Allen-Bradley Micrologix 1500 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:

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

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.

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

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

Chapter 1

List of controller series, OS FRN numbers,

and RSLogix versions

Page 1-5

Updated list of recommended surge

suppressors

Page 3-6

Ethernet Connectivity Page 4-23

Typical CPU hold-up time Page A-1

Updated system loading and heat

dissipation worksheets

Appendix F

System loading graphs for 1769 power

supplies, including 1769-PA4 and 1769-PB4

pages F-5 through F-7

Publication 1764-UM001B-EN-P - March 2002

Summary of Changes iv

vPublication 1764-UM001B-EN-P - April 2002

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 Overview

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

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

Publication 1764-UM001B-EN-P - April 2002

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

Chapter 3

Wiring Your Controller

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

Communication Connections

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

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

Using Trim Pots and the Data

Access Tool (DAT)

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

Chapter 6

Using Real-Time Clock and

Memory Modules

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

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

Specifications

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

Replacement Parts

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

Appendix C

Troubleshooting Your System

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

Publication 1764-UM001B-EN-P - April 2002

Table of Contents ix

Appendix D

Upgrading Your Operating System

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

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

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

Appendix E

Understanding Communication

Protocols

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

Appendix F

System Loading and Heat

Dissipation

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

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