DL405 Family of Products
For the latest prices, please check AutomationDirect.com.
This page provides an overview of the
variety of products found in the DL405
family.
CPUs
D4-454 – 110/220 VAC P/S
D4-454DC-1 – 24VDC P/S
30.8K total memory
16 PID loops with auto-tune
Memory cartridges
UVPROM - 15.5K (D4-UV-2)
EEPROM - 15.5K (D4-EE-2)
Programming
Di rectSOFT Programming for Windows
(PC-DSOFT6)
Handheld programmer (D4-HPP-1)
Bases
4-slot base (D4-04B-1)
6-slot base (D4-06B-1)
8-slot base (D4-08B-1)
Local expansion base
power supplies
110/220 VAC P/S (D4-EX)
24VDC P/S (D4-EXDC)
Discrete
input modules
DC input
16-point 12–24 VDC (D4-16ND2)
16- point 12–24 VDC (1ms response)
(D4-16ND2F)
32-point 24VDC (D4-32ND3-1)
64-point 20–28 VDC (D4-64ND2)
AC input modules
8-point 110/220 VAC (D4-08NA)
16-point 110VAC (D4-16NA)
AC/DC input modules
16-pt 12–24 VAC/DC (D4-16NE3)
Discrete
output modules
DC output modules
16-point 5–24 VDC (D4-16TD1)
16-point 12–24 VDC (D4-16TD2)
32-point 5–26 VDC (D4-32TD1)
32-point 12–24 VDC (D4-32TD2)
64-point 5–26 VDC (D4-64TD1)
AC output modules
8-point 18–220 VAC (D4-08TA)
16-point 18–220 VAC (D4-16TA)
Relay output modules
8-point 2A (D4-08TR)
8- point 5A/pt (isolated)
(F4-08TRS-2)
8- point 10A/pt (isolated)
(F4-08TRS-1)
16-point 1A/pt (D4-16TR)
Analog modules
(12-bit)
Analog input
4-channel in, current/voltage (F4-04AD)
4- channel in, current/voltage (isolated)
(F4-04ADS)
8-channel in, current/voltage (F4-08AD)
16-channel in, current (F4-16AD-1)
16-channel in, voltage (F4-16AD-2)
Analog output
4-channel out, current (F4-04DA-1)
4-channel out, voltage (F4-04DA-2)
8-channel out, current (F4-08DA-1)
8-channel out, voltage (F4-08DA-2)
16-channel out, current (F4-16DA-1)
16-channel out, voltage (F4-16DA-2)
Temperature Input
8-channel in, type J thermocouple
(F4-08THM-J)
Analog modules
(16-bit)
Temperature Input
8-channel in, RTD (F4-08RTD)
8-channel in, thermocouple (F4-08THM)
Analog output
4- channel out, current (isolated)
(F4-04DAS-1)
Communications/
networking modules
Et hernet communications
[H4-ECOM100]
Data communications (D4-DCM)
Modbus master (F4-MAS-MB)
Specialty modules
High-speed counter I/O (H4-CTRIO)
8/16 channel input simulator (D4-16SIM)
4-loop temperature controller (F4-4LTC)
BASIC CoProcessor Module
128K triple port (F4-CP128-1 )
CPU-Slot
slave controllers
Ethernet base controller (H4-EBC)
Remote I/O modules
Ethernet
Ethernet remote Master Module
(H4-ERM100)
Ethernet base Controller (Slave)
(H4-EBC)
Remote I/O protocol (serial)
Remote I/O Master Module (D4-RM)
Remote I/O Slave 110/220 VAC (D4-RS)
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DL405 PLCs
tDL4-1
DL405 CPUs
For the latest prices, please check AutomationDirect.com.
System capacity
System capacity is the ability of the CPU
to accommodate a variety of applications.
Here are a few key considerations when
determining system capacity:
How much memory do you need?
Consider both ladder memory and data
registers (V-memory). For ladder memory,
most boolean instructions require one
word. Some other instructions, such as
timers, counters, etc., require two or more
words. Our V-memory locations are
16-bit words and are useful for data
storage, etc.
What type of memory do you need? The
D4-454 has 15.5K of built in M-RAM
ladder memory and no memory cartridge
is needed.
How many I/O points are required? You
will need to know how many field devices
are required. Compare the D4-454 specifications tables on the next page with your
application requirements.
Are there any remote I/O points? In
many applications, the cost of bringing
the individual control wiring back to the
PLC control panel can be reduced by
the use of remote I/O. The D4-454 CPU
has built-in serial remote I/O connections
on the lower 25-pin port; or use Ethernet
Remote I/O for fast and easy set-up and
communications.
Performance
If you have a time-critical application
where every millisecond is important, then
the D4-454 CPU, with the fastest overall
scan time, is the right choice. The D4-454
is very fast at performing even the most
basic of math or data instructions and will
provide a faster overall scan time.
Programming and
diagnostics
The D4-454 CPU offers a wide array of
instructions and diagnostic features that
can save you many hours of programming
and debugging time. From basic boolean
contact logic, to PID and floating point
math, we have it covered! For the D4-454
CPU, IBox programming instructions
simplify complex tasks with instructions
such as Memory, Discrete Helper, Analog
Helper, Math, Communications, and
CTRIO. The chart on the next page lists
the instructions by category. Beginning
on page tDL4-69, you will find a
detailed list showing the name and
function of each instruction.
D4-454 Parameters
Features
Total Memory
Ladder
Memory
DirectSOFT
Memory
Cartridge
Battery
Mode Switch
Port 1 and 3
Baud Rate
Port 1 and 3
Settings
Port 2 Protocol
Firmware
Update
NOTE: Any hardware with a date code less than
09X0 or with a first digit that is not 0, 1, or 2 may
not work with the D4-454. We suggest that any
hardware older than ten years and not currently
sold on the AutomationDirect.com website be
upgraded to a newer version.
D4-454
46.8K
31.5K
Yes, version 6.1 or later
No, (same amount of memory as the
largest memory cartridge)
D2-BAT-1 (CR2354)
Toggle Switch (Same position/
function)
2400, 4800, 9600, 19200, 38400
8 data bits, 1 start bit, 1 stop bit,
Odd, Even or No parity
DirectNet (master/slave), K-sequence,
Non-procedure, Modbus RTU
(master/slave)
Supported from all ports
Built-in CPU
communications
The D4-454 CPU provides at least two
built-in communications ports. Each
CPU supports our DirectNET protocol
on the lower port for easy, economical
networking. Need Modbus RTU? Then the
D4-454 CPU with built-in Modbus RTU
Master and Slave capability is the right
choice. Of course, we also offer a wide
array of communications, such as our
Ethernet Communications Module, Data
Communications Module and Modbus
Master module.
Specialty I/O modules
In addition to our cost-effective discrete and
analog I/O, we also offer specialty modules
to solve the really tough applications. Our
D4-454 CPU supports specialty modules
in the local CPU base, and can also
support selected specialty modules in
expansion bases.
D4-454 Unsupported Modules Table
Bases Retired
D4-04B, D4-04BNX Yes
D4-06B, D4-06BNX Yes
D4-08B, D4-08BNX Yes
Input Modules
D4-32ND3-2 Yes
D4-16NA-1 Yes
Output Modules
D4-08TD1 Yes
Comm Modules
H4-ECOM Yes
Remote I/O Modules
D4-ERM Yes
D4-ERM-F –
Specialty Modules
D4-PULS Yes
F4-CP128-R Yes
F4-CP512-1 Yes
tDL4-2
DL405 PLCs
1-800-633-0405
DL405 CPU Specifications
DL405 CPU Specifications
D4-454
System Capacity
Total memory available (words)
Ladder memory (words)
built-in memory
with memory cartridge
V-memory (words)
Battery backup
Total CPU memory I/O pts. available (actual
I/O points depend on I/O configuration selected)
I/O module point density
I/O module slots per base
Local/local expansion
Serial Remote I/O (including local & exp. I/O
Remote I/O Channels
I/O pts. per remote module channel
Ethernet Remote I/O (including local/exp. I/O)
discrete I/O pts.
Analog I/O channels
Remote I/O channels
I/O per remote channel
46.8K
31.5K
N/A
15.3K
Yes, MRAM*
8192 (X+Y+GX+GY)
2/4/8/16/32/64
4/6/8
1024 in/1024 out
4224 max.
3
512, 2048
Yes,
8192 max.
(Including local and exp. I/O)
Map into V-memory
Limited by power budget
16,384 (16 fully expanded
H4-EBC slaves using
V-memory and bit-of-word
instructions)
For the latest prices, please check AutomationDirect.com.
Performance
Contact execution (boolean)
Typical scan (1K boolean)
Programming and Diagnostics
RLL ladder style
RLL PLUS/flowchart style (Stages)
Run time editing
Supports Overrides
Variable/fixed scan
Instructions
Control relays
Timers
Counters
Immediate I/O
Subroutines
For/next loops
Timed interrupt
Integer math
Floating-point math
Trigonometric functions
Table instructions
PID
Drum sequencers
Bit of word
Real-time clock/calendar
Internal diagnostics
Password security
System and User error log
IBox instructions
CPU Ports Communications
Built-in ports
K-sequence (proprietary protocol)
DirectNET
Modbus master/slave
ASCII out (Print)
Maximum baud rate
0.96 µs
4–5 ms
Yes
Yes/1024
Yes
Yes
Fixed or variable
210
2048
256
256
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Multi-level
Yes
Yes
4 ports
Yes
Yes
Yes
Yes
38.4K
*Battery used for Real Time Clock backup
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DL405 PLCs
tDL4-3
D4-454 Key Features
D4–454
ts
For the latest prices, please check AutomationDirect.com.
D4-454 CPUs
D4-454 $925.00
D4-454DC-1 $925.00
D4-454 CPU*
The D4-454 CPUs provides tremendous
capability using updated microprocessor
technology allowing the D4-454 to be
the CPU of choice for the DL405 family.
Built-in CPU
Communications Ports
The D4-454 offers four built-in ports for
extra convenience. The 15-pin port offers
our proprietary K-sequence protocol
and is primarily used for programming
connections to a PC running DirectSOFT6
programming software (version 6.1 or later)
or to a D4-HPP-1 handheld programmer.
It can also be used to connect to
a C-more panel or other operator
interfaces. The 6-pin phone jack supports
K-sequence; DirectNET master/slave,
ASCII output and Modbus RTU master/
slave protocols. The bottom 25-pin port
contains two logical ports with different
pins for each port. It is primarily a
networking port that supports DirectNET
master/slave or Modbus master/slave
protocols. The bottom port can be used
as an ASCII output port for connections
to devices that can accept ASCII input. It
can also be used as a remote I/O Master.
The Communications Ports table on the
next page has a complete description of
each port.
16 PID Loops
The D4-454 CPU can process up to
16 PID loops directly in the CPU. You
can select from various control modes
including automatic control, manual
control, and cascade control. There are
a wide variety of alarms including Process
Variable, Rate of Change, and Deviation.
The various loop operation parameters
are stored in V-memory, which allows easy
access from operator interfaces. Setup
is accomplished with our DirectSOFT6
Programming Software. An overview of the
various loop specifications and features is
on page mDL4-7.
offers four built-in communication ports
ilt-incommunicationpor
Floating-point Math
The D4-454 CPU supports IEEE format
floating-point math calculations. This
feature means the D4-454 includes
full trigonometric functions and various
forms of integer/floating point number
conversions.
Power Supplies
We offer a choice of two power supplies
for the D4-454 CPUs. The power supplies
are built into the CPU. Available power
supplies are:
• 110/220 VAC version - D4-454
• 24VDC version - D4-454DC-1
*
The D4-454 CPU is a direct replace-
ment for the retired D4-450 CPU.
tDL4-4
DL405 PLCs
NOTE: Any hardware older than tens years old may not work with the D4-454. We suggest that any hardware older than ten years and not currently sold on the AutomationDirect.com website be upgraded to a newer version.
1-800-633-0405
D4-454 Features
The diagram on this page shows the
various hardware features found on the
D4-454 CPU.
For the latest prices, please check AutomationDirect.com.
RUN
TERM
STOP
PWR
RUN
CPU
BATT
DIAG
I/O
TXD
RXD
Phone
Jack
Port 2
15-pin
Port 0
CPU Keyswitch
Forces CPU to RUN mode. Locks Comm port - will
not receive incoming data.
Allows peripherals (HPP, DCM, DirectSOFT, etc.) to
select operating mode
Forces CPU out of RUN
CPU Status Indicators
ON
CPU power good
OFF
CPU power failure
ON
CPU is in RUN mode
OFF
CPU is in STOP mode
ON
CPU self-diagnostics error
OFF
CPU self-diagnostics good
ON
CPU battery is low
OFF
CPU battery is good or disabled
ON
CPU diagnostics or local bus error
OFF
CPU diagnostics or local bus good
ON
I/O self-diagnostics error
OFF
I/O self-diagnostics good
ON
Data is being transmitted
OFF
No data is being transmitted
ON
Data is being transmitted
OFF
No data is being transmitted
Communications Ports
General purpose port for RS232. Baud rate is
selectable up to 38.4Kb. Connects to DirectSOFT
programming software, C-more panels, network, etc.
Supports K-sequence protocol, DirectNET (master
or slave) protocol, Non-squence (ASCII out), and
Modbus RTU (master or slave) protocol.
Programming port, RS232, 9600 baud, connects to
HPP, DirectSOFT, DV-1000, C-more panels, etc.
K-sequence protocol (fixed station address=1)
D4-454 CPU Hardware Features
Run relay
Logic ground
Chassis ground
DC power
CPU
battery
Wiring
terminals
D4-454 communications ports pin-out
Phone jack
15-pin connector
General purpose port for RS232 and RS422
(RS485 Remote I/O Master available on Port 3 only.)
Baud rate selectable via software up to 38.4K baud.
25-pin
Port 1
and
Port 3
Connects to DirectSOFT, C-more panels, network,etc
Two logical ports (separate pins on connector).
Software selectable protocol includes:
Protocol Port 1 Port 3
K-sequence 3 3
DirectNETMaster/Slave 3 3
Modbus Master/Slave 3 3
Remote I/O n/a 3
ASCII Out 3 3
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Port 2
Port 0
25-pin connector
Port 1 Port 3
25-pin connector
DL405 PLCs
tDL4-5
D4-454 Features
D4-454 Scan control
The D4-454 CPU provides several scan
control options, which are useful in some
high-speed machine control applications.
Variable — The scan varies as necessary from scan to scan. The actual scan
time depends on the instructions being
executed.
Limited — This is similar to a variable
scan in that the scan varies as necessary.
However, if the actual scan time exceeds
a specified target scan time, then a scan
overrun condition is indicated.
Fixed — If the scan is finished before the
time specified, idle time is added to ensure
a fixed scan period. If the scan exceeds the
time specified, the scan is extended to ensure
all instructions are executed. A scan overrun
condition is also reported.
For the latest prices, please check AutomationDirect.com.
Memory
D4-454 is fully contained in the CPU and
stored in MRAM which is a non-volatile
form of memory. No memory card is
required. The battery is used for retention of
the Real Time Clock.
— The memory of the
Full array of instructions
Imagine if someone asked you to write a
book, but then told you that you could only
use 50 different words? That would be a
tough job! The same is true for writing a
PLC program. The right instruction can
greatly simplify your control program.
The D4-454 supports over 200 powerful
instructions. These include:
• Four types of drum sequencers, each with
16 steps and up to 16 outputs
• Leading and trailing edge triggered
oneshots
• Bit of word manipulation
(bit set, reset, etc.)
• Trigonometric functions
• Floating point conversions
• Ibox instructions that simplify tasks such
as configuring analog modules or
performing complex math equations
DirectSOFT 6.1 or later,
is required to program the D4-454.
tDL4-6
DL405 PLCs
1-800-633-0405
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D4-454 PID loops
PID Loop Specifications and Key Features
Number of Loops
CPU V-memory Required
PID Algorithm
Auto Tuning
Sample Rate
Loop Operation Modes
Ramp/Soak
Square Root PV
Limit SP
Limit OUT
Gain
Reset
Rate
Rate Limiting
Bumpless Transfer I
Bumpless Transfer II
Step Bias
Anti-windup
Error Deadband
Error Squared
Deadband
PV Alarm Points
PV Deviation
Rate of Change
Need Temperature Control?
If you’re only interested in controlling temperature, then there may be a better solution than the D4-454 CPU. Check out the F4-4LTC module. This module has the capabilities of our single loop controllers built into one economical module! Detailed specifications can be found later in this section. This module can directly control up to
four loops and it even includes built-in relay outputs for heater or chiller control! If you use the built-in PID capability of the D4-454 CPU, you still have to purchase the
analog input modules and the output modules (either discrete or analog) in order to complete the loop.
This can result in a much higher overall cost when compared to the F4-4LTC.
Selectable, 16 maximum
32 V-memory locations per loop selected (An additional 32 V-memory locations per loop required if using Ramp/Soak)
Position or velocity form of the PID equation. Optionally specify direct or reverse acting, square root of the error and error squared control.
Open loop step response method and closed loop limit cycle method.
Specify the time interval between PV samples, 0.05 to 99.99 in units of seconds or minutes. If using all 16 loops, the smallest sample rate is limited to
either 0.2 seconds or (PLC scan time x number of loops).
Loop can be in automatic control, manual (operator) control, or cascade control. PV alarm monitoring continues when loops are in manual mode.
Up to 16 steps (8 ramp, 8 soak) per loop, with indication of Ramp/Soak step.
Specify a square root of the PV for a flow control application.
Specify a maximum and minimum value for allowable setpoint changes.
Specify a maximum and minimum value for the output range.
Specify proportional gain of 0.01 to 99.99.
Specify integral time of 0.1 to 99.98 in units of seconds or minutes.
Specify the derivative time, 0.00 to 99.99 seconds.
Specify a derivative gain limiting coefficient to filter the PV used in calculating the derivative term (0 to 20).
Bias and setpoint are initialized automatically when the loop is switched from manual to automatic. This provides for a bumpless transfer, which reduces
the chance of sharp changes in the output as a result of entering automatic mode.
Bias is set equal to the Output when the module is switched from manual to automatic. This allows switching in and out of automatic mode without
having to re-enter the setpoint.
Provides proportional bias adjustment for large setpoint changes. This may stabilize the loop faster and reduce the chance of the output going out of
range. Step bias should be used in conjunction with the normal adjusted bias operation.
If the position form of the PID equation is specified, the reset action is stopped when the PID output reaches 0 or 100%. Select adjusted bias or freeze
bias operation.
Specify an incremental value above and below the setpoint in which no change in output is made.
Squaring the error minimizes the effect a small error has on the Loop output, however, both Error Squared and Error Deadband control may be enabled.
Alarm Specifications
Specify 0.1% to 5% alarm deadband on all alarms except Rate of Change.
Specify PV alarm settings for low-low, low, high, and high-high conditions. You can also specify a deadband to minimize the alarm cycles when the PV
approaches alarm limits.
Specify alarms to indicate two ranges of PV deviation from the setpoint value (yellow and red deviation).
Specify a rate-of-change limit for the PV.
Operator Interface
S
DL405 Analog
Input Modules
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D4–454 CPU
DL405
Analog Output
or Discrete Output
PID Loop Control
Block Diagram
DL405 PLCs
tDL4-7
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DL405 Programming Tools and Cables
Select a
programming device
There are two tools for programming
the DL405 CPUs: DirectSOFT PC-based
programming software and the D4-HPP-1
handheld programmer.
DirectSOFT
programming software
Our powerful Windows-based programming packages make it easy for you to
program and monitor your DL405 PLC
system. The version of the software that
supports the DL405 CPUs is described
in the table below. See the DirectLOGIC
Overview Section DL in this catalog for
detailed information on DirectSOFT.
Direct Soft
Part Number
PC-DSOFT6
PC-DS100
Price Description
Programs all PLC families
$427.00
DL05/06/105/205/305/405
Free version of DirectSOFT;
programs all DirectLOGIC PLC
Free
CPUs; limited to 100 word
program
DL405 programming cables
Choose the proper cable to connect
the DL405 CPU to your PC running
DirectSOFT.
CPU Price Port Cable Price
D4-454
$925.00
Top port
(15 pin)
Lower port
(25pin)
Phone jack
(RJ12)
D4-DSCBL
D3-DSCBL-2
D2-DSCBL
$52.00
$49.50
$24.00
Handheld programmer
The D4-HPP-1 handheld programmer
connects to the 15-pin port on any of
the DL405 CPUs. A memory cartridge
is located on the side of the handheld
programmer. This slot allows you to copy
memory cartridges (including UV PROMs)
and transfer data/programs between the
CPU and a memory cartridge.
tDL4-8
DL405 PLCs
1-800-633-0405
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