Rockwell Automation 1764-xxxx User Manual
MicroLogix™ 1500
Programmable
Controllers
Bulletin 1764
User Manual
Important User Information
Because of the variety of uses for the products described in this
publication, those responsible for the application and use of this
control equipment must satisfy themselves that all necessary steps
have been taken to assure that each application and use meets all
performance and safety requirements, including any applicable laws,
regulations, codes and standards.
The illustrations, charts, sample programs and layout examples shown
in this guide are intended solely for purposes of example. Since there
are many variables and requirements associated with any particular
installation, Allen-Bradley does not assume responsibility or liability
(to include intellectual property liability) for actual use based 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.
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
Summary of Changes iv
Publication 1764-UM001B-EN-P - March 2002
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
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
Publication 1764-UM001B-EN-P - April 2002
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
Publication 1764-UM001B-EN-P - April 2002
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
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
Table of Contents x
Publication 1764-UM001B-EN-P - April 2002
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)
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
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
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
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)
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
Publication 1764-UM001B-EN-P - April 2002
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.
Publication 1764-UM001B-EN-P - April 2002
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
Publication 1764-UM001B-EN-P - April 2002
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
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.
Publication 1764-UM001B-EN-P - April 2002
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.
Publication 1764-UM001B-EN-P - April 2002
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.
Publication 1764-UM001B-EN-P - April 2002
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.
Publication 1764-UM001B-EN-P - April 2002
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
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.
Publication 1764-UM001B-EN-P - April 2002
1-12 Hardware Overview
Publication 1764-UM001B-EN-P - April 2002
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
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.
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.
Publication 1764-UM001B-EN-P - April 2002
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.
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