V dc

115-125V dc 115-125V dc

230-250V dc 230-250V dc

150V max, ac or DC

199-FSMA9

199-FSMA9

199-FSMA10

199-FSMA11

700-N24

700-N24

(2)

(2)

devices limited to 35 sealed VA

(1) Varistor – Not recommended for use on relay outputs.

(2) RC Type – Do not use with triac outputs.

In solid-state control systems, grounding and wire routing helps limit the effects of noise due to electromagnetic interference (EMI). Run the ground connection from the ground screw of the base unit to the electrical panel’s ground bus prior to connecting any devices. Use AWG #14 wire. This connection must be made for safety purposes.

Publication 1764-UM001B-EN-P - April 2002

Page 57

Wiring Your Controller 3-7

This product is intended to be mounted to a well grounded mounting surface such as a metal panel. Refer to the Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1, for additional information. Additional grounding connections from the mounting tabs or DIN rail, if used, are not required unless the mounting surface cannot be grounded. You must also provide an acceptable grounding path for each device in your application.

TIP

Grounding Stamping

TIP

It is recommended to use all four mounting positions for panel mounting installation.

Grounding Stamping

This symbol denotes a protective earth ground terminal which provides a low impedance path between electrical circuits and earth for safety purposes and provides noise immunity improvement. This connection must be made for safety purposes

ATTENTION

!

Remove the protective debris strips before applying power to the controller. Failure to remove the strips may cause the controller to overheat.

Publication 1764-UM001B-EN-P - April 2002

Page 58

3-8 Wiring Your Controller

Wiring Diagrams

This section shows the wiring diagrams for the MicroLogix 1500 controllers. Controllers with dc inputs can be wired as either sinking or sourcing configuration. (Sinking and sourcing does not apply to ac inputs.) See pages 3-12 through 3-15 for sinking and sourcing wiring diagrams.

TIP

This symbol denotes a protective earth ground terminal which provides a low impedance path between electrical circuits and earth for safety purposes and provides noise immunity improvement. This connection must be made for safety purposes.

Miswiring - 1764-28BXB Only

The following table shows miswiring conditions and the consequences of improper wiring:

Condition Result

Operating with Voltage Less than 20.4V dc

This will not damage the base unit. The base unit may not power up.

IMPORTANT

Reverse Wiring of the Line Terminals (0 to 30V dc)

Applied Voltage Level Exceeds the Published Recommended Value (i.e. applying 120V ac to 240V ac)

Reverse wiring will not damage the base unit. The base unit will not power up.

Exceeding the published recommended voltage may result in permanent damage to the base unit.

This is not recommended. You must verify that the line voltage remains within specified limits.

Publication 1764-UM001B-EN-P - April 2002

Page 59

Wiring Your Controller 3-9

Terminal Block Layouts

The base unit terminal block layouts are shown below. The shading on the labels indicates how the terminals are grouped. A detail of the groupings is shown in the table following the terminal block layouts.

Group 0 Group 1 Group 2

Inputs

1764-24BWA

Outputs

Inputs

1764-24AWA

Outputs

85-265

VAC

85-265

VAC

L1

L1

POWER

L2

L2

DC

OUT

VAC

VDC 0

VAC

VDC 0

+24V

G

NOT

USED

O / 0

r

o

u

G

r

o

COM

VAC

VDC 1

p

0

NOT

USED

VAC

VDC 1

u

p

0

DC

I / 1

I / 3

COM 0

G

r

o

I / 0

VAC

VDC 2

u

p

1

G

r

o

I / 2

VAC

VDC 3

u

p

2

I / 4

DC

I / 5

COM 1

VAC

O / 5

VDC 4

O / 3

O / 4O / 1O / 0 O / 2 O / 6 O / 9 O / 11

G

r

o

u

G

p

r

3

Group 0 Group 1 Group 2

AC

I / 1

I / 3

O / 3

G

AC

COM 1

VAC

VDC 4

r

o

u

p

3

I / 4

O / 4

I / 5

O / 5

G

COM 0

I / 2

I / 0

VAC

VAC

VDC 2

VDC 3

O / 2 O / 6 O / 9 O / 11

O / 1

G

G

r

r

o

o

u

u

p

p

2

1

DC

I / 6

COM 2

I / 7

O / 7 O / 8

VAC

VDC 5

o

u

p

4

AC

I / 6

COM 2

I / 7

O / 7 O / 8 O / 10

VAC

VDC 5

r

o

u

p

4

I / 8

I / 8

I / 9

I / 9

I / 10

O / 10

G

r

o

u

G

r

o

p

5

I / 10

u

p

5

I / 11

24BWA

24BWA

I / 11

24AWA

24AWA

Inputs

1764-28BXB

Outputs

24 VDC

NOT

USED

+24V

NOT

USED

COM

Group 0 Group 1 Group 2

DC

COM 0

I / 0

VAC

VDC 0

I / 1 I / 3

I / 2

VAC

VDC 1

G

G

r

o

u

p

0

I / 4 I / 6

DC

COM 1

VDC 2 O / 5O / 3

r

o

u

p

1

I / 5

DC

COM 2

I / 7

I / 8 I / 10

O / 7

O / 4

O / 6O / 1O / 0 O / 2 O / 11

COM 2

G

r

o

u

p

2

I / 9

VDC

VAC

VDC 3

I / 12 I / 14

O / 9 O / 10

O / 8

G

r

o

u

p

3

I / 13I / 11

VAC

VDC 4

G

I / 15

r

o

u

p

28BXB

28BXB

4

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Page 60

3-10 Wiring Your Controller

Terminal Groupings

Controller Inputs

Input Group Common Terminal Input Terminal

1764-24BWA Group 0 DC COM 0 I/0 through I/3

Group 1 DC COM 1 I/4 through I/7 Group 2 DC COM 2 I/8 through I/11

1764-24AWA Group 0 AC COM 0 I/0 through I/3

Group 1 AC COM 1 I/4 through I/7 Group 2 AC COM 2 I/8 through I/11

1764-28BXB Group 0 DC COM 0 I/0 through I/3

Group 1 DC COM 1 I/4 through I/7 Group 2 DC COM 2 I/8 through I/15

Controller Outputs

Output Group Voltage Terminal Output Terminal

1764-24BWA Group 0 VAC/VDC 0 O/0

Group 1 VAC/VDC 1 O/1 Group 2 VAC/VDC 2 O/2 Group 3 VAC/VDC 3 O/3 Group 4 VAC/VDC 4 O/4 through O/7 Group 5 VAC/VDC 5 O/8 through O/11

1764-24AWA Group 0 VAC/VDC 0 O/0

Group 1 VAC/VDC 1 O/1 Group 2 VAC/VDC 2 O/2 Group 3 VAC/VDC 3 O/3 Group 4 VAC/VDC 4 O/4 through O/7 Group 5 VAC/VDC 5 O/8 through O/11

1764-28BXB Group 0 VAC/VDC 0 O/0

Group 1 VAC/VDC 1 O/1 Group 2 VDC 2, VDC COM 2 O/2 through O/7 Group 3 VAC/VDC 3 O/8 and O/9 Group 4 VAC/VDC 4 O/10 and O/11

Sinking and Sourcing Input Circuits

Publication 1764-UM001B-EN-P - April 2002

Any of the MicroLogix 1500 DC embedded input groups can be configured as sinking or sourcing depending on how the DC COM is wired on the group. See pages 3-12 through 3-15 for sinking and sourcing wiring diagrams.

Type Definition

Sinking Input

connection of a PNP sourcing device

Sourcing Input

connection of an NPN sinking device

The input energizes when high-level voltage is applied to the input terminal (active high). Connect the power supply VDC (-) to the DC COM terminal.

The input energizes when low-level voltage is applied to the input terminal (active low). Connect the power supply VDC (+) to the DC COM terminal.

Page 61

1764-24AWA Wiring Diagram

Input Terminals

L2

Wiring Your Controller 3-11

NOT

USEDACCOM 0

NOT

USED

L1

“NOT USED” terminals are not intended for use as connection points.

IN 1

IN 0 IN 2

IN 3

AC

COM 1

L2 L1

IN 4

IN 5 IN 7 IN 8 IN 10

IN 6

AC

COM 2

Output Terminals

L2

(Lo)

VAC/

VAC/

VAC/

VAC/

VAC NEUT

120/240

VAC

VDC 0

EARTH

GND

VDC 1

VDC 2

VDC 3

VAC/ VDC 4

IN 9

IN 11

CR CR

OUT 6OUT 4OUT 3OUT 2OUT 1OUT 0

VDC 5

VAC/

OUT 10OUT 8OUT 7OUT 5

OUT 11OUT 9

(Hi)

L1

CR CRCR CR

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Page 62

3-12 Wiring Your Controller

1764-24BWA Wiring Diagram with Sinking Inputs

Input Terminals

+24V

POWER

Output Terminals

L2

(Lo)

120/240

OUT

VAC

COM

VAC

NEUT

DC

COM 0

IN 0 IN 2

EARTH

GND

IN 1

VAC/

VDC 0

IN 3 IN 4 IN 6

DC

IN 5

COM 1

-DC +DC

VAC/

VAC/

VDC 2

VDC 1

OUT 1OUT 0

OUT 2

VAC/

VDC 3

DC

COM 2

IN 7 IN 8

VAC/

VDC 4

OUT 3

OUT 4

IN 9

IN 11

IN 10

CR CR

VAC/

OUT 6

VDC 5

OUT 10OUT 8OUT 7OUT 5

OUT 11OUT 9

Publication 1764-UM001B-EN-P - April 2002

(Hi)

L1

CR CRCR CR

Page 63

Wiring Your Controller 3-13

1764-24BWA Wiring Diagram with Sourcing Inputs

Input Terminals

+24V

POWER

OUT

COM

Output Terminals

L2

(Lo)

120/240

COM 0

VAC

DC

IN 1

IN 0 IN 2

VAC

NEUT

EARTH

GND

IN 3 IN 4 IN 6

COM 1

+DC

VAC/

VAC/

VDC 1

VDC 0

DC

OUT 1OUT 0

-DC

VAC/

VDC 2

IN 5

OUT 2

COM 2

IN 7 IN 8

VAC/

VDC 3

OUT 3

DC

VAC/

VDC 4

IN 9

OUT 4

IN 11

IN 10

CR CR

OUT 6

VAC/

VDC 5

OUT 10OUT 8OUT 7OUT 5

OUT 11OUT 9

(Hi)

L1

CR CRCR CR

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Page 64

3-14 Wiring Your Controller

1764-28BXB Wiring Diagram with Sinking Inputs

Input Terminals

-DC +DC

NOT

USEDDCCOM 0

NOT

IN 0 IN 2

USED

“NOT USED” terminals are not intended for use as connection points.

IN 3 IN 4 IN 6

IN 1

DC

COM 1

IN 5

DC

COM 2

IN 7 IN 8

IN 9

IN 10

Output Terminals (FET Outputs Are Sourcing Only)

-DC

CR

IN 13

IN 11

IN 12

CR CR

-DC +DC

IN 15

IN 14

Publication 1764-UM001B-EN-P - April 2002

+DC

+24v

COM

VDC 0

EARTH

GND

VAC/

VAC/

VDC 1

OUT 1OUT 0

CR CR CR

OUT 2

OUT 3VDC 2

OUT 5

OUT 4

OUT 6

OUT 7

COM 2

VDC

VAC/

VDC 3

OUT 8

VAC/

VDC 4

OUT 10OUT 9

OUT 11

Page 65

Wiring Your Controller 3-15

1764-28BXB Wiring Diagram with Sourcing Outputs

Input Terminals

+DC

-DC

NOT

USEDDCCOM 0

NOT

IN 0 IN 2

USED

“NOT USED” terminals are not intended for use as connection points.

IN 3 IN 4 IN 6

IN 1

DC

COM 1

IN 5

DC

COM 2

IN 7 IN 8

IN 9

IN 10

Output Terminals (FET Outputs Are Sourcing Only)

-DC

CR

IN 13

IN 11 IN 15

IN 14

IN 12

CR CR

+DC

-DC

+DC

+24V

COM

EARTH

GND

VAC/

VDC 0

VAC/

VDC 1

OUT 1OUT 0

CR CR CR

OUT 2

OUT 3VDC 2

OUT 5

OUT 4

OUT 6

Publication 1764-UM001B-EN-P - April 2002

OUT 7

COM 2

VDC

VAC/

VDC 3

OUT 8

VAC/

VDC 4

OUT 10OUT 9

OUT 11

Page 66

3-16 Wiring Your Controller

Controller I/O Wiring

Minimizing Electrical Noise

Because of the variety of applications and environments where controllers are installed and operating, it is impossible to ensure that all environmental noise will be removed by input filters. To help reduce the effects of environmental noise, install the MicroLogix 1500 system in a properly rated (i.e. NEMA) enclosure. Make sure that the MicroLogix 1500 system is properly grounded.

A system may malfunction may occur due to a change in the operating environment after a period of time. We recommend periodically checking system operation, particularly when new machinery or other noise sources are installed near the Micrologix 1500 system.

Transistor Output Transient Pulses

ATTENTION

!

A brief transient current pulse may flow through transistor outputs if the external supply voltage is suddenly applied at the V dc and V dc com terminals (e.g. via the master control relay). It is a fast rate-of-change of voltage at the terminals that causes the pulse. This condition is inherent in transistor outputs and is common to solid state devices. The transient pulses may occur regardless of whether the controller is powered or running.

Publication 1764-UM001B-EN-P - April 2002

The transient energy is dissipated in the load, and the pulse duration is longer for loads with high impedance. The graph below illustrates the relation between pulse duration and load current. Power-up transients will not exceed the times shown in the graph. For most applications the pulse energy is not sufficient to energize the load.

To reduce the possibility of inadvertent operation of devices connected to transistor outputs, consider adding an external resistor in parallel to the load to increase the on-state load current. The duration of the transient pulse is reduced when the on-state load current is increased or the load impedance is decreased.

Page 67

1.0

Wiring Your Controller 3-17

0.9

0.8

0.7

0.6

0.5

0.4

0.3

0.2

Transient Pulse Duration as a

Function of Load Current

Time - Duration of Transient (ms)

0.1

0.0 10009008007006005004003002001001

On-State Load Current (mA)

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Page 68

3-18 Wiring Your Controller

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Page 69

Chapter

4

Communication Connections

This chapter describes how to set up communications for your control system. The method you use and cabling required depend on your application. This chapter also describes how the controller establishes communication with the appropriate network. Topics include:

• Default Communication Configuration

• Communications Toggle Push Button

• Connecting to the RS-232 Port

• Connecting to a DH-485 Network

• Connecting to DeviceNet

• Connecting to Ethernet

Default Communication Configuration

ATTENTION

All devices communicating within a network, must use the same protocol.

!

The MicroLogix 1500 has the following default communication configuration.

Table 4.1 DF1 Full-Duplex Configuration Parameters

Parameter Default

Baud Rate 19.2K Parity none Source ID (Node Address) 1 Control Line no handshaking Error Detection CRC Embedded Responses auto detect Duplicate Packet (Message) Detect enabled ACK Timeout 50 counts NAK retries 3 retries ENQ retries 3 retries Stop Bits 1

1 Publication 1764-UM001B-EN-P - April 2002

Page 70

4-2 Communication Connections

Communications Toggle Push Button

TIP

The default configuration is present when:

• The controller is powered-up for the first time.

• The communications toggle push button specifies

default communications (the DCOMM LED is on).

• An OS upgrade is completed.

For more information about communications, see Understanding Communication Protocols on page E-1.

The Communications Toggle Push Button is located on the processor. You must remove processor door or DAT to access the Communications Toggle Push Button.

Use the Communications Toggle Push Button to change from the user-defined communication configuration to the default communications configuration and back. The Default Communications (DCOMM) LED operates to show when the controller is in the default communications mode (settings shown on page 4-1).

Publication 1764-UM001B-EN-P - April 2002

TIP

COMMS

DC INPUTS

24V SINK/SOURCE

DC/RELAY OUT

24V SOURCE

The Communication Toggle Push Button must be pressed and held for two seconds to activate.

The Communication Toggle Push Button only affects the communication configuration of Channel 0.

Page 71

Communication Connections 4-3

Connecting to the RS-232 Port

DF1 Full-Duplex Communication Parameters

When a communication channel is configured for DF1 Full-Duplex, the following parameters can be changed.

Table 4.2 DF1 Full-Duplex Configuration Parameters

Parameter Options Default

Baud Rate 300, 600, 1200, 2400, 4800, 9600, 19.2K, 38.4K 19.2K Parity none, even none Source ID (Node

Address) Control Line no handshaking, Full-Duplex modem

Error Detection CRC, BCC CRC Embedded Responses auto-detect, enabled auto detect Duplicate Packet

(Message) Detect ACK Timeout 1 to 65535 counts (20 ms increments) 50 counts NAK retries 0 to 255 3 retries ENQ retries 0 to 255 3 retries Stop Bits not a setting, always 1 1

0 to 254 decimal 1

no

handshaking

enabled, disabled enabled

handshaking

Making a DF1 Full-Duplex Point-to-Point Connection

You can connect the MicroLogix 1500 programmable controller to your personal computer using a serial cable from your personal computer’s serial port to the controller, as shown in the illustrations below.

ATTENTION

!

Chassis ground, internal 24V ground, user 24V dc ground, and RS-232 ground are internally connected. You must connect the chassis ground terminal screw to ground prior to connecting any devices. It is important that you understand your personal computer’s grounding system before connecting to the controller. An optical isolator, such as the 1761-NET-AIC, is recommended between the controller and your personal computer when using Channel 0. An isolator is not required when using Channel 1 (1764-LRP).

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Page 72

4-4 Communication Connections

Channel 0

We recommend using an Advanced Interface Converter (AIC+), catalog number 1761-NET-AIC, or similar optical isolator, as shown below. See page 4-16 for specific AIC+ cabling information.

1761-CBL-AM00

TX

TX PWR

TERM

A

B

COM

SHLD

CHS GND

TX

DC SOURCE CABLE

EXTERNAL

or 1761-CBL-HM02

24V dc

MicroLogix 1500 provides power to the AIC+ or an external power supply may be used.

Channel 1

MicroLogix 1500 with 1764-LSP or 1764-LRP processor

1747-CP3 or 1761-CBL-AC00

Personal Computer

MicroLogix 1500 Controller with 1764-LRP processor

Publication 1764-UM001B-EN-P - April 2002

Personal Computer

1747-CP3

Page 73

Personal Computer

Using a Modem

You can use modems to connect a personal computer to one MicroLogix 1500 controller (using DF1 Full-Duplex protocol), or to multiple controllers (using DF1 Half-Duplex protocol), or Modbus Slave RTU protocol, as shown in the following illustration. Do not use DH-485 protocol through modems under any circumstance. (See Using Modems with MicroLogix 1500 Programmable Controllers on page E-3 for information on types of modems you can use with the MicroLogix controllers.)

Modem Cable

(straight-through)

Modem

Communication Connections 4-5

MicroLogix1500 Controller with 1764-LRP Processor

Protocol

DF1 Full-Duplex protocol (to 1 controller) DF1 Half-Duplex Slave protocol (to multiple controllers when a DF1 Half-Duplex Master is present)

Isolated Modem Connection

We recommend using an AIC+, catalog number 1761-NET-AIC, as your optical isolator for Channel 0. See page 4-16 for specific AIC+ cabling information. Using an AIC+ to isolate the modem is illustrated below:

1761-CBL-AM00 or 1761-CBL-HM02

User supplied modem cable

24V dc MicroLogix 1500 provides power to the AIC+ or an external power supply may be used.

Modem

MicroLogix 1500 with 1764-LSP or 1764-LRP processor

Modem

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Page 74

4-6 Communication Connections

Constructing Your Own Modem Cable

If you construct your own modem cable, the maximum cable length is

15.24 m (50 ft) with a 25-pin or 9-pin connector. Refer to the following typical pinout for constructing a straight-through cable:

pins 4 and 6 are internally connected for 1764-LRP only

AIC+ Optical Isolator or 1764-LRP Channel 1

9-Pin 25-Pin 9-Pin 3TXD TXD2 3 2RXD RXD3 2 5GND GND7 5 1CD CD8 1 4DTR DTR204 6DSR DSR6 6 8CTS CTS5 8 7RTS RTS4 7

Modem

Constructing Your Own Null Modem Cable

If you construct your own null modem cable, the maximum cable length is 15.24m (50 ft) with a 25-pin or 9-pin connector. Refer to the following typical pinout:

Publication 1764-UM001B-EN-P - April 2002

Optical Isolator Modem

9-Pin 25-Pin 9-Pin 3TXD TXD2 3 2 RXD RXD 3 2 5GND GND7 5 1CD CD8 1 4DTR DTR204 6DSR DSR6 6 8CTS CTS5 8 7RTS RTS4 7

Page 75

Connecting to a DF1 Half-Duplex Network

When a communication port is configured for DF1 Half-Duplex Slave, available parameters include:

Table 4.3 DF1 Half-Duplex Configuration Parameters

Parameter Options

Baud Rate 300, 600, 1200, 2400, 4800, 9600, 19.2K, 38.4K Parity none, even Source ID (Node Address) 0 to 254 decimal Control Line no handshaking, handshaking Error Detection CRC, BCC EOT Suppression enabled, disabled

When EOT Suppression is enabled, the slave does not respond when polled if no message is queued. This saves modem transmission power and time when there is no message to transmit.

Communication Connections 4-7

Duplicate Packet (Message) Detect

Poll Timeout (x20 ms) 0 to 65535 (can be set in 20 ms increments)

RTS Off Delay (x20 ms) 0 to 65535 (can be set in 20 ms increments)

RTS Send Delay (x20 ms) 0 to 65535 (can be set in 20 ms increments)

Message Retries 0 to 255

Pre Transmit Delay (x1 ms)

enabled, disabled Detects and eliminates duplicate responses to a message. Duplicate packets may be sent under noisy communication conditions if the sender’s Message Retries are not set to 0.

Poll Timeout only applies when a slave device initiates a MSG instruction. It is the amount of time that the slave device waits for a poll from the master device. If the slave device does not receive a poll within the Poll Timeout, a MSG instruction error is generated, and the ladder program needs to requeue the MSG instruction. If you are using a MSG instruction, it is recommended that a Poll Timeout value of zero not be used. Poll Timeout is disabled when set to zero.

Specifies the delay time between when the last serial character is sent to the modem and when RTS is deactivated. Gives the modem extra time to transmit the last character of a packet.

Specifies the time delay between setting RTS until checking for the CTS response. For use with modems that are not ready to respond with CTS immediately upon receipt of RTS.

Specifies the number of times a slave device attempts to resend a message packet when it does not receive an ACK from the master device. For use in noisy environments where message packets may become corrupted in transmission.

0 to 65535 (can be set in 1 ms increments)

• When the Control Line is set to

Required for 1761-NET-AIC physical Half-Duplex networks. The 1761-NET-AIC needs delay time to change from transmit to receive mode.

• When the Control Line is set to

receiving the last character of a packet and the RTS assertion.

no handshaking

DF1 Half-Duplex Modem

, this is the delay time before transmission.

, this is the minimum time delay between

Publication 1764-UM001B-EN-P - April 2002

Page 76

4-8 Communication Connections

DF1 Half-Duplex Master-Slave Network

Use this diagram for DF1 Half-Duplex Master-Slave protocol without hardware handshaking.

SLC 5/03 (DF1 Master)

CH0

1761-CBL-AP00 or

AIC+

MicroLogix 1500 (DF1 Slave)

1761-CBL-PM02

straight 9-25 pin cable

AIC+

radio modem or lease line

radio modem or lease line

CH0 to port 1 or port 2

1761-CBL-AM00 or 1761-CBL-HM02

1761-CBL-AP00 or 1761-CBL-PM02

MicroLogix 1500 (DF1 Slave)

CH0

1761-CBL-AM00 or 1761-CBL-HM02

AIC+

straight 9-25 pin cable

MicroLogix 1500 (DF1 Slave)

CH0 to port 1 or port 2

1761-CBL-AM00 or 1761-CBL-HM02

AIC+

1761-CBL-AP00 or 1761-CBL-PM02

REFERENCE: AIC+ Port Identification

Port 3: RS-485

Port 1: DB-9 RS-232

Publication 1764-UM001B-EN-P - April 2002

Port 2: mini-DIN 8 RS-232

Page 77

Rockwell Software RSLinx 2.0 (or higher), SLC 5/03, SLC 5/04, and SLC 5/05, or PLC-5 processors configured for DF1 Half-Duplex Master.

Communication Connections 4-9

DF1 Half-Duplex Network (Using PC and Modems)

DF1 Half-Duplex Protocol

Modem

TERM

A

B

COM

SHLD

CHS GND

TX

TX

TX PWR

DC SOURCE CABLE

EXTERNAL

MicroLogix 1000 (Slave)

TERM

A

B

COM

SHLD

CHS GND

TX

TX

TX PWR

DC SOURCE CABLE

EXTERNAL

MicroLogix 1200 (Slave)

TERM

A

B

COM

SHLD

CHS GND

TX

TX

TX PWR

DC SOURCE CABLE

EXTERNAL

MicroLogix 1500 with 1764-LSP or 1764-LRP Processor (Slave)

SLC 5/03 (Slave)

MicroLogix 1500 with 1764-LRP Processor (Slave)

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Page 78

4-10 Communication Connections

Connecting to a DH-485 Network

connection from port 1 or port 2 to MicroLogix Channel 1

1761-CBL-AP00 or 1761-CBL-PM02

AIC+

TERM

A

B

COM

SHLD

CHS GND

TX

TX PWR

EXTERNAL

24V dc (user supply needed if not connected to a controller)

1747-CP3 or 1761-CBL-AC00

AIC+

TERM

A

B

COM

SHLD

CHS GND

TX

TX PWR

The following network diagrams provide examples of how to connect MicroLogix 1500 controllers to the DH-485 network using the Advanced Interface Converter (AIC+, catalog number 1761-NET-AIC). For more information on the AIC+, see the Advanced Interface Converter and DeviceNet Interface Installation Instructions, Publication 1761-5.11.

DH-485 Network with a MicroLogix 1500 Controller

MicroLogix 1500

1761-CBL-AM00 or 1761-CBL-HM02

EXTERNAL

connection from port 1 or port 2 to MicroLogix Channel 0

1761-CBL-AP00 or 1761-CBL-PM02

Personal Computer

PC to port 1 or port 2

24V dc (user supply needed if not connected to a controller)

REFERENCE: AIC+ Port Identification

TERM

A

B

COM

SHLD

Port 2: mini-DIN 8 RS-232

Port 3: RS-485

Port 1: DB-9 RS-232

CHS GND

TX

TX PWR

EXTERNAL

AIC+

24V dc (user supplied)

1761-CBL-AP00 or 1761-CBL-PM02

TERM

A

B

COM

SHLD

CHS GND

TX

TX

TX PWR

DC SOURCE CABLE

EXTERNAL

1747-CP3 or 1761-CBL-AC00

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Page 79

Typical 3-Node Network (Channel 0 Connection)

AIC

PanelView 550

A-B

Communication Connections 4-11

PanelView

RJ45 port

1761-CBL-AS09 or 1761-CBL-AS03

TERM

A

B

COM

SHLD

CHS GND

TX

TX

TX PWR

DC SOURCE

CABLE

EXTERNAL

1747-CP3 or 1761-CBL-AC00

Typical 3-Node Network (Channel 1 Connection)

A-B

A-B

1761-CBL-AS09 or 1761-CBL-AS03

1747-CP3 or 1761-CBL-AC00

RJ45 port

TERM

TERM

A

A

B

B

COM

COM

SHLD

SHLD

CHS GND

CHS GND

TX

TX

TX

TX

1747-CP3 or

TX PWR

TX PWR

DC SOURCE

DC SOURCE

CABLE

CABLE

EXTERNAL

EXTERNAL

1761-CBL-AC00

1761-CBL-AM00 or 1761-CBL-HM02

PanelView

PanelView

PanelView 550

MicroLogix 1500 with 1764-LRP Processor

MicroLogix 1500 with 1764-LSP or 1764-LRP Processor

Networked Operator Interface Device and MicroLogix Controllers

AIC+

TERM

A

B

COM

SHLD

CHS GND

TX

TX

TX PWR

DC SOURCE

CABLE

EXTERNAL

SLC 5/04

DH-485 Network

AIC+ AIC+ AIC+

TERM

A

B

COM

SHLD

CHS GND

TX

TX

TX PWR

DC SOURCE

CABLE

EXTERNAL

MicroLogix 1000

TERM

A

B

COM

SHLD

CHS GND

TX

TX

TX PWR

DC SOURCE

CABLE

EXTERNAL

MicroLogix 1200

TERM

A

B

COM

SHLD

CHS GND

TX

TX

TX PWR

DC SOURCE

CABLE

EXTERNAL

MicroLogix 1500

+

TERM

A

B

A-B

COM

SHLD

CHS GND

TX

TX

TX PWR

DC SOURCE

CABLE

EXTERNAL

PanelView

PanelView 550

AIC+

TERM

A

B

COM

SHLD

CHS GND

TX

TX

TX PWR

DC SOURCE

CABLE

EXTERNAL

Personal Computer

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Page 80

4-12 Communication Connections

DH-485 Configuration Parameters

When MicroLogix communications are configured for DH-485, the following parameters can be changed:

Table 4.4 DF1 Full-Duplex Configuration Parameters

Parameter Options

Baud Rate 9600, 19.2K Node Address 1 to 31 decimal Token Hold Factor 1 to 4

See Software Considerations on page E-10 for tips on setting the parameters listed above.

Recommended Tools

To connect a DH-485 network, you need tools to strip and attach the shielded cable. We recommend the following equipment (or equivalent):

Table 4.5 Working with Cable for DH-485 Network

Description Part Number Manufacturer

Shielded Twisted Pair Cable #3106A or #9842 Belden Stripping Tool 45-164 Ideal Industries 1/8” Slotted Screwdriver Not Applicable Not Applicable

DH-485 Communication Cable

The communication cable consists of a number of cable segments daisy-chained together. The total length of the cable segments cannot exceed 1219 m (4000 ft). However, two segments can be used to extend the DH-485 network to 2438m (8000 ft). For additional information on connections using the AIC+, refer to the Advanced Interface Converter (AIC+) User Manual, publication 1761-6.4.

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Page 81

Communication Connections 4-13

Communication Cable Connection to the DH-485 Connector

TIP

A daisy-chained network is recommended. We do not recommend the following:

Belden #3106A or #9842

Connector

Connector

Incorrect

Connector

Single Cable Connection

When connecting a single cable to the DH-485 connector, use the following diagram.

Orange with White Stripes

White with Orange Stripes

Shrink Tubing Recommended

Blue (#3106A) or Blue with White Stripes (#9842)

6 Termination 5 A 4 B 3 Common 2 Shield 1 Chassis Ground

Drain/Shield

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Page 82

4-14 Communication Connections

Multiple Cable Connection

When connecting multiple cables to the DH-485 connector, use the following diagram.

to Previous Device

to Next Device

Table 4.6 Connections using Belden #3106A Cable

For this Wire/Pair Connect this Wire To this Terminal

Shield/Drain Non-jacketed Terminal 2 - Shield Blue Blue Terminal 3 - (Common) White/Orange White with Orange

Stripe Orange with White

Stripe

Terminal 4 - (Data B)

Terminal 5 - (Data A)

Table 4.7 Connections using Belden #9842 Cable

For this Wire/Pair Connect this Wire To this Terminal

Shield/Drain Non-jacketed Terminal 2 - Shield Blue/White White with Blue Stripe Cut back - no

connection

Blue with White Stripe Terminal 3 -

(Common)

White/Orange White with Orange

Stripe Orange with White

Stripe

(1) To prevent confusion when installing the communication cable, cut back the white with blue stripe wire

immediately after the insulation jacket is removed. This wire is not used by DH-485.

Terminal 4 - (Data B)

Terminal 5 - (Data A)

(1)

Grounding and Terminating the DH-485 Network

Only one connector at the end of the link must have Terminals 1 and 2 jumpered together. This provides an earth ground connection for the shield of the communication cable. Both ends of the network must have Terminals 5 and 6 jumpered together, as shown below. This

connects the termination impedance (of 120Ω) that is built into each

AIC+ as required by the DH-485 specification.

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Page 83

End-of-Line Termination

Communication Connections 4-15

Jumper

Belden #3106A or #9842 Cable 1219 m (4000 ft) Maximum

Jumper

Jumper

Connecting the AIC+

The AIC+, catalog number 1761-NET-AIC, enables MicroLogix controllers to connect to a DH-485 network when they are configured for DH-485 protocol. The AIC+ has two isolated RS-232 ports and one RS-485 port. When two MicroLogix controllers are closely positioned, you can connect a controller to each of the RS-232 ports on the AIC+.

The AIC+ can also be used as an RS-232 isolator, providing an isolation barrier between the controllers communications port and any equipment connected to it (i.e. personal computer, modem, etc.)

The following figure shows the connections and specifications of the AIC+.

Item Description

1 Port 1 - DB-9 RS-232, DTE 2 Port 2 - mini-DIN 8 RS-232 DTE 3 Port 3 - RS-485 Phoenix plug 4 DC Power Source selector switch

(cable = port 2 power source, external = external power source connected to item 5)

5 Terminals for external 24V dc power supply

and chassis ground

3

2

1

5

4

For additional information on connecting the AIC+, refer to the Advanced Interface Converter (AIC+) User Manual, publication 1761-6.4.

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4-16 Communication Connections

Cable Selection Guide

1761-CBL-AP00

1761-CBL-PM02

Cable Length Connections from to AIC+ External Power

Supply

(1)

1761-CBL-AP00 1761-CBL-PM02

45cm (17.7 in) 2m (6.5 ft)

Required

1764-LRP processor, channel 1 port 2 yes external SLC 5/03 or SLC 5/04 processors, channel 0 port 2 yes external MicroLogix 1000 or 1500 port 1 yes external PanelView 550 through NULL modem adapter port 2 yes external DTAM Plus / DTAM Micro port 2 yes external PC COM port port 2 yes external

(1) External power supply required unless the AIC+ is powered by the device connected to port 2, then the selection switch should be set to

1761-CBL-AM00

Cable Length Connections from to

AIC+

External Power Supply Required

1761-CBL-HM02

cable

Power Selection

(1)

Switch Setting

.

Power Selection Switch

(1)

Setting

(1)

1761-CBL-AM00 1761-CBL-HM02

(1) External power supply required unless the AIC+ is powered by the device connected to port 2, then the selection switch should be set to

45cm (17.7 in) 2m (6.5 ft)

MicroLogix 1000 or 1500 port 2 no cable to port 2 on another AIC+ port 2 yes external

cable

.

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Page 85

1761-CBL-AC00

Communication Connections 4-17

1747-CP3

Cable Length Connections from to AIC+ External Power

Supply Required

1747-CP3 1761-CBL-AC00

3m (9.8 ft) 45cm (17.7 in)

1764-LRP processor, channel 1 port 1 yes external SLC 5/03 or SLC 5/04 processor, channel 0 port 1 yes external PC COM port port 1 yes external PanelView 550 through NULL modem adapter port 1 yes external DTAM Plus / DTAM Micro™ port 1 yes external Port 1 on another AIC+ port 1 yes external

(1) External power supply required unless the AIC+ is powered by the device connected to port 2, then the selection switch should be set to

user supplied cable

Cable Length Connections from to

AIC+

straight

— modem or other communication device port 1 yes external

External Power Supply Required

(1)

9-25 pin

(1) External power supply required unless the AIC+ is powered by the device connected to port 2, then the selection switch should be set to

Power Selection

(1)

Switch Setting

cable

.

Power Selection Switch Setting

cable

.

(1)

(1)

1761-CBL-AS09

1761-CBL-AS03

Cable Length Connections from to AIC+ External Power

Supply

(1)

1761-CBL-AS03 1761-CBL-AS09

3m (9.8 ft)

9.5m (31.17 ft)

SLC 500 Fixed, SLC 5/01, SLC 5/02, and SLC 5/03 processors

Required

port 3 yes external

PanelView 550 RJ45 port port 3 yes external

(1) External power supply required unless the AIC+ is powered by the device connected to port 2, then the selection switch should be set to

Publication 1764-UM001B-EN-P - April 2002

cable

Power Selection Switch

Setting

.

(1)

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4-18 Communication Connections

1761-CBL-PM02 (or equivalent) Cable Wiring Diagram

9

8 7 6

5

4

3

2 1

Programming Device

9-Pin D-Shell 8-Pin Mini Din 9 RI 24V 1 8CTS GND2 7RTS RTS3 6 DSR RXD 4 5GND DCD5 4DTR CTS6

Controller

7

8

6

3

4

5

12

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3TXD TXD7 2RXD GND8 1DCD

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Communication Connections 4-19

Recommended User-Supplied Components

The components in Table 4.8 can be purchased from your local electronics supplier.

Table 4.8 User Supplied Components

Component Recommended Model

external power supply and chassis

power supply rated for 20.4-28.8V dc

ground NULL modem adapter standard AT straight 9-25 pin RS-232 cable see table below for port information if making own

cables

Port 1 Port 2 Port 3

6

7

8

9

DB-9 RS-232

1

2 3

4

5

(2) The 8-pin mini-DIN connector is not commercially available.

8-pin mini-DIN

3

4

(2)

876

5

2

1

RS-485 connector

6

5

4

3

2

1

Table 4.9 AIC+ Terminals

Pin Port 1: DB-9 RS-232

Port 2

(2)

Port 3: RS-485 Connector

1 received line signal

24V dc chassis ground

detector (DCD) 2 received data (RxD) ground (GND) cable shield 3 transmitted data (TxD) request to send (RTS) signal ground 4

DTE ready (DTR)

(1)

received data (RxD) DH-485 data B

5 signal common (GND) received line signal detector (DCD) DH-485 data A 6

DCE ready (DSR)

(2)

clear to send (CTS) termination

7 request to send (RTS) transmitted data (TxD) not applicable 8 clear to send (CTS) ground (GND) not applicable 9 not applicable not applicable not applicable

(1) On port 1, pin 4 is electronically jumpered to pin 6. Whenever the AIC+ is powered on, pin 4 will match the state

of pin 6.

(2) An 8-pin mini DIN connector is used for making connections to port 2. This connector is not commercially

available.

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4-20 Communication Connections

Safety Considerations

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

.

WARNING

EXPLOSION HAZARD

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.

!

See Safety Considerations on page 2-3 for additional information.

Installing and Attaching the AIC+

1. Take care when installing the AIC+ in an enclosure so that the

cable connecting the MicroLogix 1500 controller to the AIC+ does not interfere with the enclosure door.

2. Carefully plug the terminal block into the RS-485 port on the

AIC+ you are putting on the network. Allow enough cable slack to prevent stress on the plug.

3. Provide strain relief for the Belden cable after it is wired to the

terminal block. This guards against breakage of the Belden cable wires.

Publication 1764-UM001B-EN-P - April 2002

Powering the AIC+

In normal operation with a MicroLogix programmable controller connected to port 2 of the AIC+, the controller powers the AIC+. Any AIC+ not connected to a MicroLogix controller requires a 24V dc power source. The AIC+ requires 120 mA at 24V dc.

If both the controller and external power are connected to the AIC+, the power selection switch determines what device powers the AIC+.

ATTENTION

If you use an external power supply, it must be 24V dc. Permanent damage results if higher voltage is used.

!

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Communication Connections 4-21

Set the DC Power Source selector switch to EXTERNAL before connecting the power supply to the AIC+. The following illustration shows where to connect external power for the AIC+.

24VDC

Bottom View

DC

NEUT

CHS

GND

ATTENTION

Always connect the CHS GND (chassis ground) terminal to the nearest earth ground. This connection must be made whether or not an external 24V dc supply is used.

!

Power Options

Below are two options for powering the AIC+:

• Use the 24V dc user power supply built into the MicroLogix

1500 controller. The AIC+ is powered through a hard-wired connection using a communication cable (1761-CBL-HM02, or equivalent) connected to port 2.

• Use an external DC power supply with the following

specifications:

– operating voltage: 24V dc +20% or -15% – output current: 150 mA minimum – rated NEC Class 2

Make a hard-wired connection from the external supply to the screw terminals on the bottom of the AIC+.

ATTENTION

If you use an external power supply, it must be 24V dc. Permanent damage results if miswired with the wrong power source.

!

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4-22 Communication Connections

Connecting to DeviceNet

You can connect a MicroLogix 1500 using DF1 Full-Duplex protocol to a DeviceNet network using the DeviceNet Interface (DNI), catalog number 1761-NET-DNI. For additional information on using the DNI, refer to the DeviceNet Interface User Manual, publication 1761-6.5. The following figure shows the external wiring connections of the DNI.

V– CAN_L

NET

SHIELD

CAN_H

NODE

DANGER

GND

V+

TX/RX

MOD

RS-232 (Port 2)

DeviceNet Node (Port 1) (Replacement connector part no. 1761-RPL-0000)

Use this write-on area to mark the DeviceNet node address.

Cable Selection Guide

1761-CBL-AM00

Cable Length Connections from to DNI

1761-CBL-AM00 1761-CBL-HM02

1761-CBL-AP00

45 cm (17.7 in) 2m (6.5 ft)

MicroLogix 1000 port 2 MicroLogix 1500 port 2

Cable Length Connections from to DNI

1761-CBL-AP00 1761-CBL-PM02

45 cm (17.7 in) 2m (6.5 ft)

SLC 5/03 or SLC 5/04 processors, channel 0

PC COM port port 2 1764-LRP processor, channel 1 port 2

1761-CBL-HM02

1761-CBL-PM02

port 2

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Communication Connections 4-23

Connecting to Ethernet

You can connect a MicroLogix 1500 to an Ethernet network using the Ethernet Interface (ENI), catalog number 1761-NET-ENI. For additional information on using the ENI, refer to the Ethernet Interface User Manual, publication 1761-UM006. The following figure shows the external wiring connections of the ENI.

ETHERNET

RS232

FAULT

NET

Ethernet Port (ENI Port 1)

IP

EXTERNAL

CABLE

TX/RX

TX/RX

PWR

RS-232 Mini-DIN (ENI Port 2)

Ethernet Connections

The Ethernet connector, port 1, is an RJ45, 10Base-T connector. The pin-out for the connector is shown below:

Pin Pin Name

1Tx+ 2Tx3Rx+ 4 not used by 10Base-T 5 not used by 10Base-T 6Rx7 not used by 10Base-T 8 not used by 10Base-T

When to use straight-through and cross-over cable:

• ENI Ethernet port to 10Base-T Ethernet switch cables utilize a

straight-through pin-out (1-1, 2-2, 3-3, 6-6).

• Direct point-to-point 10Base-T cables connecting the ENI

Ethernet port directly to another ENI Ethernet port (or a computer 10Base-T port) require a cross-over pin-out (1-3, 2-6, 3-1, 6-2).

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4-24 Communication Connections

RS-232 Connections

Port 2 of the ENI is an 8-pin mini-DIN RS-232 port that provides connection to DF1 compatible RS-232 devices. The connector pin assignments are shown below.

7

8

6

8-pin mini-DIN

5

4

2

3

1

Pin Port 2

1 24V dc 2 ground (GND) 3 no connection 4 ENI input data, RxD 5 no connection 6 no connection 7 ENI output data, TxD 8 ground (GND)

The table below describes the RS-232 compatible cables.

Publication 1764-UM001B-EN-P - April 2002

ENI Connected to: Catalog Number Use Cable

MicroLogix (all series)

1761-CBL-AM00 1761-CBL-HM02

SLC 5/03, SLC 5/04, or SLC 5/05 Channel 0 1761-CBL-AP00

1761-CBL-PM02

PLC-5

1761-CBL-AP00 1761-CBL-PM02

Mini DIN to Mini DIN 45 cm (17.7 in) 2m (6.5 ft.)

Mini DIN to D-Shell 45 cm (17.7 in) 2m (6.5 ft.)

Mini DIN to D-Shell 45 cm (17.7 in) 2m (6.5 ft.)

Page 93

Chapter

Using Trim Pots and the Data Access Tool (DAT)

5

Trim Pot Operation

The processor has two trimming potentiometers (trim pots) which allow modification of data within the controller. Adjustments to the trim pots change the value in the corresponding Trim Pot Information (TPI) register. The data value of each trim pot can be used throughout the control program as timer, counter, or analog presets depending upon the requirements of the application.

The trim pots are located below the mode switch under the left access door of the processor.

Trim Pot 0

Trim Pot 1

REM

RUN PROG

Use a small flathead screwdriver to turn the trim pots. Adjusting their value causes data to change within a range of 0 to 250 (fully clockwise). The maximum rotation of each trim pot is three-quarters, as shown below. Trim pot stability over time and temperature is typically ±2 counts.

Minimum (fully counterclockwise)

Trim pot data is updated continuously whenever the controller is powered-up.

1 Publication 1764-UM001B-EN-P - April 2002

Maximum (fully clockwise)

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5-2 Using Trim Pots and the Data Access Tool (DAT)

Trim Pot Information Function File

The composition of the Trim Pot Information (TPI) Function File is described in the MicroLogix 1200 and MicroLogix 1500 Instruction Set Reference Manual, publication 1762-RM001.

Error Conditions

If the controller detects a problem/error with either trim pot, the last values read remain in the data location, and an error code is put in the error code byte of the TPI file for whichever trim pot had the problem. Once the problem/error is corrected, the error code is cleared. The error codes are described in the MicroLogix 1200 and MicroLogix 1500 Instruction Set Reference Manual, publication 1762-RM001.

Data Access Tool (DAT)

The DAT is a convenient and simple tool that provides an interface for editing and monitoring data. The DAT has five primary features:

• provides direct access to 48 bit elements

• provides direct access to 48 integer elements

• provides two function keys

• displays controller faults

• allows removal/insertion under power

DAT Keypad and Indicator Light Functions

The DAT has a digital display, 6 keys, an up/down key, and 7 indicator lights. Their functions are described in the table on page 5-3.

PROTECTED

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BIT

F1

INT

F2

ESC

ENTER

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Using Trim Pots and the Data Access Tool (DAT) 5-3

Feature Function

Digital Display Displays address elements, data values, faults and errors. Up/Down Key Selects element numbers and change data values. The up/down key scrolls when held. F1 Key and Indicator Light Controls the F1 status bit. When the F1 key is pressed or latched, the F1 indicator LED is lit. F2 Key and Indicator Light Controls the F2 status bit. When the F2 key is pressed or latched, the F2 indicator LED is lit. ESC Key Cancels a current operation. BIT Key and Indicator Light Pressing the BIT key puts the DAT in bit mode. The bit indicator light is on when the DAT is in bit

mode.

INT Key and Indicator Light Pressing the INT key puts the DAT in integer mode. The integer indicator light is on when the DAT

is in integer mode. ENTER Key Press to select the flashing element number or enter data value. PROTECTED Indicator Light Indicates element data cannot be changed using the DAT (element is read-only).

TIP

The F1, F2, ESC, BIT, INT, and ENTER keys do not repeat when held. Holding down any one of these keys results in only one key press. The Up/Down arrow key is the only key that repeats when held.

Power-Up Operation

The DAT receives power when it is plugged into the controller. Upon power-up, the DAT performs a self-test.

If the test fails, the DAT displays an error code, all indicator lights are deactivated, and the DAT does not respond to any key presses. See DAT Error Codes on page 5-10.

PROTECTED

F1

BIT

INT

F2

ESC

ENTER

After a successful self-test, the DAT reads the DAT function file to determine its configuration.

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5-4 Using Trim Pots and the Data Access Tool (DAT)

DAT Function File

DAT configuration is stored in the processor in a specialized configuration file called the DAT Function File. The DAT Function File, which is part of the user’s control program, is described in the

MicroLogix 1200 and MicroLogix 1500 Instruction Set Reference Manual, publication 1762-RM001.

Following a successful power-up sequence, the DAT enters the bit monitoring mode.

PROTECTED

-

ff

o

00

0

F1

BIT

INT

F2

ESC

ENTER

Power Save Timeout (PST) Parameter

The power save timeout turns off the DAT display after keypad activity has stopped for a user-defined period of time. The power-save (DAT:0.PST) value is set in the DAT Function File. The valid range is 0 to 255 minutes. The power-save feature can be disabled by setting the PST value to 0, which keeps the display on continuously. The default value is 0.

In power-save mode, a dash flashes in the left-most segment of the display. Press any key (except F1 or F2) to return the DAT to its previous mode. If F1 or F2 is pressed, the DAT will change the value of the F1 or F2 status bits, but the display remains in power-save mode.

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Using Trim Pots and the Data Access Tool (DAT) 5-5

Understanding the DAT Display

When the DAT enters either the bit or integer mode, the element number and its data are displayed, as shown below. The element number is either the integer or bit location.

Bit Mode Display Integer Mode Display

PROTECTED

276

3

F2

INT

integer data

• -32,768 to 32,767

• – – – (undefined)

ENTER

8

ESC

00

F1

BIT

bit element number

• 0 to 47

PROTECTED

ff

o

F2

INT

bit data

• OFF - 0

• ON - 1

• – – – (undefined)

-

0

ESC

ENTER

21

F1

BIT

integer element number

• 0 to 47

-

If the displayed element is defined in the controller’s data file, and is not protected, the element number flashes, indicating that it can be modified. If the displayed element is protected, the PROTECTED indicator light illuminates, and the element number does not flash, indicating that the element cannot be modified.

If the element is undefined, the data field displays three dashes. The element number does not flash because the element does not exist.

PROTECTED

INT

---

F2

ESC

ENTER

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50

F1

BIT

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5-6 Using Trim Pots and the Data Access Tool (DAT)

Entering Bit Mode

Bit mode allows you to view and modify up to 48 contiguous bit locations in the controller. The DAT enters the bit mode automatically following a successful power-up. The bit mode can also be selected by pressing the BIT key. If the bit mode was previously active, the DAT displays the last bit element monitored. If the integer mode was active, the DAT displays the first bit element in the data file. However, there may be a brief delay while the DAT requests information from the controller. During the delay, the working screen will display. See Working Screen Operation on page 5-7.

Entering Integer Mode

Integer mode allows you to view and modify up to 48 contiguous 16-bit integer data locations in the controller. To initiate integer mode, press the INT key. If the integer mode was previously active, the DAT displays the last integer element monitored. If the bit mode was active, the DAT displays the first integer element in the data file. However, there may be a brief delay while the DAT requests information from the controller. If there is a delay, the working screen is displayed. See Working Screen Operation on page 5-7.

Monitoring and Editing

1. Press the INT or BIT key to enter the desired mode. The element

number flashes (if not protected).

2. Use the up/down key to scroll and select an element (to scroll

rapidly, hold the up/down key).

3. Press ENTER to edit the element. The element number becomes

steady and the data flashes if it is not protected.

4. Use the up/down key to change the data. Bit values toggle

between “ON” and “OFF”. Integer values increment or decrement. Holding down the up/down key causes the integer value to increment or decrement quickly.

TIP

If the data is protected or undefined, pressing the up/down key scrolls to the next element in the list.

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Using Trim Pots and the Data Access Tool (DAT) 5-7

5. Press ENTER to load the new data. Press ESC or INT/BIT to

discard the new data.

F1 and F2 Functions

The function keys, F1 and F2, correspond to bits and can be used throughout the control program as desired. They have no effect on bit or integer monitoring.

Each key has two corresponding bits in the DAT function file. The bits within the DAT function file are shown in the table below.

Key Bits Address Data Format Type User Program

Access

F1 Key Pressed DAT:0/F1P Binary Status Read/Write

Latched DAT:0/F1L Binary Status Read/Write

F2 Key Pressed DAT:0/F2P Binary Status Read/Write

Latched DAT:0/F2L Binary Status Read/Write

F1 or F2 Key Pressed

The pressed bits (DAT:0/F1P and DAT:0/F2P) function as push-buttons and provide the current state of either the F1 or F2 key on the keypad. When the F1 or F2 key is pressed, the DAT sets (1) the corresponding pressed key bit. When the F1 or F2 key is not pressed, the DAT clears (0) the corresponding pressed key bit.

F1 or F2 Key Latched

The latched bits (DAT:0/F1L and DAT:0/F2L) function as latched push-buttons and provide latched/toggle key functionality. When the F1 or F2 key is pressed, the DAT sets (1) the corresponding latched key bit within the DAT Function File. When the F1 or F2 key is pressed a second time, the DAT clears (0) the corresponding latched key bit.

Working Screen Operation

Because the DAT is a communications device, its performance is affected by the scan time of the controller. Depending on the user program, if a long scan time is encountered and the DAT waits for information from the controller, a working screen is displayed. The

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5-8 Using Trim Pots and the Data Access Tool (DAT)

working screen consists of three dashes that move across the display from left to right. While the working screen is displayed, key presses are not recognized. Once the DAT receives data from the controller, it returns to its normal mode of operation.

If you encounter excessive working screen conditions, you can minimize the effect by adding an SVC instruction to the control program. Refer to the MicroLogix 1200 and MicroLogix 1500 Programmable Controllers Instruction Set Reference Manual, publication 1762-RM001, for information on the SVC instruction.

Non-Existent Elements

When the DAT determines that an element number does not exist in the controller, the element value displays as three dashes.

If the protection bit for an element is undefined, the DAT will assume that the element is unprotected.

Controller Faults

The DAT checks for controller faults every 10 seconds. When the DAT detects a controller fault, the display shows “FL” in the element number field and the value of the controller’s major fault word (S2:6) is displayed in the value field, as shown below.

PROTECTED

TIP

lf

F1

BIT

If an element value is being modified when the fault is detected, the fault is stored until the modification is accepted or discarded. Then, the fault will be displayed.

0002H

F2

INT

ESC

ENTER

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