Allen-Bradley ControlLogix 1756-PLS User manual

Publication 1756-IN594A-EN-P - November 2003
Installation Instructions
ControlLogix Programmable Limit Switch Module
Catalog Number 1756-PLS
Use this document to install the ControlLogix™ Programmable Limit Switch module.
Obtain a User Manual
This product also has a user manual (publication number 1756-UM002). To view it,
visit www.ab.com/manuals or www.theautomationbookstore.com.
To purchase a manual, you can:
•contact your distributor or Rockwell Automation representative
•visit www.theautomationbookstore.com and place an order
•call 800.963.9548 (USA/Canada) or 001.320.725.1574 (outside USA/Canada)
To: See page:
Prevent Electrostatic Discharge 3
Use Compatible Resolver 6
Identify the Module Components 6
Note the Power Requirements 7
Install the Module 7
Key the Module and Removable Terminal Block/Interface Module 8
Wire the Removable Terminal Block 9
Wire the Resolver Module 12
Wire the I/O Modules 13
Assemble the Removable Terminal Block and the Housing 15
Install the Removable Terminal Block onto the Module 15
Check the Status Indicators 16
Remove the Removable Terminal Block from the Module 17
Remove the Module 17
1756-PLS Specifications 18
Allen-Bradley Automation

2ControlLogix Programmable Limit Switch Module
Publication 1756-IN594A-EN-P - November 2003
Important User Information
Solid state equipment has operational characteristics differing from those of electromechanical equipment.
Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (Publication
SGI-1.1 available from your local Rockwell Automation sales office or online at
http://www.ab.com/manuals/gi) describes some important differences between solid state equipment and
hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of
uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves
that each intended application of this equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages
resulting from the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many
variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot
assume responsibility or liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits,
equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell
Automation, Inc. is prohibited.
Throughout this manual we use notes to make you aware of safety considerations.
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.
IMPORTANT Identifies information that is critical for successful application and understanding of the
product.
ATTENTION Identifies information about practices or circumstances that can lead to personal injury
or death, property damage, or economic loss. Attentions help you:
•identify a hazard
•avoid a hazard
•recognize the consequence
SHOCK HAZARD Labels may be located on or inside the drive to alert people that dangerous voltage may
be present.
BURN HAZARD Labels may be located on or inside the drive to alert people that surfaces may be
dangerous temperatures.

ControlLogix Programmable Limit Switch Module 3
Publication 1756-IN594A-EN-P - November 2003
Environment and Enclosure
Prevent Electrostatic Discharge
ATTENTION This equipment is intended for use in a Pollution Degree 2
industrial environment, in overvoltage Category II applications (as
defined in IEC publication 60664-1), at altitudes up to 2000 meters
without derating.
This equipment is considered Group 1, Class A industrial
equipment according to IEC/CISPR Publication 11. Without
appropriate precautions, there may be potential difficulties
ensuring electromagnetic compatibility in other environments due
to conducted as well as radiated disturbance.
This equipment is supplied as "open type" equipment. It must be
mounted within an enclosure that is suitably designed for those
specific environmental conditions that will be present and
appropriately designed to prevent personal injury resulting from
accessibility to live parts. The interior of the enclosure must be
accessible only by the use of a tool. Subsequent sections of this
publication may contain additional information regarding specific
enclosure type ratings that are required to comply with certain
product safety certifications.
NOTE: See NEMA Standards publication 250 and IEC publication
60529, as applicable, for explanations of the degrees of protection
provided by different types of enclosure. Also, see the appropriate
sections in this publication, as well as the Allen-Bradley
publication 1770-4.1 ("Industrial Automation Wiring and
Grounding Guidelines"), for additional installation requirements
pertaining to this equipment.
ATTENTION This equipment is sensitive to electrostatic discharge, which can
cause internal damage and affect normal operation. Follow these
guidelines when you handle this equipment:
•Touch a grounded object to discharge potential static.
•Wear an approved grounding wriststrap.
•Do not touch connectors or pins on component boards.
•Do not touch circuit components inside the equipment.
•If available, use a static-safe workstation.
•When not in use, store the equipment in appropriate
static-safe packaging.
Allen-Bradley Automation

4ControlLogix Programmable Limit Switch Module
Publication 1756-IN594A-EN-P - November 2003
Removal and Insertion Under Power
Be sure that power is removed or the area is nonhazardous before proceeding.
Repeated electrical arcing causes excessive wear to contacts on both the module
and its mating connector. Worn contacts may create electrical resistance that can
affect module operation.
European Hazardous Location Approval
If you install the module in a European Zone 2 location, consider:
WARNING When you insert or remove the module while backplane power is
on, an electrical arc can occur. This could cause an explosion in
hazardous location installations.
European Zone 2 Certification (The following applies when the product bears
the EEx Marking)
This equipment is intended for use in potentially explosive atmospheres as defined by
European Union Directive 94/9/EC.
The LCIE (Laboratoire Central des Industries Electriques) certifies that this equipment has
been found to comply with the Essential Health and Safety Requirements relating to the
design and construction of Category 3 equipment intended for use in potentially
explosive atmospheres, given in Annex II to this Directive. The examination and test
results are recorded in confidential report No. 28 682 010.
Compliance with the Essential Health and Safety Requirements has been assured by
compliance with EN 50021.
IMPORTANT When using this product, also consider the following:
•This equipment is not resistant to sunlight or other sources of
UV radiation.
•The secondary of a current transformer shall not be
open-circuited when applied in Class I, Zone 2 environments.
•Equipment of lesser Enclosure Type Rating must be installed in
an enclosure providing at least IP54 protection when applied in
Class I, Zone 2 environments.
•This equipment shall be used within its specified ratings defined
by Allen-Bradley.
•Provision shall be made to prevent the rated voltage from being
exceeded by transient disturbances of more than 40% when
applied in Class I, Zone 2 environments.

ControlLogix Programmable Limit Switch Module 5
Publication 1756-IN594A-EN-P - November 2003
North American Hazardous Location Approval
The following information applies when
operating this equipment in hazardous
locations:
Informations sur l’utilisation de cet équipement
en environnements dangereux:
Products marked “CL I, DIV 2, GP A, B, C, D” are
suitable for use in Class I Division 2 Groups A, B, C,
D, Hazardous Locations and nonhazardous locations
only. Each product is supplied with markings on the
rating nameplate indicating the hazardous location
temperature code. When combining products within
a system, the most adverse temperature code
(lowest “T” number) may be used to help determine
the overall temperature code of the system.
Combinations of equipment in your system are
subject to investigation by the local Authority Having
Jurisdiction at the time of installation.
Les produits marqués "CL I, DIV 2, GP A, B, C, D" ne
conviennent qu’à une utilisation en environnements de
Classe I Division 2 Groupes A, B, C, D dangereux et non
dangereux. Chaque produit est livré avec des
marquages sur sa plaque d’identification qui indiquent
le code de température pour les environnements
dangereux. Lorsque plusieurs produits sont combinés
dans un système, le code de température le plus
défavorable (code de température le plus faible) peut
être utilisé pour déterminer le code de température
global du système. Les combinaisons d’équipements
dans le système sont sujettes à inspection par les
autorités locales qualifiées au moment de
l’installation.
WARNING EXPLOSION HAZARD
•Do not disconnect
equipment unless power
has been removed or the
area is known to be
nonhazardous.
•Do not disconnect
connections to this
equipment unless power
has been removed or the
area is known to be
nonhazardous. Secure
any external connections
that mate to this
equipment by using
screws, sliding latches,
threaded connectors, or
other means provided
with this product.
•Substitution of
components may impair
suitability for Class I,
Division 2.
•If this product contains
batteries, they must only
be changed in an area
known to be
nonhazardous.
AVERTISSEMENT RISQUE D’EXPLOSION
•Couper le courant ou
s’assurer que
l’environnement est
classé non dangereux
avant de débrancher
l'équipement.
•Couper le courant ou
s'assurer que
l’environnement est
classé non dangereux
avant de débrancher les
connecteurs. Fixer tous
les connecteurs externes
reliés à cet équipement à
l'aide de vis, loquets
coulissants, connecteurs
filetés ou autres moyens
fournis avec ce produit.
•La substitution de
composants peut rendre
cet équipement inadapté
à une utilisation en
environnement de Classe
I, Division 2.
•S’assurer que
l’environnement est
classé non dangereux
avant de changer les
piles.
Allen-Bradley Automation

6ControlLogix Programmable Limit Switch Module
Publication 1756-IN594A-EN-P - November 2003
Use Compatible Resolver
This module can only be used with the following resolvers:
•Allen-Bradley Resolver # 846-SJxxxx-R3-x (x=customer option)
For more information on how to connect the center section to Allen-Bradley
Resolver # 846-SJxxxx-R3-X, see .
Identify the Module Components
You received the following components with your order:
•1756-PLS module – Three separate sections (I/O section, resolver section
and I/O section) joined together
•Removable Terminal Block (RTB) door labels (one for each section)
If you did not receive these components, contact your local distributor Rockwell
Automation sales office.
This module mounts in a 1756 chassis and uses a separately-ordered RTB or a
Bulletin 1492 Interface Module (IFM)(1) to connect all field-side wiring. This module
uses one of the following RTBs:
•1756-TBNH 20 position NEMA RTB
•1756-TBSH 20 position Spring Clamp RTB
Use an extended-depth cover (1756-TBE) for applications with heavy gauge wiring
or requiring additional routing space. When using an IFM, consult the
documentation that came with it to connect wiring.
(1) The ControlLogix system has been agency certified using the only the ControlLogix RTBs (i.e. 1756-TBCH, 1756-TBNH
1756-TBSH and 1756-TBS6H). Any application that requires agency certification of the ControlLogix system using other
wiring termination methods may require application specific approval by the certifying agency.
IMPORTANT Before you install your module, you should:
•install and ground a 1756 chassis and power supply.
•order and receive an RTB or IFM, and its components, for
your application.

ControlLogix Programmable Limit Switch Module 7
Publication 1756-IN594A-EN-P - November 2003
Note the Power Requirements
This module receives power from the 1756 chassis power supply and requires 2
sources of power from the ControlLogix backplane:
•1A at 5.1V dc
•125mA at 24V dc
Add this current/power value (8.1W) to the requirements of all other modules in
the chassis to prevent overloading the power supply.
Install the Module
You can install or remove the module while chassis power is applied.
Be sure that power is removed or the area is nonhazardous before proceeding.
Repeated electrical arcing causes excessive wear to contacts on both the module
and its mating connector. Worn contacts may create electrical resistance that can
affect module operation.
1. Align the center circuit board with the top and bottom chassis guides.
2. Slide the module into chassis until module locking tabs click.
WARNING When you insert or remove the module while backplane power is
on, an electrical arc can occur. This could cause an explosion in
hazardous location installations.
Printed
Circuit
Board
41633
Locking tab
41634
Allen-Bradley Automation

8ControlLogix Programmable Limit Switch Module
Publication 1756-IN594A-EN-P - November 2003
Key the Module and Removable Terminal Block/Interface
Module
Use the wedge-shaped keying tabs and U-shaped keying bands to prevent
connecting the wrong wires to your module.
Key positions on the module that correspond to unkeyed positions on the RTB. For
example, if you key the first position on the module, leave the first position on the
RTB unkeyed.
1. To key the module, insert the U-shaped band, as shown.
2. Push the band until it snaps in place.
3. To key the RTB or IFM, insert the wedge-shaped tab with rounded edge first,
as shown.
4. Push the tab until it stops.
Reposition the tabs to rekey future module applications.
U-shaped
bands
41635
20851–M
Wedge-shaped tab
20851

ControlLogix Programmable Limit Switch Module 9
Publication 1756-IN594A-EN-P - November 2003
Wire the Removable Terminal Block
Separate RTBs connect wiring to each section on the module. Wire each RTB
before installing it onto the module. Use a 5/16 inch (8mm) maximum flat-bladed
screwdriver.
Be sure that power is removed or the area is nonhazardous before proceeding.
Choosing Cables
Shielded cable is required when wiring the resolver. We recommend using Alpha
cable # 6054C to wire the resolver RTB.
We recommend using nonshielded cable to wire the I/O portions of this module.
However, single conductor shielded cable should be used in extremely noisy
environments. The RTB terminations can accommodate 14-22 gauge wire.
Connect Grounded End of the Cable
1. Prepare one end of the cable for grounding.
2. Ground the drain wire. We recommend grounding the drain wire at the field
device as shown below.
3. Connect the insulated wires to the field device.
WARNING When you connect or disconnect the Removable Terminal Block
(RTB) while field side power is on, an electrical arc can occur. This
could cause an explosion in hazardous location installations.
A. Remove a length
of cable jacket
from the
connecting cable.
B. Pull the foil shield
and bare drain
wire from the
insulated wire.
C. Twist the foil shield
and drain wire
together to form a
single strand.
D. Attach a ground
lug and apply heat
shrink tubing to the
exit area.
20104-M
Field
Device
Drain wire
43183
Allen-Bradley Automation

10 ControlLogix Programmable Limit Switch Module
Publication 1756-IN594A-EN-P - November 2003
If you cannot ground at the field device, follow these steps:
1. Prepare one end of the cable as shown in step 1 on page 9.
2. Ground at an earth ground on the chassis as shown below.We recommend
grounding the drain wire at the field-side. If you cannot ground at the
field-side, ground at an earth ground on the chassis as shown.
3. Connect the insulated wires to the RTB.
Connect Ungrounded End of the Cable
1. Prepare the non-grounded end of the cable.
20918-M
Connect the drain wire to a
chassis mounting tab.
Use any chassis mounting tab
that is designated as a functional
earth ground terminal. This
symbol appears near the tab.
Chassis mounting tab
Drain wire with ground lug
4M or 5M (#10 or #12)
phillips screw and star
washer (or SEM screw)
4M or 5M (#10 or
#12) star washer
A. Remove a length
of cable jacket
from the
connecting cable.
B. Pull the foil shield
and bare drain
wire from the
insulated wire.
C. Cut foil shield and drain wire
back to the cable casing and
apply shrink wrap, exposing
only the insulated wires.
43182