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User

Manual

MicroLogix 1000

Programmable

Controllers

(Bulletin 1761 Controllers)

Allen-Bradley

Important User Information

Because of the variety of uses for the products described in this publication, those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements, including any applicable laws, regulations, codes, and standards.

The illustrations, charts, sample programs and layout examples shown in this guide are intended solely for purposes of example. Since there are many variables and requirements associated with any particular installation, Allen-Bradley does not assume responsibility or liability (to include intellectual property liability) for actual use based on the examples shown in this publication.

Allen-Bradley publication SGI-1.1, Safety Guidelines for the Application, Installation, and Maintenance of Solid-State Control (available from your local Allen-Bradley office), describes some important 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 in part, without written permission of Allen-Bradley Company, Inc., is prohibited.

Throughout this manual, we use notes to make you aware of safety considerations:

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

Attention statements help you to:

• identify a hazard
• avoid the hazard
• recognize the consequences

Note Identifies information that is critical for successful application and

understanding of the product.

SLC 500, SLC 5/01, SLC 5/02, SLC 5/03, SLC 5/04, MicroLogix, DTAM, DTAM Micro, PanelView, RediPANEL, Dataliner, DH+, and Data Highway Plus are trademarks of Rockwell Automation. PLC-2, PLC-5 are registered trademarks of Rockwell Automation. A.I. Series and WINtelligent LINX are trademarks of Rockwell Software Inc.

MicroLogix 1000 Programmable Controllers User Manual Preface

Table of Contents

Table of Contents

MicroLogix 1000 Programmable Controllers User Manual Preface

• Preface P– Table of Contents
  • Who Should Use this Manual .P–
  • Purpose of this Manual .P–
  • Common Techniques Used in this Manual .P–
  • Allen-Bradley Support .P–
• 1 Installing Your Controller 1– Hardware
  • Compliance to European Union Directives .1–
  • Hardware Overview .1–
  • Master Control Relay .1–
  • Using Surge Suppressors .1–
  • Safety Considerations .1–
  • Power Considerations .1–
  • Preventing Excessive Heat .1–
  • Controller Spacing .1–
  • Mounting the Controller .1–
• 2 Wiring Your Controller 2–
  • Grounding Guidelines .2–
  • Sinking and Sourcing Circuits .2–
  • Wiring Recommendations .2–
  • Wiring Diagrams, Discrete Input and Output Voltage Ranges .2–
  • Analog Cable Recommendation .2–
  • Minimizing Electrical Noise on Analog Controllers .2–
  • Wiring Your Analog Channels .2–
  • Analog Voltage and Current Input and Output Ranges .2–
  • Wiring Your Controller for High–Speed Counter Applications .2–
• 3 Connecting the System 3–
  • Connecting the DF1 Protocol .3–
  • Connecting to a DH-485 Network .3–
  • Connecting the AIC+ .3–
  • Establishing Communication .3– toc–ii
  • DeviceNet Communications .3–
• 4 Programming Overview 4– Programming
  • Principles of Machine Control .4–
  • Understanding File Organization .4–
  • Understanding How Processor Files are Stored and Accessed .4–
  • Addressing Data Files .4–
  • Applying Ladder Logics to Your Schematics .4–
  • Developing Your Logic Program – A Model .4–
• 5 Using Analog 5–
  • I/O Image .5–
  • I/O Configuration .5–
  • Input Filter and Update Times .5–
  • Converting Analog Data .5–
• 6 Using Basic Instructions 6–
  • About the Basic Instructions .6–
  • Bit Instructions Overview .6–
  • Examine if Closed (XIC) .6–
  • Examine if Open (XIO) .6–
  • Output Energize (OTE) .6–
  • Output Latch (OTL) and Output Unlatch (OTU) .6–
  • One-Shot Rising (OSR) .6–
  • Timer Instructions Overview .6–
  • Timer On-Delay (TON) .6–
  • Timer Off-Delay (TOF) .6–
  • Retentive Timer (RTO) .6–
  • Counter Instructions Overview .6–
  • Count Up (CTU) .6–
  • Count Down (CTD) .6–
  • Reset (RES) .6–
  • Basic Instructions in the Paper Drilling Machine Application Example .6–
• 7 Using Comparison Instructions 7–
  • About the Comparison Instructions .7–
  • Comparison Instructions Overview .7–
  • Equal (EQU) .7– toc–iii
  • Not Equal (NEQ) .7–
  • Less Than (LES) .7–
  • Less Than or Equal (LEQ) .7–
  • Greater Than (GRT) .7–
  • Greater Than or Equal (GEQ) .7–
  • Masked Comparison for Equal (MEQ) .7–
  • Limit Test (LIM) .7–
  • Comparison Instructions in the Paper Drilling Machine Application Example .7–
• 8 Using Math Instructions 8–
  • About the Math Instructions .8–
  • Math Instructions Overview .8–
  • Add (ADD) .8–
  • Subtract (SUB) .8–
  • 32-Bit Addition and Subtraction .8–
  • Multiply (MUL) .8–
  • Divide (DIV) .8–
  • Double Divide (DDV) .8–
  • Clear (CLR) .8–
  • Square Root (SQR) .8–
  • Scale Data (SCL) .8–
  • Math Instructions in the Paper Drilling Machine Application Example .8–
• 9 Using Data Handling Instructions 9–
  • About the Data Handling Instructions .9–
  • Convert to BCD (TOD) .9–
  • Convert from BCD (FRD) .9–
  • Decode 4 to 1 of 16 (DCD) .9–
  • Encode 1 of 16 to 4 (ENC) .9–
  • Copy File (COP) and Fill File (FLL) Instructions .9–
  • Move and Logical Instructions Overview .9–
  • Move (MOV) .9–
  • Masked Move (MVM) .9–
  • And (AND) .9–
  • Or (OR) .9–
  • Exclusive Or (XOR) .9–
  • Not (NOT) .9–
  • Negate (NEG) .9–
  • FIFO and LIFO Instructions Overview .9–
  • FIFO Load (FFL) and FIFO Unload (FFU) .9–
  • LIFO Load (LFL) and LIFO Unload (LFU) .9–
  • Data Handling Instructions in the Paper Drilling Machine Application Example .9– toc–iv
• 10 Using Program Flow Control Instructions 10–
  • About the Program Flow Control Instructions .10–
  • Jump (JMP) and Label (LBL) .10–
  • Jump to Subroutine (JSR), Subroutine (SBR), and Return (RET) .10–
  • Master Control Reset (MCR) .10–
  • Temporary End (TND) .10–
  • Suspend (SUS) .10–
  • Immediate Input with Mask (IIM) .10–
  • Immediate Output with Mask (IOM) .10–
    • Application Example .10– Program Flow Control Instructions in the Paper Drilling Machine
• 11 Using Application Specific Instructions 11–
  • About the Application Specific Instructions .11–
  • Bit Shift Instructions Overview .11–
  • Bit Shift Left (BSL) .11–
  • Bit Shift Right (BSR) .11–
  • Sequencer Instructions Overview .11–
  • Sequencer Output (SQO) and Sequencer Compare (SQC) .11–
  • Sequencer Load (SQL) .11-
  • Selectable Timed Interrupt (STI) Function Overview .11–
  • Selectable Timed Disable (STD) and Enable (STE) .11–
  • Selectable Timed Start (STS) .11–
  • Interrupt Subroutine (INT) .11– - Application Example .11– Application Specific Instructions in the Paper Drilling Machine
• 12 Using High-Speed Counter Instructions 12–
  • About the High-Speed Counter Instructions .12–
  • High-Speed Counter Instructions Overview .12–
  • High-Speed Counter (HSC) .12–
  • High-Speed Counter Load (HSL) .12-
  • High-Speed Counter Reset (RES) .12–
  • High-Speed Counter Reset Accumulator (RAC) .12–
  • High-Speed Counter Interrupt Enable (HSE) and Disable (HSD) .12–
  • Update High-Speed Counter Image Accumulator (OTE) .12–
  • What Happens to the HSC When Going to REM Run Mode .12– - Application Example .12– High-Speed Counter Instructions in the Paper Drilling Machine
• 13 Using the Message Instruction 13– toc–v
  • Types of Communication .13–
  • Message Instruction (MSG) .13–
  • Timing Diagram for a Successful MSG Instruction .13–
  • MSG Instruction Error Codes .13–
  • Application Examples that Use the MSG Instruction .13–
• 14 Troubleshooting Your System 14– Troubleshooting
  • Understanding the Controller LED Status .14–
  • Controller Error Recovery Model .14–
  • Identifying Controller Faults .14–
  • Calling Allen-Bradley for Assistance .14–
• A Hardware Reference .A– Reference
  • Controller Specifications A–
  • Controller Dimensions A–
  • Replacement Parts A–
• B Programming Reference .B–
  • Controller Status File .B–
  • Instruction Execution Times and Memory Usage .B–
• C Valid Addressing Modes and File Types for Instruction Parameters C–
  • Available File Types .C–
  • Available Addressing Modes .C–
• D Understanding the Communication Protocols .D–
  • RS-232 Communication Interface D–
  • DF1 Full-Duplex Protocol D–
  • DF1 Half-Duplex Slave Protocol D–
  • DH-485 Communication Protocol D–
• E Application Example Programs E– toc–vi
  • Paper Drilling Machine Application Example .E–
  • Time Driven Sequencer Application Example .E–
  • Event Driven Sequencer Application Example .E–
  • Bottle Line Example .E–
  • Pick and Place Machine Example .E–
  • RPM Calculation Application Example .E–
  • On/Off Circuit Application Example .E–
  • Spray Booth Application Example .E–
  • Adjustable Timer Application Example .E–
• F Optional Analog Input Software Calibration F–
  • Calibrating an Analog Input Channel .F–
• Glossary G–

MicroLogix 1000 Programmable Controllers User Manual Preface

soc–ii

Notes:

Preface

P–

Preface

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

• who should use this manual
• the purpose of this manual
• conventions used in this manual
• Allen-Bradley support

Preface

P–

Contents of this Manual

Tab Chapter Title Contents

Preface

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

1 Installing YourController Provides controller installation procedures andsystem safety considerations.

Hardware 2 Wiring Your Controller Provides wiring guidelines and diagrams.

3 Connecting the System Gives information on wiring your controllersystem for the DF1 protocol or DH-485 network.

4 Programming Overview

Provides an overview of principles of machine control, a section on file organization and addressing, and a program development model.

5 Using Analog

Provides information on I/O image file format, I/O configuration, input filter and update times, and conversion of analog data.

6 Using Basic Instructions

Describes how to use ladder logic instructions for relay replacement functions, counting, and timing.

7 Using ComparisonInstructions

Describes how to use the instructions to compare values of data in your ladder logic program.

Programming

8 Using Math Instructions Describes how to use the ladder logicinstructions that perform basic math functions. Programming

9 Using Data HandlingInstructions

Describes how to perform data handling instructions, including move and logical instructions and FIFO and LIFO instructions.

10 Using Program FlowControl Instructions Describes the ladder logic instructions that affectprogram flow and execution.

11 Using ApplicationSpecific Instructions Describes the bit shift, sequencer and STIrelated instructions.

12 Using High-SpeedCounter Instructions Describes the four modes of the high-speedcounter and its related instructions.

13 Using the MessageInstruction

Provides a general overview of the types of communication, and explains how to establish network communication using the message instruction.

Troubleshooting 14 Troubleshooting YourSystem Explains how to interpret and correct problemswith your MicroLogix 1000 controller system.

MicroLogix 1000 Programmable Controllers User Manual Preface

P–

Tab Chapter Title Contents

Appendix A Hardware Reference Provides physical, electrical, environmental, andfunctional specifications.

Appendix B ProgrammingReference Explains the system status file and providesinstruction execution times.

Reference

Appendix C

Valid Addressing Modes and File Types for Instruction Parameters

Provides a listing of the instructions along with R f c their parameters and valid file types.

Appendix D

Understanding the Communication Protocols

Contains descriptions of the DF1 protocol and DH-485 network.

Appendix E Application ExamplePrograms

Provides advanced application examples for the high-speed counter, sequencer, bit shift, and message instructions.

Appendix F Optional Analog InputSoftware Calibration Explains how to calibrate your controller usingsoftware offsets.

Glossary Contains definitions for terms and abbreviationsthat are specific to this product.

MicroLogix 1000 Programmable Controllers User Manual Preface

P–

Common Techniques Used in this Manual

The following conventions are used throughout this manual:

• Bulleted lists such as this one provide information, not procedural steps.
• Numbered lists provide sequential steps or hierarchical information.
• Italic type is used for emphasis.

Allen-Bradley Support

Allen-Bradley offers support services worldwide, with over 75 Sales/Support Offices, 512 authorized Distributors and 260 authorized Systems Integrators located throughout the United States alone, plus Allen-Bradley representatives in every major country in the world.

Local Product Support

Contact your local Allen-Bradley representative for:

• sales and order support
• product technical training
• warranty support
• support service agreements

Technical Product Assistance

If you need to contact Allen-Bradley for technical assistance, please review the information in the Troubleshooting chapter first. Then call your local Allen-Bradley representative.

Your Questions or Comments on this Manual

If you find a problem with this manual, or you have any suggestions for how this manual could be made more useful to you, please contact us at the address below:

Allen-Bradley Company, Inc. Control and Information Group Technical Communication, Dept. 602V, T P.O. Box 2086 Milwaukee, WI 53201- or visit our internet page at: http://www.ab.com/micrologix

Hardware

Installing Your Controller

1–

1 Installing Your Controller

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

• compliance to European Union Directives
• hardware overview
• master control relay
• surge suppressors
• safety considerations
• power considerations
• preventing excessive heat
• controller spacing
• mounting the controller

Hardware

Installing Your Controller

1–

Hardware Overview

The MicroLogix 1000 programmable controller is a packaged controller containing a power supply, input circuits, output circuits, and a processor. The controller is available in 10 I/O, 16 I/O and 32 I/O configurations, as well as an analog version with 20 discrete I/O and 5 analog I/O.

The catalog number for the controller is composed of the following:

1761-L20AWA-5A

Bulletin Number Base Unit Unit I/O Count: 20

Input Signal: A = 120V ac B = 24V dc

Power Supply: A = 120/240V ac B = 24V dc Output Type: W = Relay B = MOSFET A = Triac

Analog I/O Analog Circuits: Inputs = 4 Outputs = 1

The hardware features of the controller are:

4

1 3 5 6 7 8 9 1 3 4 5 6 7 8 9

3 20142

Input terminals

Mounting hole Input LEDs Status LEDs RS-232 communication channel Output LEDs Power supply line power Ground screw 10 10

Output terminals

(^22) dc output terminals (or not used)

POWERRUN FAULTFORCE

IN

OUT

MicroLogix 1000 Programmable Controllers User Manual Preface

1–

Master Control Relay

A hard-wired master control relay (MCR) provides a reliable means for emergency controller shutdown. Since the master control relay allows the placement of several 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 figure on page 1–6.

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

Note If you are using an external dc output 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 external ac line of the dc output power supply should be fused.

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

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

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

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

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

Note 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.